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CROSS-REFERENCE TO RELATED APPLICATIONS
This Non-Provisional U.S. Patent Application claims priority of U.S. Provisional Application Ser. No. 60/105,678 filed on Oct. 26, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to reclaiming, rejuvenation and the re-gradation of aggregates of asphalt concrete from pavement surfaces composed thereof and, more specifically, to an apparatus and process for converting existing asphalt concrete pavement mixtures into a paving mixture having improved performance, durability, safety and efficiency over currently used paving mixtures, the improved paving mixture having qualities similar to the asphalt concrete pavement superpave mixture developed under the 1987 Strategic Highway Research Program (SHRP).
2. Description of the Prior Art
The present invention relates to the technology of reclaiming, rejuvenating and the re-gradation of aggregates of asphalt concrete mixtures from pavement surfaces. The process and apparatus of the present invention converts existing asphalt concrete pavement mixtures into a new and improved paving mixture having the qualities of the asphalt concrete pavement “super” mixture developed under the USA, 1987 Strategic Highway Research Program (SHRP). The 1987 Strategic Highway Research Program was a 5-year, large scale, applied research program which was established by the U.S. Congress and aimed at improving the performance, durability, safety and efficiency of the Nation's highway systems.
Asphalt concrete is a major component of the highway system in the United States, covering more than 90 percent of the nation's paved roads. Every year, state and local highway agencies spend $10 billion on asphalt pavements, and private sector expenditures total an additional $5 billion. Steadily increasing traffic volumes and loads are taking their toll on these roads, forcing highway agencies to commit extensive resources to rehabilitation projects. As a result, motorists frequently encounter work zones that disrupt traffic, as well as rough pavements that pose safety risks and damage tires and suspensions. SHRP'S solution was to develop a completely new approach to asphalt mix design—the Superpave system. (“Superpave” is a Registered Trademark of the National Academy of Sciences-NAS). The superpave system provides designers with the tools to custom—design asphalt pavements for the specific weather and traffic conditions at a particular job site, instead of simply replicating existing mixes that have served reasonable well in the past.
The superpave system has three components:
(1) An asphalt binder specification;
(2) A design and analysis system based on the volumetric properties of the aggregates; and
(3) Mix analysis test and performance prediction models.
Materials engineers use these components to select materials and a mix design best able to resist two key types of pavement distress: permanent deformation and low-temperature cracking. Permanent deformation can result when a pavement is exposed to heavy traffic and hot weather and lacks the strength to withstand rutting. Low-temperature cracking occurs when the pavement shrinks in cold weather.
Since 1992, when the Strategic Highway Program ended, many highway agencies that have built pavements having a design mix in accordance the specifications for a superpave mix report that the new system is producing more durable pavements. On highways across the country, pavements having a superpave design mix are holding up well to heavy traffic and extremes of climate.
In 1995, for example, the Alabama Department of Transportation (DOT) resurfaced 8 km (5 mi) of badly rutted Route 165 with a superpave mix design. Despite heavy traffic and extremely hot weather, the pavement showed virtually no signs of rutting 2 years later, and the Alabama DOT expects the pavement to last considerably longer than it would have if it were constructed with the conventional mix previously used by the state.
In a similar case, Arizona's DOT used a superpave design mix to construct an overlay on a section of Interstate 10 near Phoenix in 1995. In its first summer, the pavement withstood heavy traffic loads and 17 consecutive days of temperatures above 43 degrees C. (110 degrees F.). The pavement's performance to date indicates that it will be very resistant to permanent deformation.
Superpave design mix pavements have also proven durable in cold climates. After 4 years of cold weather and heavy traffic, early superpave mix test sections constructed on Interstate 43 in Waukesha County and on Interstate 94 in Monroe County, Wisconsin, are holding up much better than adjacent sections constructed using Wisconsin's conventional mix. Cold weather is also no problem for an overlay built using a superpave design mix on a rural road in Blue Earth County, Minn., in August 1995. The overlay is suffering much less low-temperature cracking than a nearby, same-age overlay built using Minnesota's conventional mix.
After building several pavements using mixes that meet the superpave specifications, the Texas DOT predicts that the new superpave mixes will have tremendous benefits. Texas estimates that converting only 25 percent of the asphalt that it now uses to mixes that meet the superpave specifications will save the state $2.2 billion over 30 years.
A study of data from the long-term pavement performance (LTPP) program's general pavement studies (GPS) experiments has determined that using asphalt concrete mixes that meet the superpave mix specifications will prevent permanent pavement deformation or rutting, as it is commonly known, in asphalt pavements. The study, “Rutting Trends in Hot-Mix Asphalt Concrete Pavements,” was based on data collected at 575 GPS sites. This study looked at full-depth asphalt pavements, asphalt pavements over a granular base, asphalt pavements over a portland cement treated base and asphalt overlays on asphalt and portland cement pavements. The pavement ranged in age from newly constructed to more than 20 years old. The study team focused on the test sections consisting of asphalt pavements over a granular base, which are the most common types of asphalt pavements existing today. They found that pavements with high levels of rutting on average were generally constructed of asphalt mixes containing more fine aggregate or sand than recommended by the superpave aggregate specifications. Pavements with minimal rutting were within the superpave aggregate specifications.
According to the Federal Highway Administration (FHWA), the study makes it clear that it is well worth the time and effort to use aggregate blends that meet the superpave specifications as a way to prevent excessive rutting and permanent pavement deformation. Since virtually all new superpave mixes are products of highly technical hot-mix asphalt plants, the mixes are composed of carefully metered quantities of predetermined superpave specified sizes of aggregates that are heated, dried and coated with an appropriate amount and grade of an asphalt cement binder. Asphalt cement binders are derivatives of the petroleum refining process and are available in various viscosities for use as determined by local climate and traffic loading conditions.
A highway agency's cost for a superpave mix of all virgin, non-renewal natural resource materials can vary from $35 to $75 per tonne depending upon:
(1) Cost of discovery, collection, refining and hauling of necessary asphalt cement;
(2) Cost of mining, crushing, sizing, separating, storing and handling multiple sizes of aggregates;
(3) Cost of asphalt plant operations including, material handling, fuel for heating, drying and mixing aggregates with asphalt cement; and
(4) Cost of hauling to remote paving sites for paving and compaction.
Each tonne (2200 lbs) of superpave mixture is made-up entirely of non-renewable natural resources including: 10-15 gallons of petroleum based asphalt cement plus approximately 2,100 lbs. of aggregate. Additionally, the whole process requires the use of more than 650,000 Btu of energy in non-renewable resource fuels.
It is thus desirable to provide a method and apparatus for converting existing roadways made from pavements having inferior grade mixtures into asphalt having a mixture in accordance with the specifications for a superpave mix. It is further desirable to provide a method and system for paving the existing roadways with the converted asphalt mixture to thereby improve the performance and life of the roadway.
SUMMARY OF THE INVENTION
The present invention relates generally to reclaiming, rejuvenation and the re-gradation of aggregates of asphalt concrete from pavement surfaces composed thereof and, more specifically, to an apparatus and process for converting existing asphalt concrete pavement mixtures into a paving mixture having improved performance, durability, safety and efficiency over currently used paving mixtures, the improved paving mixture having qualities similar to the asphalt concrete pavement superpave mixture developed under the 1987 Strategic Highway Research Program (SHRP).
A primary object of the present invention is to provide a method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture that will overcome the shortcomings of prior art devices.
Another object of the present invention is to provide a method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture which is able to convert existing pavement on a roadway into a superpave mixture having improved qualities from the existing roadway.
A further object of the present invention is to provide a method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture which is able to heat and remove layers of previously paved asphalt from a roadway and convert the removed asphalt into a superpave mixture.
A yet further object of the present invention is to provide a method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture wherein the altered asphalt has improved performance, durability, safety and efficiency over the paving mixture being altered.
A still further object of the present invention is to provide an apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture including a heating device for heating and thereby softening the asphalt on a roadway.
A further object of the present invention is to provide an apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture having a milling device for chopping the heated asphalt and thereby removing a layer of asphalt from the roadway.
A further object of the present invention is to provide an apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture including a hopper containing new asphalt concrete mixture materials for combination with the layer of asphalt removed from the roadway and altering the gradation of the existing asphalt into a superpave mixture.
Another object of the present invention is to provide an apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture including a height adjustable shield device for filtering out fine aggregates or sand from the asphalt removed from the roadway to thereby alter the gradation of the existing asphalt into a superpave mixture.
Another object of the present invention is to provide an apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture that is simple and easy to use.
A still further object of the present invention is to provide a method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture that is economical in cost to manufacture.
Additional objects of the present invention will appear as the description proceeds.
The present invention consists of a process and apparatus for recovering existing rutted and cracked asphalt concrete highway material for reuse in making a new mixture which meets all the specifications for a superpave mixture. Most existing asphalt concrete paving mixtures used in the past were specified and mixed according to various standard specifications. These standard specifications required older asphalt concrete mixtures to adhere to various percentages, as measured by weight, of crushed stone aggregates which could be measured in sizes from the largest of ½″ diameter to the smallest of very fine sand. Before formation of the superpave system, standard mixes which were commonly used by most DOT's included:
(1) Type-4 mixtures made up of asphalt cement with very small aggregates;
(2) Type-3 and Type-4 mixtures made up of asphalt cement and slightly larger aggregates; and
(3) Type-1A and Type-1B which were made up of asphalt cement and even higher percentage of larger aggregates.
Curiously, all of these former standard mixes contained high percentages, when compared to the new superpave mixes, of fine aggregates and/or sand, which according to the new research data, is the very ingredient most responsible for rutting and/or permanent pavement deflection. Thus, when a certain percentage of the unnecessary fine aggregates are removed and necessary large aggregates are added, the new mix will be in compliance with the volumetric mix specifications for the standard superpave mix.
FIGS. 1A-1H provide a “Pavement Aggregate Gradation Modification Chart” used to calculate the changes that are required to convert any existing mix into the volumetric equivalent to a superpave mix. For example, when a one square yard sample of previously paved using Type-1 asphalt cement mix is analyzed for weight, a thin layer with a thickness of 1½″ will have a total weight of approximately 150 pounds (100 lbs/sqyd/1 in. layer). That being so, the combined weight of the various size aggregates of the Type-1 mix totals 150 pounds as shown under column (9) having the heading “LAYER” of FIG. 5 A. In the instant example, the modification chart also indicates that 75 pounds of ½ in. large sized aggregates must be added and a total of 25 lbs., or about 60% of all fine aggregates and/or sand 0.6 mm or smaller in size must be removed in order for the resulting mix to be in compliance with the standard superpave volumetric mix specifications. Such is indicated by column (10) having the heading “CHANGE” of FIG. 5 A.
The preferred process for altering the volumetric mix of existing asphalt concrete mixes would be to convert to mixes which meet or exceed the typical standard superpave volumetric mix specifications. It is possible to eliminate at least a small percentage of the fine aggregates and/or sand and thus produce an improved mix that is more resistant to rutting and/or permanent pavement deflection than was the original mixture. In many instances it is easy and therefore preferable to convert an existing mix from its present grade or type to a mix that is one or two grades better and therefore an overall improved and renewed mix. However, there may be instances when it is not feasible to convert a relatively fine aggregate mix such as a Type-4 mix to conform 100% to the standard superpave volumetric mix specifications.
In accordance with this process for altering existing asphalt concrete pavement mixes, the road pavement remixing apparatus disclosed herein is able to completely upgrade and renew old roadway surface materials to conform to the most desirable standard superpave mix, without requiring large amounts of new mix materials. Briefly, the road pavement remixing apparatus of this invention provides means for heating the existing pavement surface with propane fueled heaters similar to the apparatus disclosed in my previous U.S. Pat. No. 4,711,600 or other effective heaters which will heat up to a 1″ layer of the exposed asphalt concrete very quickly. The apparatus may include a storage hopper and metering device to accept and dispense either asphalt coated or non-coated aggregates, such as the larger aggregates which may be required to be added to convert the existing roadway mix to meet the desired superpave volumetric mix specifications. New aggregates and/or previously processed and windrowed existing roadway materials may also be introduced into the road pavement remixing apparatus by way of the windrow loading drag-bar conveyor which picks up wind-rowed materials from in front of the pavement remixing apparatus and therefore cleans and exposes the existing roadway surface for the heating process. The picked up and conveyed windrowed or hopper fed materials are dumped into a transfer auger conveyor which moves the picked up materials to the outside edges of the passed over heater and discharges them behind the heater onto the surface of the newly heated existing asphalt cement and in front of the outside milling and mixing augers. The outside milling and mixing augers mill the just heated layer of asphalt cement materials from the roadway and mixes milled materials with the conveyed materials creating a homogenous mixture of conveyed and milled materials. The mill cutting teeth are set on the milling drum behind and slightly off-set from each other in a spiral pattern for auguring the new mixture toward the center of the apparatus and in front of a center milling and mixing auger.
A half-round shield plate with a radius slightly larger than the outer radius of the milling auger is positioned behind the milling-mixing auger and acts as a half-round conduit for containing the milled and mixed material for conveyance toward the center of the road pavement remixing apparatus and in front of the rear centered milling, mixing and windrowing auger. This shield plate is, after adjustment as to the height of the bottom edge above the just milled road surface, locked in place with the back support foot of the long-arm draw-bar. The purpose of the locked in position half round shield is to provide an open clearance above the milled roadway surface. The shield plate clearance is adjusted so that the bottom edge is set from between substantially 0″ and substantially ½″ above the roadway surface depending upon the size and amount of the small aggregate and/or sand being removed from the existing roadway mix. The small aggregates and/or sand, which upon settling to the just milled surface during mixing action, thus pass under the shield plate and through the longitudinal slotted opening formed by the top of the milled surface and the bottom of the shield plate.
Thus, if the volumetric mix specifications require that 25 lbs/yd. 2 of fine aggregates and/or sand be removed from the milled existing pavement mix, the height of the shield bottom above the milled surface will be set at ¼″ or slightly more as necessary to obtain the quantity of fine aggregates and/or sand materials which equals the weight of the desired removal as is indicated in FIGS. 5A-5H.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
Various other 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.
FIG. 1 is a side view of the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention;
FIG. 2 is a side view of the milling and mixing auger of the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention;
FIG. 3 is a side view of the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention illustrating operation thereof;
FIG. 4 is a side view of the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention converting the asphalt on a roadway to a superpave mixture; and
FIGS. 5A-5H illustrate a “Pavement Aggregate Gradation Modification Chart” used to calculate the changes that are required to convert any existing mix into the volumetric equivalent to a superpave mix.
DESCRIPTION OF THE REFERENCED NUMERALS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the Figures illustrate the method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures.
10 apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention
12 roadway
14 a layer of existing pavement
16 structural steel frame
18 front steering wheel supports
20 rear drive wheels supports
22 power train
24 arrow indicating direction of travel of the pavement remixing machine
26 heater
28 milling-mixing auger
30 existing roadway pavement materials
32 windrow pile
34 single rear milling-mixing auger
36 multiple milling bits
38 new materials hopper
40 drag bar conveyor
42 propane storage tank
44 gas train control cabinet
46 ribbon burners
48 heating furnace chamber
50 operator seat
52 control panel
54 auger conveyor
56 front pivot
58 long-arm draw-bar
60 back support foot
62 shield
64 windrow formed by rear milling-mixing auger
66 sand
68 new mix from hopper
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 4 illustrate the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention indicated generally by the numeral 10 .
FIG. 1 illustrates a side elevation view of a road pavement remixing machine 10 positioned on a roadway 12 including a layer of existing pavement 14 thereon. The pavement remixing machine 10 includes a structural steel frame 16 set on front steering wheel supports 18 and on rear drive wheels supports 20 . A power train 22 is set on the steel frame 16 and includes a diesel powered engine and high pressure hydraulic pumps for driving hydraulic motors located on various work station components of the pavement remixing machine 10 . The direction of travel of the pavement remixing machine 10 along the roadway 12 is indicated by reference numeral 24 .
A heater 26 is connected to the pavement remixing machine 10 below the steel frame 16 and between the front steering wheel supports 18 and the rear drive wheel supports 20 and is positioned at a desired distance above the roadway 12 . The height of the heater 26 is adjustable based upon the amount of heat desired and the temperature to which it is desired to heat the roadway 12 . The high temperature heating furnace 26 is fired with propane gas from a propane storage tank 42 after it is mixed with sufficient amounts of pressurized combustion air by a gas train of mixing valves, pressure regulators, high pressure fan and pre-heated coil located in a gas train control cabinet 44 . The heating furnace 26 is equipped with multiple rows of ribbon burners 46 and flexible front, sides and back skirts to allow pressurization of the heating furnace chamber 48 as it passes over the roadway surface.
During a first pass along the roadway 12 , the existing pavement is heated by the heater 26 and milled and mixed by a milling-mixing auger 28 . Existing roadway pavement materials 30 are left in a windrow pile 32 on the roadway 12 . The milling-mixing auger 28 includes left and right milling-mixing augers for milling and mixing the roadway pavement 14 heated by the heater 26 as the pavement remixing machine 10 travels along the roadway 12 . A single rear milling-mixing auger 34 is positioned behind the millling-mixing auger 28 for further milling and mixing of the pavement 14 . Each of the left milling mixing auger, right milling-mixing auger and the single rear milling-mixing auger 34 rotate in a counterclockwise direction and include multiple milling bits 36 for milling and mixing the pavement 14 of the roadway 12 . The milling bits of the left and right milling-mixing augers are formed in a spiral pattern such that the milled and mixed material will be swept towards a center line of the pavement remixing machine 10 and in front of the rear milling mixing auger 34 . The rear milling-mixing auger 34 is thus able to further mill and mix the material deposited thereinfront by the milling-mixing auger 28 . Multiple milling bits 36 are also attached to the rear milling-mixing auger 34 . These milling bits 36 are attached in a left hand spiral pattern on one end and in a right hand spiral pattern on the other end such that the milled and mixed material form both sides will be swept toward the center line of the pavement remixing machine 10 and left as a homogenous asphalt concrete mix.
A hopper 38 is provided in a front of the steel frame 16 for depositing new asphalt concrete mixtures necessary for altering the mixture of the windrow pile 32 formed on the roadway 12 as can be seen in FIGS. 3 and 4. The materials from the new materials hopper 38 are metered out at a pre-selected rate and dropped onto the windrow pile 32 to be swept up and lifted from the roadway surface by a drag-bar conveyor 40 . The heated, milled, mixed pavement which was left in the windrow pile 32 is swept from the road into the drag-bar conveyor 40 along with the new asphalt concrete mixtures deposited by the hopper 38 . The dragbar conveyor 40 extends from the front of the pavement remixing machine 10 and over the heater 26 towards the milling-mixing auger 28 . The picked up windrow pile 32 is discharged from the drag bar conveyor 40 into an auger conveyor 54 which transfers one-half of the picked up material for discharge between the milling bits 36 of the left front of the left-side milling-mixing auger and one-half of the picked up material for discharge between the milling bits 36 of the right front of the right-side milling-mixing auger. The milling-mixing augers 28 and the single rear milling-mixing auger 34 rotate counter clock-wise when viewed as shown in FIG. 1, thus down-cutting and milling the heated and softened existing asphalt concrete to a predetermined depth.
The milling-mixing auger 28 is supported near the back end of a front pivot 56 of a long-arm draw-bar 58 which extends from a front pivot connected to the steel frame 16 through auger axis and to a back support foot 60 as can be seen in FIG. 2 . FIG. 2 is an enlarged side view of milling-mixing auger 28 and half rounded shield plate 62 . The geometry of such an arrangement causes the bottom most part of the milling-mixing auger 28 and thus the depth of cut and the bottom of the back support foot 60 to move exactly parallel with the line of travel of the front pivot 56 of the long-arm draw-bar 58 .
Positioned behind the milling-mixing auger 28 is a shield plate 62 . The half rounded shield plate 62 is positioned behind the milling-mixing auger 28 so that it can be rotated around the center rotating axis of milling-mixing auger 28 . The half rounded shield plate 62 is spring loaded to rotate in a clock-wise direction so as to scrape and clean the surface of the just milled roadway or stopped from rotation and locked to the back support foot 60 in a position just above the milled roadway surface so that a desired amount of fine aggregates and/or sand, which have settled to the bottom of the mixture due to the mixing action, can pass under the half rounded shield plate 62 and thereby be removed from the resulting mix in order to meet the intended volumetric properties of the aggregates in the new mix. The resulting thin layer of fine aggregates and/or sand can be scraped to the outer edges of the roadway and discarded or left in place as a binder and paving base for the resulting new mix. The layer of fine aggregates and/or sand is relatively thin as compared to the much thicker repaved new mix and therefore not structurally significant in the attempt to prevent permanent pavement deflection of the much thicker repaved new mix in the future.
The half rounded shield plate 62 is adjustable as to the height of the bottom edge above the just milled road surface is locked in place with the back support foot 60 of the long-arm draw-bar 58 . The purpose of the locked in position of the half rounded shield plate 62 is to provide an open clearance above the milled roadway surface. The clearance of the shield plate 62 is adjusted so that the bottom edge is set from between substantially 0″ and substantially ½″ above the roadway surface depending upon the size and amount of the small aggregate and/or sand 66 being removed from the existing roadway mix. However, in practice the height of the shield plate 62 is not limited to ½″ and can be any height desired or required to form the superpave mix.
A seat 50 is provided on the steel frame 16 for accommodating an operator of the pavement remixing machine 10 and a control panel 52 is provided in a position in front of the operator seat 50 for controlling the operation of the pavement remixing machine 10 . The control panel 52 is positioned so as to be easily reached by the operator when in the seat 50 .
The operation of the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture will now be described with reference to the figures and specifically FIGS. 3 and 4. In operation, the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture 10 is brought to a roadway on which it is desired to convert the existing pavement into a superpave mixture and thus increase the performance, durability, safety and efficiency of the roadway. The apparatus 10 is driven over the roadway a first time with the heater 26 turned on, the milling-mixing augers 28 and 34 rotating and the hopper 38 providing a desired amount of new material to the roadway which will alter the composition of the existing roadway into a superpave mixture. The amounts and types of new materials needed to convert the pavement of an existing roadway is determined from the charts of FIGS. 5A-5H. These charts provide information on all of the commonly used asphalt concrete mixtures and what is needed to change the composition to form a superpave mixture. The necessary amounts are placed in the hopper 38 for deposit on the roadway 12 . The milling-mixing auger 28 is set at a desired height based upon the thickness of a layer of pavement 14 that is desired to be milled. Preferably, the milling-mixing auger 28 will be set to mill a slab of roadway having a thickness of between substantially 0″ to substantially substantially a ½″ at one time. However, the milling-mixing auger 28 can be set to mill a slab of roadway having any desired thickness. The thickness of the slab to be milled being dependent upon the depth to which the heater is able to heat the pavement of the roadway.
The apparatus 10 is then driven over the roadway 12 a first time. As the apparatus traverses the roadway 12 , the hopper 38 deposits the material placed therein on the roadway 12 . This material is picked up by the drag bar conveyor 40 and travels therealong over the heater 26 and back to the milling-mixing auger 28 , on top of which it is deposited. The heater 26 is heated at this time and acts to heat the pavement 14 to a temperature at which it can be easily broken up.
As the milling-mixing auger 28 passes along the roadway 12 , it mills a layer of pavement having a thickness based upon the height at which it is set using the milling bits extending therearound and the depth at which the heater is able to heat the pavement on the roadway. The material deposited thereon by the drag bar conveyor is received in the milling bits and is deposited on the roadway with the milled pavement. The milling bits are shaped so as to direct the milled pavement and the material deposited thereon along a center line of the apparatus. Positioned behind the milling-mixing auger 28 is a rear milling-mixing auger 34 which will further mix the milled pavement and material deposited therewith by the milling-mixing auger 28 .
At this time a second apparatus 10 will pass along the roadway behind and along the path of the first apparatus 10 . This second apparatus 10 will not deposit any new material on the roadway 12 as all the new material needed to alter the composition of the pavement to a superpave mix has been deposited by the first apparatus 10 . The heater 26 will heat the pavement as it passes thereover. This apparatus will have its milling-mixing auger 28 at a distance below that of the first milling-mixing auger 28 to thereby mill a slice of pavement below the pavement milled by the first apparatus 10 . The thickness of the slab of roadway to be milled being based upon the height at which it is set using the milling bits extending therearound and the depth at which the heater is able to heat the pavement on the roadway. As the second apparatus passes along the roadway 12 , the drag bar conveyor 40 will pick up the milled pavement and material deposited there by the first apparatus for delivery to the milling-mixing auger thereof The milling-mixing auger 28 will then mill the heated pavement while also receiving the milled pavement and new material picked up by the drag bar conveyor 40 . The new material and milled pavement deposited on the milling-mixing auger 28 by the drag bar conveyor 40 is received in the milling bits 36 and is deposited on the roadway with the newly milled pavement. The milling bits 36 are shaped so as to direct the milled pavement and the material deposited thereon along a center line of the apparatus. The newly milled pavement is then mixed with the new material and pavement milled by the first apparatus by the milling-mixing auger 28 . Positioned behind the milling-mixing auger 28 is a rear milling-mixing auger 34 which will further mix the milled pavement and material deposited therewith by the milling-mixing auger 28 and provide the mixed combination along a center line of the apparatus.
A shield plate 62 is connected to the milling-mixing auger 28 and is maintained at a height above the surface of the pavement 14 . The shield plate 62 is able to allow fine aggregate or sand to pass thereunder and thus be separated from the mixture of milled pavement and new material thus increasing the particle size of the asphalt within the mixture. The fine aggregate or sand passing under the shield plate 62 is left on a side of the roadway and separated from the mixture. This fine aggregate or sand forms a layer positioned beneath the superpave mix and thus the superpave mix remains unaffected thereby. The size of the particles allowed to pass under the shield plate 62 is determined by the height at which the shield plate 62 is set. The shield plate 62 is height adjustable and is set at a height in accordance with the necessary height for forming a superpave mixture as indicated on the charts of FIGS. 5A-5H. Numerous factors determine the height needed for the shield plate 62 including the type of mixture forming the pavement to be converted and the amounts and types of new material added to the milled pavement by the hopper 38 .
The process performed by the second apparatus is then repeated with a third apparatus and possibly additional apparatuses until a layer of pavement of a desired thickness is stripped from the roadway and mixed with new material or filtered to remove the fine aggregate or sand therein to form a superpave mix. Preferably, a slab of pavement having a thickness of substantially 1½″ is milled by this process. However, a slab having any desired thickness may be milled by simply setting the milling-mixing augers 28 to a desired height and passing any desired number of apparatusses along the roadway in a series fashion. Throughout the process the pavement and mixture is constantly heated and remains at an elevated temperature. At this temperature the pavement is easily removed, milled and mixed by the apparatus and is at a temperature at which it can be easily repaved over the roadway. At this point either a paver is passed along the roadway to pave the roadway with the converted superpave mix or the superpave mix is lifted from the pavement by another apparatus for use at a desired location.
Thus, this apparatus and method of use is able to recycle existing poorly mixed pavements and convert the mixture to a superpave mixture having improved qualities which are able to stand up to changing elements such as cold and heat and also withstand a greater amount of use by vehicles. It is now unnecessary to simply discard old pavement once it is removed as this pavement can be recycled and converted to a pavement having improved qualities which provide improved performance.
From the above description it can be seen that the apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture of the present invention is able to overcome the shortcomings of prior art devices by providing a ladder including storage areas which is able to convert existing pavement on a roadway into a superpave mixture having improved qualities from the existing roadway whereby layers of previously paved asphalt from a roadway are to heated and removed prior to conversion into a superpave mixture. The method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture creates a superpave mix having improved performance, durability, safety and efficiency over the paving mixture being altered. The apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture includes a heating device for heating and thereby softening the asphalt on a roadway, a milling device for chopping the heated asphalt and thereby removing a layer of asphalt from the roadway, a hopper containing new asphalt concrete mixture materials for combination with the layer of asphalt removed from the roadway and altering the gradation of the existing asphalt into a superpave mixture and a height adjustable shield device for filtering out fine aggregates or sand from the asphalt removed from the roadway to thereby alter the gradation of the existing asphalt into a superpave mixture. Furthermore, the ladder including storage areas of the present invention is simple and easy to use and economical in cost to manufacture.
It will be understood that each of the elements described above, or two or more together may also find a useful application in other types of methods differing from the type described above.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A method and apparatus for altering an aggregate gradation mixture of an asphalt concrete mixture. The apparatus includes a heater for heating a layer of existing roadway materials, a milling and mixing auger for milling the heated layer of existing roadway materials and a hopper and conveyor for providing a predetermined amount of treated new usable aggregates to the milling and auger for mixing with the heated layer of existing roadway materials in order to produce a new asphalt concrete mixture. The auger including a plurality of milling bits extending therearound for receiving the predetermined amount of aggregates and mixing them with the milled layer of existing roadway materials, the milling bits are slanted to direct the aggregates received thereby and milled layer to a center line of the apparatus. A second auger is positioned along the center line of the apparatus and behind the auger for further mixing the new asphalt concrete mixture. A shield plate is adjustably secured to the auger for separating and removing selected unusable aggregates from the material. The hopper is preloaded with the predetermined amount of treated new usable aggregates and the conveyor retrieves the aggregates from the hopper and provides the aggregates to the auger. The new mixture formed by the method and apparatus has the volumetric requirements for a superpave mix in accordance with the design system developed by the Strategic Highway Research Program of 1987. | 4 |
FIELD
The technology relates to a fault detection system using motor current signature analysis. More specifically, the technology relates to a method and system for eccentricity fault detection.
BACKGROUND
A certain degree of asymmetry always exists even in a newly manufactured machine. If the percentage of asymmetry exceeds 10% of the nominal air gap length, the machine is said to be eccentric. Eccentricity results in excessive noise, vibration, higher torque ripple, increased electromagnetic stress, increased temperature and in the worst case causes a stator rotor rub. Due to such detrimental effects, monitoring the motor for eccentric conditions gains paramount significance.
A theoretical background for current signature based eccentricity detection in induction motors has been provided by S. Nandi, R. M. Bharadwaj and H. A. Toliyat in “Mixed eccentricity in three phase induction machines: Analysis, simulation and experiments,” published in Conf. Rec. IEEE - IAS Annual Meeting , Pittsburgh, Pa., vol. 3, pp. 1525-1532, October 2002. A modified winding function approach (MWFA) based modeling of machines reported in this work has been used in the field of condition monitoring for many subsequent researches.
In the field of synchronous machines, an index for non-invasive diagnosis of eccentricity in permanent magnet machines has been proposed by B. M. Ebrahimi, J. Faiz and M. J. Roshtkhari in “Static-eccentricity, dynamic-eccentricity, and mixed-eccentricity fault diagnoses in pelitianent magnet synchronous motors,” published in IEEE Trans. Industrial Electronics , vol. 56, no. 11, pp. 4727-4739, November 2009. As all types of eccentricities affected the same frequency components the authors had to resort to k-Nearest Neighbour classifier and three-layer Artificial Neural Network to detect the type and degree of eccentricity. The network was trained using 280 current vectors out of a total population of 400 current vectors.
C. Bruzzese and G. Joksimovic have identified the harmonic components present in the rotor field and stator voltages of a no-load salient pole synchronous generator in “Harmonic signatures of static eccentricities in the stator voltages and in the rotor current of no-load salient-pole synchronous generators,” published in IEEE Trans. Industrial Electronics , vol. 58, no. 5, pp. 1606-1624, May 2011. The effect of the stator magneto-motive force (MMF) has not been included as the authors have focused their attention on synchronous generator operating at no-load. In case of a synchronous motor, the effect of the stator MMF can play a very significant role in the generation of eccentricity related harmonics.
None of the contemporary works have taken into consideration the effect of supply unbalance, supply harmonics, constructional asymmetry etc. Accordingly, there is a need for a method to determine the specific harmonic components in the motor current spectrum, which will indicate the type and the degree of eccentricity fault under any level of load, supply unbalance and internal asymmetry of the machine.
SUMMARY
In some examples, methods of detecting air gap eccentricity and stator inter-turn faults in a multi-phase electric machine include determining a spectral magnitude at a selected fault frequency based on at least one of a stator current and a field current, and indicating a fault based on the determined spectral magnitude and the selected fault frequency. In some embodiments, a residue correction is applied to the spectral magnitude, wherein the fault is determined based on the residue-corrected spectral magnitude. In other examples, the residue correction is based on spectral characteristics corresponding to a non-eccentric multi-phase machine. According to some embodiments, the spectral magnitude is associated with a frequency associated with a dynamic eccentricity, and the residue correction is based on a spectral magnitude corresponding to an air gap lacking static eccentricity. In typical examples, the indicated fault is associated with an air gap eccentricity such as a dynamic air gap eccentricity, a static air gap eccentricity, or a mixed static and dynamic air gap eccentricity. In other embodiments, the indicated fault is associated with an inter-turn short circuit. In some examples, a fault frequency is selected based on a fault to be identified such as a static eccentricity, a dynamic eccentricity, or a mixed eccentricity. In some particular examples, the selected fault frequency is
f fault = ( n ± 6 h ± km p ) f ,
wherein n=1, 5, 7, 11, 13 . . . , m is a non-negative even integer for static eccentricity, m is a positive integer for mixed eccentricity, p is a fundamental pole pair number, f is a stator line frequency, and k and h are non-negative integers. The disclosed methods can be implemented on a computing system with computer executable instructions stored on a computer-readable medium.
Apparatus, comprise a signal processor configured to estimate a spectral magnitude associated with at least one of a stator current and a field current of an induction machine, and based on the estimated spectral magnitude, identify at least one of a static eccentricity, a dynamic eccentricity, and a mixed eccentricity. In some examples, the signal processor is configured to identify at least one of a static eccentricity, a dynamic eccentricity, and a mixed eccentricity based on the spectral magnitude and frequency at associated fault frequencies. In some examples, a signal conditioner is configured to couple an electrical signal associated with at least one of the stator current and the field current to the signal processor, typically as a digitized electrical signal. According to representative embodiments, the signal processor is configured to obtain a Fourier transform of the electrical signal and estimate the spectral magnitude based on the Fourier transform. In some examples, the signal processor is configured to estimate a contribution of an eccentric condition to the spectral magnitude based on a contribution associated with a non-eccentric condition. According to some examples, the signal processor is configured to estimate the spectral magnitude associated with at least one of the stator current and the field current based on a stator voltage.
Methods comprise obtaining a spectral magnitude associated with at least one of a stator current and a field current in a motor, and based on the spectral magnitude and at least one fault frequency, identifying an eccentricity type in a motor. In some embodiments, the identified type is at least one of a static eccentricity, a dynamic eccentricity, and a mixed eccentricity. In particular examples, the at least one fault frequency is
f fault = ( n ± 6 h ± km p ) f ,
wherein n=1, 5, 7, 11, 13 . . . , m is a non-negative even integer for static eccentricity, m is a positive integer for mixed eccentricity, p is a fundamental pole pair number, f is a stator line frequency, k and h are non-negative integers.
The present technology is capable of detecting eccentricity fault in a three-phase electric machine, which is rotating in nature. The inverse air gap of the machine, which gets affected by eccentricity, has been modeled using a binomial series expression for the first time. The major advantages of such a representation are (i) the expression can be generalized to deal with any type of multi-phase rotating machines such as induction machines and synchronous machines, both round rotor and salient pole types, and (ii) the expression will constitute constant coefficient co-sinusoidal terms that can identify eccentricity specific frequency components in the line current spectrum when multiplied with magneto-motive force in the machine.
In order to use the present technology, no intrusive sensors are necessary. Only line currents and line to line voltages need to be monitored and fed through a data acquisition system for analysis using a computer program or dedicated processing system. For machines having external field connections, field current data can also be acquired. This program enables real time visualisation of the captured quantities in the frequency domain. The end user needs to focus on the modulation of the amplitude of the fault specific frequency components in the spectrum. These modulations can be rise, fall, presence and/or absence of the fault specific frequency components. The type of eccentricity can be accurately predicted by observing these modulations. In some examples, some or all of line currents, line voltages, field currents, or other such currents or voltages are estimated or measured.
The typical fault frequencies in the stator line current spectrum and where applicable, the field current spectrum can be defined as:
f ste = ( n ± 6 h ± k m p ) f f rte = ( ± 6 h ± k m p ) f
wherein f ste is a frequency of the harmonic component present in the stator current under different eccentric conditions, f rte is a frequency of the harmonic component present in the field current under different eccentric conditions, f is a stator line frequency, n=1, 5, 7, 11, 13, . . . ; h=1, 2, 3 . . . ; k=0, 1, 2, 3 . . . ; m=0 for healthy and dynamic eccentric condition, m=0, 2p, 4p, . . . for static eccentric conditions and m=0, 1, 2, 3 . . . for mixed eccentric conditions, and p is a fundamental pole pair number.
For inter-turn short-circuit faults on a multi-phase stationary stator winding of electric machines, fault specific frequencies in the motor line currents are similar to f ste corresponding to static eccentricity fault frequencies given above. Under short-circuit faults also modulations of the amplitude of these fault specific components occur. These modulations can be rise, fall, presence and/or absence of the fault specific components. Thus, in some exceptions, the described methods and approaches can be configured to diagnose stator inter-turns faults as well.
These and other aspects of the disclosed technology are set forth below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-view of an experimental synchronous motor with modified enclosure.
FIG. 2 illustrates a new bearing along with a set of eccentric bushings for physically implementing eccentricity faults on a healthy synchronous machine.
FIG. 3 shows an air gap function of a healthy salient pole synchronous machine g h (φ, θ r ) for θ r =0. Effective d-axis air gap length=d meters; effective q-axis air gap length=q meters.
FIG. 4 illustrates a double sided FFT plot of the MWFA simulated stator line current space phasor of the healthy synchronous machine working at full load.
FIG. 5 contains the double sided FFT plot of the MWFA simulated stator line current space phasor of the 33.34% static eccentric synchronous machine working at full load.
FIG. 6 contains the double sided FFT plot of the MWFA simulated stator line current space phasor of the 33.34% dynamic eccentric synchronous machine working at full load.
FIG. 7 contains the double sided FFT plot of the MWFA simulated stator line current space phasor of the 33.34% mixed eccentric synchronous machine working at full load.
FIG. 8 shows the variation of the residue eliminated +9f component of the stator line current space phasor of the experimental synchronous machine for different levels of static eccentricity (SE) working at full load.
FIG. 9 shows the variation of the residue eliminated +7f component of the stator line current space phasor of the experimental synchronous machine for different levels of dynamic eccentricity (DE) working at full load.
FIG. 10 shows the variation of the residue eliminated +2f component of the stator line current space phasor of the experimental synchronous machine for different levels of mixed eccentricity (ME) working at full load.
FIG. 11 contains the variation of the residue eliminated +9f component of the stator line current space phasor of the experimental synchronous machine for different levels of load working at 16.67% static eccentricity.
FIG. 12 contains the variation of the residue eliminated +7f component of the stator line current space phasor of the experimental synchronous machine for different levels of load working at 16.67% dynamic eccentricity.
FIG. 13 contains the variation of the residue eliminated +2f component of the stator line current space phasor of the experimental synchronous machine for different levels of load working at 33.34% mixed eccentricity.
FIG. 14 contains the FFT plot of the MWFA simulated field current phasor of the healthy synchronous machine working at full load.
FIG. 15 contains the FFT plot of the MWFA simulated field current phasor of the 50% static eccentric synchronous machine working at full load.
FIG. 16 contains the FFT plot of the MWFA simulated field current phasor of the 33.34% dynamic eccentric synchronous machine working at full load.
FIG. 17 contains the FFT plot of the MWFA simulated field current phasor of the 66.67% mixed eccentric synchronous machine working at full load.
FIG. 18 shows the variation of the residue eliminated 4f component of the field current phasor of the experimental synchronous machine for different levels of static eccentricity working at full load.
FIG. 19 shows the variation of the residue eliminated 6f component of the field current phasor of the experimental synchronous machine for different levels of dynamic eccentricity working at full load.
FIG. 20 shows the variation of the residue eliminated 3.5f component of the field current phasor of the experimental synchronous machine for different levels of mixed eccentricity working at full load.
FIG. 21 contains the variation of the residue eliminated 4f component of the field current phasor of the experimental synchronous machine for different levels of load working at 16.67% static eccentricity.
FIG. 22 contains the variation of the residue eliminated 6f component of the field current phasor of the experimental synchronous machine for different levels of load working at 16.67% dynamic eccentricity.
FIG. 23 contains the variation of the residue eliminated 3.5f component of the field current phasor of the experimental synchronous machine for different levels of load working at 33.34% mixed eccentricity.
FIG. 24 is a block diagram of a representative system configured to detect air-gap eccentricity and/or inter-turn short circuit faults of multi-phase, multi-winding rotating electric machines.
DETAILED DESCRIPTION
As used in this application and in the claims, the singular forms “a”, “an” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises”. The systems, apparatus, and methods described herein should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and non-obvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The disclosed systems, methods, and apparatus are not limited to any specific aspect or feature or combinations thereof, nor do the disclosed systems, methods and apparatus require that any one or more specific advantages be present or problems be solved.
Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed systems, methods and apparatus can be used in conjunction with other systems, methods and apparatus. Additionally, the description sometimes uses terms like “produce” and “provide” to describe the disclosed methods. These terms are high-level abstractions of the actual operations that are performed. The actual operations that correspond to these terms will vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art.
Experimental results for representative approaches were obtained by inserting customized bushings with a bearing in a 3 hp synchronous motor. A comparative study of the characteristic frequency components was completed with different types and levels of eccentricity faults and supply unbalance. Firstly, the inverse of the air gap length of the machine over the entire inner periphery of the stator (known as the inverse air gap function) was represented using a binomial expression. Secondly, using this binomial expression, various equations were developed to predict the harmonics best suited for detecting different types of eccentricity faults (static eccentricity, dynamic eccentricity and mixed eccentricity) in any synchronous machine. The utility of the equations were then verified.
Example 1
(i) Description of Motor and Selection of Fault
A salient pole synchronous motor was used for the experiments. It was a 208 V, 1800 rpm, 60 Hz, 3 hp, 3-phase, 4-pole star connected machine, with a nominal air gap length of 0.6 mm along d-axis and 40.27 mm along q-axis. The enclosure of the machine was modified so as to facilitate air gap measurements using a feeler gauge. The bearings and end bells were also changed. Two sets of eccentric bushings, each offset by 16.67%, 33.34% and 50% of the air gap, were used to obtain different combinations of static, dynamic and mixed eccentricity conditions. FIG. 1 shows the modified enclosure whereas a new bearing along with a set of eccentric bushings are shown in FIG. 2 .
(ii) Mechanism of Induction of Harmonics in the Stator Line Current Under Healthy Condition
The stator MMF produced by a balanced three phase sinusoidal supply is given by (1)
F s =Σ n=1,5,7,11, . . . ∞ M sn cos [ npφ±ωt], (1)
wherein p is the number of fundamental pole pairs (half the number of fundamental poles), φ is the stator space angle, and M sn is a real number. The specific permeance function P h of a healthy multi-phase rotating electromechanical machine was represented as in (2). This can be obtained by multiplying the ideal representation of the inverse air gap function, as shown in (18), with permeability of air.
P h =Σ q=0,2p,4p, . . . ∞ P hq cos [ q (φ−θ r )] (2)
where θ r is the rotor position with respect to stator and P hq is a real number.
The flux density produced due to the interaction of the stator MMF and the specific permeance function can be expressed as
B sn =M sn P hq cos [ npφ±ωt ] cos [ q (φ−θ r )]. (3)
High frequency currents were induced in the damper bars of the synchronous machine because of (3). These circulating currents generated an MMF, which was given with respect to the rotor as
F rn = M rn cos [ ( m 1 ) φ ′ ± 6 h ω t + θ 1 ] ; m 1 = 1 , 2 , 3 … , h = 1 , 2 , 3 , ⋯ , φ ′ = φ - ω r t , ω r = ω p , θ r = ω r t . M rn is a real number ( 4 )
The MMF so produced reacted with the specific permeance function (2) and resulted in another flux density. Thus, with respect to stator frame of reference the total flux density in the air-gap was represented by (5).
B srn = 1 2 M srn P hq cos { ( m 1 + q ) φ - ( ± 6 h + m 1 + q p ) ω t + θ 1 } + 1 2 M srn P hq cos { ( m 1 - q ) φ - ( ± 6 h + m 1 - q p ) ω t + θ 1 } ( 5 )
where is a real number.
Current in the stator winding was induced due to the flux density given above if and when the pole pair numbers (m 1 ±q)/p of (5) matched with n of (1). Thus, the frequencies of such induced currents were obtained using (6).
f he =( n± 6 h ) f; n= 1,5,7 . . . ; h= 1,2,3 (6)
For example, if n=1, h=1; then f h =5f, +7 f and if n=1, h=2; then f h =−11f, +13f. Ideally, a healthy salient pole synchronous machine was found to contain all odd harmonics except the triple harmonics.
(iii) Mechanism of Induction of Harmonics in the Stator Line Current Under Static Eccentric (SE) Condition
The specific permeance function of a multi-phase rotating electromechanical machine under static eccentric condition was represented as in (7).
P se =Σ l=0,1,2,3 . . . ∞ Σ m=0,2p,4p . . . ∞ P selm cos( lφ±mθ r ) (7)
where P selm is a real number.
When the stator MMF of (1) interacted with the SE permeance function (7), it resulted in a flux density in the air-gap, which with respect to stator was given by (8).
B sen =M sen P selm cos [ npφ±ωt ] cos [ lφ±mθ r ]. (8)
M sen is a real number.
The above flux density induced currents in the rotor bars that resulted in a rotor MMF expressed using (9).
F ren = M ren cos [ ( m 1 ) φ ′ + ( ± 6 h + ± l ± m p ) ω t + θ 2 ] ; ( 9 )
M ren is a real number.
The MMF so produced reacted with the SE specific permeance function (7) and resulted in another flux density. Thus, with respect to stator frame of reference the total flux density in the air-gap can be represented by (10):
B srsen = 1 2 M sren P selm [ cos { ( m 1 + l ) φ - ( ± 6 h + ( m 1 ± l p ) ± km p ) ω t + θ 2 } + cos { ( m 1 - l ) φ - ( ± 6 h + ( m 1 ± l p ) ± km p ) ω t + θ 2 } ] ( 10 )
where M sren is a real number.
Current in the stator winding was induced under SE condition due to the flux density given above if and when the pole pair numbers (m 1 ±l)/p of (10) matched with n of (1). Thus, the frequencies of such induced currents were obtained using (11).
f
se
=
(
n
±
6
h
±
km
p
)
f
;
where
n
,
h
as
in
(
6
)
;
k
=
0
,
1
,
2
…
;
m
=
0
,
2
p
,
4
p
,
…
(
11
)
For example, if n=1, h=1, m=4, p=2, k=2; then f se =(1±6±4) f=− 9f, −f, +3f, +11f and if n=1, h=2, m=4, p=2, k=2; then f se =(1±12±4)f=−15f, =7f, +9f, +17f. Thus, it is evident that SE introduced triplen harmonics in the line current spectrum in addition to other odd harmonics.
(iv) Mechanism of Induction of Harmonics in the Stator Line Current Under Dynamic Eccentric (DE) Condition
The specific permeance function of a multi-phase rotating electromechanical machine under dynamic eccentric condition was represented as in (12).
P de =Σ m=0,1,2,3 . . . ∞ P dem cos { m (φ−θ r )} (12)
When the stator MMF of (1) interacted with the DE permeance function (12), it resulted in a flux density in the air-gap. This flux density induced circulating currents in the rotor bars that resulted in a rotor MMF. This rotor MMF interacted with the DE permeance function (12) resulting in another flux density in the air gap. Hence, with respect to the stator frame of reference, the total air gap flux density was represented by (13):
B srden = 1 2 M srden P dem [ cos { ( m 1 + l ) φ - ( ± 6 h + ( m 1 ± l p ) ) ω t + θ 3 } + cos { ( m 1 - l ) φ - ( ± 6 h + ( m 1 + l p ) ) ω t + θ 3 } ] ( 13 )
M srden , P dem are real numbers.
When the pole pair numbers (m 1 ±l)/p of the flux density in (13) matched with n of (1), currents were induced in the stator windings. The frequencies of these currents were computed using (14).
f de =( n± 6 h ) f; n= 1,5,7 . . . ; h= 1,2,3 (14)
For example, if n=1, h=1; then f de =−5f, +7f and if n=1, h=2; then f de =−11f, +13f. Thus, it is evident that DE did not introduce any additional harmonic components as SE. Instead it only modified the existing odd harmonics of the healthy machine.
(v) Mechanism of Induction of Harmonics in the Stator Line Current Under Mixed Eccentric (ME) Condition
The specific permeance function of a multi-phase rotating electromechanical machine under mixed eccentric condition was represented as in (15):
P me =Σ l=0,1,2,3 . . . ∞ Σ m=0,1,2,3, . . . ∞ P melm cos( lφ±mθ r ) (15)
where P melm , is a real number.
Following similar mathematical derivations as before, the interaction of the MMF (1) with the specific permeance (15) resulted in components in the line current of the faulty machine given as:
f me = ( n ± 6 h ± km p ) f ; m = 0 , 1 , 2 , 3 … ; n , h , k as in ( 11 ) ( 16 )
For example, if n=1, h=1, k=1, m=1, p=2; then
f me =−5.5f, −4.5f, +6.5f, +7.5f and if n=1, h=1, k=5, m=2, p=2; then
f me =−10f, 0f, +2f, +12f. The line current spectrum was found to consist of all harmonics, both even and odd. Moreover, side band components were also predicted under ME fault.
TABLE I
FIRST FEW HARMONIC COMPONENTS OF STATOR LINE
CURRENT PHASOR UNDER DIFFERENT CONDITIONS
HE
+1f
−5f
+7f
−11f
+13f
−17f
SE
±1f
±3f
±5f
±7f
±9f
±11f
DE
+1f
−5f
+7f
−11f
+13f
−17f
ME
±0.5f
±1f
±1.5f
±2f
±2.5f
±3f
Example 2
(i) Derivation of Binomial Series Based Inverse Air Gap Function
Conventionally, the inverse air gap function, which was needed for obtaining the specific permeance function of any rotating electric machines, had been modeled using Fourier series. However, the major disadvantage in this approach was the presence of the coefficients in the inverse air gap function as rotor position dependent non-linear functions. This made it impossible to explicitly predict the fault related harmonics in the stator line current under different types of eccentricity conditions. So in this present work, a binomial series based air gap function had been developed for healthy and eccentric cases, where the coefficients of the trigonometric terms were all constants. Hence, simple and accurate predictions of fault related harmonics were possible.
Mixed eccentric condition had been considered as the generalized case, as healthy condition, static eccentricity and dynamic eccentricity were treated theoretically as special cases of the mixed eccentric case itself. The air gap function of a machine with mixed eccentricity was given by (17).
g me (φ,θ r )= g h (φ,θ r )− a s cos φ− a d cos(φ−θ r ) (17)
where φ=angular reference in stator, θ r =rotor position with respect to stator, a s =absolute value of SE and a d =absolute value of DE and g h (φ,θ r )=air gap of a healthy machine. The air gap function of the healthy machine is described by (18). Here p=number of pole pairs. Note that it is a rectangular function as shown in FIG. 3 .
g h (φ,θ r )=Σ q=0,2p,4p,6p . . . ∞ A hq cos { q (φ−θ r )} (18)
In (17), two new parameters a 1 and a 2 were introduced, which were
a 1 = a s g h ( φ , θ r ) ; a 2 = a d g h ( φ , θ r ) ( 19 )
Thus, (17) was rewritten as shown in (20). This equation was used for representing the air gap function for any type of eccentricity later on.
g me (φ,θ r )= g h (φ,θ r )[1− a 1 cos φ− a 2 cos(φ−θ r )] (20)
In case of pure static eccentricity, a 2 vanishes and therefore (20) is modified
g se (φ,θ r )= g h (φ,θ r )[1− a 1 cos φ] (21)
For preventing stator-rotor rub or for maintaining possible running condition, 0≦a 1 ≦1, which implied that a 1 cos(φ)<1. Therefore, the inverse air gap function g se −1 (φ,θ r ) was expressed as a binomial series:
g se - 1 ( φ , θ r ) = 1 g h ( φ , θ r ) [ 1 + ( S ) + ( S ) 2 + ⋯ ] ; where S = a 1 cos φ ( 22 )
Note that [g h (φ,θ r )] ±m 2 ) has the same harmonic content as g h (φ,θ r ) for any m 2 εZ, where ε is the set of all integers. This is considering the ideal rectangular nature of g h (φ,θ r ). Using identities (23) and (24), along with this harmonic invariance property of the air gap, the inverse air gap function for pure SE was expressed as (25).
cos m φ = 1 2 m - 1 Σ k = 0 m - 1 2 m c k cos { ( m - 2 k ) φ } ; m = odd ( 23 ) cos m φ = 1 2 m m c m 2 + 1 2 m - 1 Σ k = 0 m 2 - 1 m c k cos { ( m - 2 k ) φ } ; m = even
Where m c k = m ! ( k ) ! ( m - k ) ! and m c m 2 = m ! ( m 2 ) ! ( m 2 ) ! ( 24 ) g se - 1 ( φ , θ r ) = Σ l = 0 , 1 , 2 , 3 … ∞ Σ m = 0 , 2 p , 4 p , 6 p… ∞ G selm cos ( lφ ± m θ r ) ( 25 )
where G selm is a real number.
Multiplying this inverse air gap function with the permeability of air yielded the specific permeance function under SE condition, which was previously introduced in (7).
In case of pure dynamic eccentricity, a 1 vanishes and therefore (20) is modified to:
g de (φ,θ r )= g h (φ,θ r )[1− a 2 cos(φ−θ r )] (26)
For preventing stator-rotor rub or for maintaining possible running condition, 0≦a 2 <1, which implied that a 2 cos(φ−θ r )<1. Thus, the inverse air gap function was represented as a binomial series
g de - 1 ( φ , θ r ) = 1 g h ( φ , θ r ) [ 1 + ( D ) + ( D ) 2 + ⋯ ] ; where D = a 2 cos ( φ - θ r ) ( 27 )
Again using identities (23) and (24), and the harmonic preserving property of [g h (φ,θ r )] ±(m 2 ) , the inverse air gap function for pure DE was expressed as
g de −1 (φ,θ r )=Σ m=0,1,2,3 . . . G dem cos { m (φ−θ r )} (28)
G den , is a real number.
Multiplying this inverse air gap function with the permeability of air yielded the specific permeance function under DE condition which was previously introduced in (12).
In case of mixed eccentricity, both a 1 and a 2 existed subject to the condition 0≦a 1 +a 2 <1, which implied: a 1 cos φ+a 2 cos(φ−θ r )<1. Therefore, g me −1 (φ,θ r ) was also expressed as a binomial series:
g me - 1 ( φ , θ r ) = 1 g h ( φ , θ r ) [ 1 + ( S + D ) + ( S + D ) 2 + ⋯ ] ( 29 )
Using identities (23), (24) and (30), and the harmonic preserving property of [g h (φ,θ r )] ±(m 1 ) , the inverse air gap function for a ME machine was represented as in (31).
( S+D ) m=Σ k=0 m m C k S m-k D k (30)
g me −1 (φ,θ r )=Σ l=0,1,2,3 . . . ∞ Σ m=0,1,2,3 . . . ∞ G melm cos( lφ±mθ r ) (31)
G melm is a real number. Multiplying this inverse air gap function with the permeability of air, gave the specific permeance function under ME condition which was previously introduced in (15).
Example 3
(i) Motor Line Current Based Eccentricity Detection
Simulation Results
In order to simulate the performance of the machine under healthy, static, dynamic and mixed eccentric conditions, a state space model of a salient-pole synchronous machine was developed according to the coupled electromagnetic circuit based approach. The various inductances required in the state space model were computed using Modified Winding Function Approach (MWFA). The generic equation representing the inductance between any two windings computed using MWFA was given by (32).
L ab = μ 0 rl [ ∫ 0 2 π n a ( φ , θ r ) . n b ( φ , θ r ) . g - 1 ( φ , θ r ) ⅆ φ - 2 π < N a ( θ r ) > . < N b ( θ r ) > . < g - 1 ( φ , θ r ) > ] ( 32 ) where < N a ( θ r ) >= 1 2 π < g - 1 ( φ , θ r ) > ∫ 0 2 π n a ( φ , θ r ) . g - 1 ( φ , θ r ) ⅆ φ ( 33 ) < N b ( θ r ) >= 1 2 π < g - 1 ( φ , θ r ) > ∫ 0 2 π n b ( φ , θ r ) . g - 1 ( φ , θ r ) ⅆ φ ( 34 ) < g - 1 ( φ , θ r ) >= 1 2 π ∫ 0 2 π g - 1 ( φ , θ r ) ⅆ φ ( 35 )
μ 0 is the permeability of air, r is the mean radius of the motor and l is the stack length of the motor.
The transient and steady state performances of the machine were then computed by feeding the values of these stored inductances and their derivatives into the state space model. MATLAB's inbuilt ODE45 solver was used to solve for different state variables. Then, the double sided Fast Fourier Transform (FFT) plots were obtained for the stator line current space phasors under healthy and eccentric conditions for identifying the harmonics.
The double sided FFT of the stator line current space phasor of the healthy synchronous machine at full load, simulated using the above-mentioned MWFA technique has been shown in FIG. 4 . As predicted by (6), the predominant harmonics in the healthy machine's stator line current were non-triplen odd harmonics such as −5f and +7f.
Similarly, the static, dynamic and mixed eccentric cases, each of 33.34%, were also simulated using MWFA technique, for corroborating the theoretical results. FIG. 5 shows the double sided FFT of the stator line current space phasor of the static eccentric machine, simulated by MWFA technique. The line current spectrum showed the presence of triplen harmonics along with other odd harmonics, as predicted by (11). FIG. 6 shows the double sided FFT of the stator line current space phasor of the dynamic eccentric machine, again simulated by MWFA technique. The line current spectrum showed existence of only those haunonics which were originally present in the stator line current of the healthy machine, but their magnitudes were modified. This was in accordance with (14). FIG. 7 shows the double sided FFT of the stator line current space phasor of the mixed eccentric machine, simulated by MWFA technique. The line current spectrum was found to comprise of both even as well as odd harmonics. Moreover, the presence of side band components as predicted by (16) was also confirmed in these simulation results.
(ii) Experimental Results
A 3 phase, 3 hp, 208V, 4 pole, 60 Hz, star connected synchronous motor was used as the laboratory prototype for validating the proposed diagnostic scheme. The enclosure of the machine was modified so as to facilitate air gap measurements using feeler gauge. The bearings and end bells were also changed. Two sets of eccentric bushings, each offset by 16.67%, 33.33%, and 50% of the air gap, were used to obtain different combinations of SE, DE and ME conditions. The machine was fed from a three phase auto-transformer, whose input was supplied from a step down transformer with multiple tap settings on primary side. 10 seconds of steady state data of motor's line currents, field current and line to line voltages were acquired using a data acquisition system at 3600 Hz sampling frequency.
For certain types of rotating electric machines such as the salient pole synchronous machines, voltage unbalance, power supply harmonics, machine asymmetry etc. were found to have a significant impact on the detection of eccentricity fault. Hence, for implementing the proposed motor current signature analysis (MCSA) based eccentricity fault detection scheme experimentally, a suitable scheme for negating these factors was devised, and residues of the fault specific current harmonics under healthy condition were computed. Then these residues were removed from the measured current signatures. The resulting magnitude of the characteristic frequency component was used as the fault indicator. The stator line current space phasor residues I s,res+ and I s,res− for positive and negative frequencies respectively were computed using (36) and (37). Voltage harmonic components, which had a significant magnitude, were used in the residue computation.
I s,res+ = k 0+ V 1+ + k 1+ V 1− + k 2+ V 3+ + k 3+ V 3− + . . . + k 13+ V 13+ + k 14+ V 17− + k 15+ V 1.5+ + k 16+ V 2+ (36)
I s,res− = k 0− V 1+ + k 1− V 1− + k 2− V 3+ + k 3− V 3− + . . . + k 13− V 13+ + k 14− V 17− + k 15− V 1.5+ + k 16− V 2+ (37)
A complex two sided FFT of line current space phasor was obtained using the acquired data under healthy (HE), SE, DE and ME conditions at five different load conditions. At each load level, residues were computed using (36) and (37) for the fault specific frequency components using the prominent line voltage harmonics. For SE condition +9f (f is the stator frequency) component was chosen as fault indicating frequency; for DE condition +7f component was selected and for ME condition +2f component was used.
Variation of Fault Specific Frequency Component with Changing Levels of Eccentricity at Full Load
The variation of the residue eliminated fault specific +9f component of the stator line current space phasor under different levels of static eccentric condition at full load is shown in FIG. 8 . The variation of the residue eliminated +7f component of the stator line current space phasor under different levels of dynamic eccentric conditions at full load is shown in FIG. 9 . FIG. 10 shows the variation of the residue eliminated +2f component of the stator line current space phasor under different levels of mixed eccentric conditions at full load. It is clear from FIGS. 8, 9 and 10 that low to moderate levels of any type of eccentricity were easily identified by monitoring the variation in the corresponding fault specific frequency in the motor line current spectrum.
Variation of Fault Specific Frequency Component with Changing Levels of Load at Constant Level of Eccentricity
The synchronous machine was run at healthy condition as well as under the influence of static, dynamic and mixed eccentricities at five different load levels for each case—no load, 25% full load, 50% full load, 75% full load and full load. The fault specific frequency components in the stator line current space phasor were monitored for all the cases and their variations were recorded after implementing the residue elimination. FIG. 11 shows the effect of load variation on +9f component of the stator line current space phasor under healthy and 16.67% static eccentric conditions. FIG. 12 shows the effect of load variation on +7f component of the stator line current space phasor under healthy and 16.67% dynamic eccentric conditions. FIG. 13 shows the effect of load variation on +2f component of the stator line current space phasor under healthy and 33.34% mixed eccentric conditions. At all load levels, the variation of the fault specific frequency components was found to be significantly larger with eccentricity. Hence, the proposed method was capable of monitoring eccentricity in the motor line current spectrum irrespective of the load variation.
Example 4
(i) Field Current Based Eccentricity Detection
Simulation Results
In rotating electric machines such as salient pole synchronous machines, where external field winding connections are available, characteristic fault components in the field currents can also be used for eccentricity detection. Then, the Fast Fourier Transform (FFT) plots are obtained for the field currents under healthy and eccentric conditions for identifying the harmonics. The FFT of the field current of the healthy synchronous machine at full load simulated using the above-mentioned MWFA technique has been shown in FIG. 14 . As indicated by (1), the predominant harmonics in the healthy machine's field current were harmonics such as 0f, 6f, 12f.
Similarly, the static, dynamic and mixed eccentric cases were also simulated using MWFA technique, for corroborating the theoretical results. FIG. 15 shows the FFT of the field current of the 50% static eccentric machine, simulated by MWFA technique. The field current spectrum showed the presence of 2f, 4f, 8f etc. along with those harmonics present under healthy condition. FIG. 16 shows the FFT of the field current of the 33.34% dynamic eccentric machine, again simulated by MWFA technique. The field spectrum showed existence of only those harmonics which were originally present in the field current of the healthy machine, but their magnitudes were modified. FIG. 17 shows the FFT of the field current of the 66.67% mixed eccentric machine, simulated by MWFA technique. The field spectrum was found to comprise of both even as well as odd harmonics. Moreover, the presence of side band components was also confirmed in these simulation results. Table II shows the frequency components present in the field current spectrum corresponding to different eccentric conditions.
TABLE II
FIRST FEW HARMONIC COMPONENTS OF FIELD
CURRENT UNDER DIFFERENT CONDITIONS
HE
0f
6f
12f
18f
24f
30f
SE
0f
2f
4f
6f
8f
10f
DE
0f
6f
12f
18f
24f
30f
ME
0f
0.5f
1f
1.5f
2f
2.5f
(ii) Experimental Results
For certain types of rotating electric machines such as salient pole synchronous machines, voltage unbalance, power supply harmonics, machine asymmetry etc. were found to have a significant impact on the detection of eccentricity fault. Hence, for implementing the proposed field current signature analysis (FCSA) based eccentricity fault detection scheme experimentally on such machines, a suitable scheme for negating these factors had to be devised. So the residues of the fault specific current harmonics under healthy condition were computed. Then these residues were removed from the measured field current signatures. The resulting magnitude of the characteristic frequency component was used as the fault indicator. The field current residues I f,res for fault specific frequencies were computed using (38). Field current components, which had a significant magnitude, were used in the residue computation.
I f,res = k f0 I f0 + k f1 I f2 + k f2 I f4 + . . . + k f7 I f14 + k f8 I f16 + k f9 I f0.5 + k f10 I f1 (38)
FFT of field current was obtained using the acquired data under healthy (HE), SE, DE and ME conditions at five different load conditions. At each load level, residues were computed using (38) for the fault specific frequency components using the prominent field current harmonics. For SE condition 4f (f is the stator frequency) component was chosen as fault indicating frequency; for DE condition 6f component was selected and for ME condition 3.5f component was used.
Variation of Fault Specific Frequency Component with Changing Levels of Eccentricity at Full Load
The variation of the residue eliminated fault specific 4f component of the field current under different levels of static eccentric condition at full load is shown in FIG. 18 . The variation of the residue eliminated 6f component of the field current under different levels of dynamic eccentric conditions at full load is shown in FIG. 19 . FIG. 20 shows the variation of the residue eliminated 3.5f component of the field current under different levels of mixed eccentric conditions at full load. It is clear from FIGS. 18, 19 and 20 that low to moderate levels of any type of eccentricity were easily identified by monitoring the variation in the corresponding fault specific frequency in the field current spectrum.
Variation of Fault Specific Frequency Component with Changing Levels of Load at Constant Level of Eccentricity
The synchronous machine was run at healthy condition as well as under the influence of static, dynamic and mixed eccentricities at five different load levels for each case—no load, 25% full load, 50% full load, 75% full load and full load. The fault specific frequency components in the field current were monitored for all the cases and their variations were recorded after implementing the residue elimination. FIG. 21 shows the effect of load variation on 4f component of the field current under healthy and 16.67% static eccentric conditions. FIG. 22 shows the effect of load variation on 6f component of the field current under healthy and 16.67% dynamic eccentric conditions. FIG. 23 shows the effect of load variation on 3.5f component of the field current under healthy and 33.34% mixed eccentric conditions. At all load levels, the variation of the fault specific frequency components was found to be significantly larger with eccentricity. Hence, the proposed method was capable of monitoring eccentricity in the motor field current spectrum irrespective of the load variation.
In case of inter-turn short circuit faults on the multi-phase stationary stator winding of the rotating electric machines, the fault specific frequency components existing in the motor line currents are exactly similar to those in case of static eccentricity fault. Under short-circuit faults also modulations of the amplitude of these fault specific components occur. These modulations can be rise, fall, presence and/or absence of the fault specific components. Thus, the proposed scheme can be extended for diagnosing stator inter-turn faults also. | Faults and fault types in electric machines can be identified based on spectra associated with stator and field currents. Signals associated with such currents can be compensated for line variations, and spectral contributions for non-eccentric machines can be reduced or eliminated to permit distinguish static eccentricities from non-eccentric machine operation. One or more of a static eccentricity, a dynamic eccentricity, and a mixed eccentricity can be identified based on spectral component magnitudes at selected frequencies. | 6 |
FIELD OF THE INVENTION
This invention relates generally to the field of sports training devises, and, more particularly, to hockey shooting and return system training devises.
BACKGROUND OF THE INVENTION
Practicing ones shot for hockey has always been a challenge. It usually involves shooting on ice in a hockey rink at the goal cage, and having to retrieve pucks after being shot. Off ice, players shoot at walls but still need to retrieve the shot pucks.
U.S. Pat. No. 6,966,853 to Jeremy Wilkerson and Richard Wilkerson discloses a hockey shooting training devise having a motorized conveyor system in a fenced area to return shot pucks. Wilkerson is limited in that a fenced area is required with a conveyor system to retrieve the shot pucks.
It is an object of the present invention to provide a hockey shooting and return system which relies solely on energy of the shot puck combined with the geometry of the return chute to have the shot puck returned to the shooter, reducing or wholly overcoming some or all of the difficulties inherent in prior known devices.
SUMMARY
The principles of the invention is to provide a very time and space efficient hockey shooting training devise to return the shot hockey puck back to the shooter. In addition to this, the devise records and displays the current shot speed, and stores data of shots, so the statistical data can be later viewed. The devise can be used for on ice training, and also for off ice training.
Main components of invention consist of a lead in shooting surface, where shot puck is delivered from by the shooter. A raised platform approximately the height of hockey skate blades borders the lead in shooting surface. Shot puck is received from the lead in shooting surface by the return chute. Shooter is typically positioned five to ten feet from the return chute, but can be as close as three feet or more than ten feet, pending on training objective and room availability. The return chute includes an elliptical surface which receives the shot puck from the shooter and returns it back to the shooter. Centrifugal force of the moving puck keeps the shot puck in contact with the elliptical surface as it travels along its surface, changing direction approximately by 180° along its length. The elliptical surface is supported at its edges by the chute sides. Chute edges exposed to the entering pucks into the chute can be protected by chute edge protective wings made from material suitable to withstand impact of a hockey puck traveling up to 120 MPH. Return chute also contain a sensing, counting, timing, recording, and display system. This sensing, counting, timing, recording, and display system is to provide instantaneous feed back to shooter on last shot and also to store, track, and compare progress of development over periods of time. To protect area in back of the return chute, extended return chute wings are used to stop pucks which are shot wide of the return chute.
Following defines the aforementioned components in more detail and references to applicable drawings and figures. This detail will include the manner and process of making and using this devise.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the shooting training devise system as a whole.
FIG. 2 shows a side view of the sensing, counting, timing, and recording system in the electronic container with side panel removed.
FIG. 3 shows the monitor.
DETAILED DESCRIPTION OF THE INVENTION
Lead in shooting surface 1 shown in FIG. 1 is typically but not limited to be made from High Density Polyethylene sheets. It can be made of any readily available durable plastic, vinyl or other material which has a smooth surface. In some cases, the existing surface the return chute is placed on can be used without adding an additional surface. This is especially true if positioned on an ice surface, or even smooth bare concrete, wood, or tile to name a few acceptable surfaces.
A raised platform 2 borders all edges of the lead in shooting surface except edge common to the return chute. This raised platform serves two purposes. First—it represents the height of a typical ice hockey skate blade. Secondly—it helps contained the returned pucks to expedite training session. The raised platform can be made out of wood or molded plastics. Its surface should be a non slip surface to provide good traction for the shooter. This raised platform would not be used when the user of this system is wearing hockey skates, either roller or ice. At the shooter discretion, these raised platforms could not be used even if shooter does not have skates on.
The return chute 3 consist of the following components: elliptical surface 4 , chute sides 5 , chute edge protective wings 9 , sensing, counting, timing, recording, and display system 13 , and extended return chute wings 10 .
Elliptical surface 4 provides the main surface shot puck will glide along while returning puck to the shooter and the horizontal confinement. Its leading edge 5 is common to the exiting edge of the lead in shooting surface 1 . It redirects the puck approximately 180° along its length. It can be hinged 6 (mechanical or plastic) at the exit end to allow directional control of the returned puck. When hinged a more downward directional path keeps puck closer to the surface of the lead in shooting surface as it exits the return chute. This provides a more controllable returned shot for the novice. A more upward directional path causes puck to return high (3″ to 12″ off the shooting surface) to the shooter as it exits the return chute. This forces the shooter to have to knock the puck out of the air as it is returned. This is good for the advanced player, allowing them to work on their eye to hand coordination; knocking pucks out of the air as the puck approaches the shooter after it exits the return chute 3 .
The elliptical surface 4 can be made of numerous formable durable materials. One such material is High Density Polystyrene plastic. It can be made from HDPE sheets, or made by using a thermoplastic mold process which the final product would incorporate all the features of the return chute, in a single or multiple section assembly. The molded version can be a single or multi-wall design.
A sound deadening layer 7 can be incorporated to the elliptical surface 4 . This can be done by adding a dense pliable material to the outer surface such as a rubber. Or an expandable material can be injected into the multi-wall thermoplastic molded version.
The chute sides 8 provide the vertical support to the elliptical surface 4 and the vertical confinement of the shot puck. They can be made from but not limited to typical sheets of particle board, plywood, High Density Polyethylene or other suitable plastic. They also can be made from moldable High Density Polyethylene or other suitable plastic. The chute sides 8 sides are parallel at the entrance point of the return chute 3 . They can continue to be parallel past this point when constructed from sheet material. If made in a thermoplastic moldable manner, the side can contour inward in a manner not to impede a consistent flow of the puck, to minimize material and space requirements.
The entrance edges of the return chute 3 are subject to abuse from inaccurate shot pucks which hit its edges and not the center of the return chute 3 as intended. This causes a need for these edges to be protected by chute edge protective wings 9 . The chute edge protective wings 9 are approximately perpendicular to the chute sides 8 . The chute edge protective wings 9 can be made from, but limited to, a durable material such as rubber based material. Sheets of the rubber material can be used to make the chute edge protective wings 9 and be mechanically fastened to the entrance edges of the return chute 3 . The also can be molded into the chute sides 8 if the chute sides 8 are molded.
Because the chute edge protective wings 9 are relatively flexible, they may need additional support. Also, the chute edge protective wings 9 are small in nature and additional surface area is needed for the unskilled user to protect the area behind the return chute 3 from inaccurately shot pucks. Due to the two previously sited statements, extended chute edge protective wings 10 may be incorporated into the return chute 3 .
They can be made from but not limited to typical sheets of particle board, plywood, or High Density Polyethylene or other suitable plastic. They also can be made from moldable High Density Polyethylene or other suitable plastic. The extended chute edge protective wings 10 are hinged 11 to return chute sides allowing them to be extended during shooting use, and retracted for storage and transit. The hinge configuration provides “give” to the extended chute edge protective wings 10 to help absorb the impact from the shot puck. They are located directly behind the chute edge protective wings 9 to provide the chute edge protective wings 9 additional support. The extended chute edge protective wings hinge 11 can be but not limited to be set at a slight angle from true vertical to allow natural tendency to be biased forward to the open position. The extended chute edge protective wings 10 in turn have detent features in them to help hold them in the retracted position when not required to be extended.
The sensing, counting, timing, and recording system, along with the monitor 13 provides a means for continuous feedback of the shooter's performance to the shooter and stores the data for future reference. Feedback includes but is not limited to time, shot speed, shots per minute, total time extended during training session, accumulated velocity, accumulated velocity per time (Total Velocity), maximum velocity, minimum velocity, average velocity, standard deviation of shot speed, sessions total shots, and grand total of shots for all sessions. A microprocessor is used to store, process, and display the data in useable and meaningful means. A typical monitor 13 would show but not be limited to, current speed, number of shots, and elapsed time and contain numerous touchpads.
There are many ways to provide the means to measure the previously listed feedback. The main element required is to be able to capture the speed of the shot puck. This is done by identifying when puck has passed two points separated by a defined distance and measuring the time required for the puck to pass between these two points. Identifying when the puck has passed a point and sending a signal to a controller can be done through, but not limited to a mechanical switch, infra red switch, magnetic reed switch, continuous wave Doppler Radar circuit or a light gate sensor. The light gate method and components will be explained below.
The light gate method requires two main components as shown in FIG. 2 : a light source 14 and a sensing, counting, timing and recording electronic system which typically is called a chronograph 15 to those skilled in the art. These components, both of which are readily available to those skilled in the art, are housed in a rugged electronic container 12 which protect the components from miss directed shot pucks. The electronic container 12 is support by a structural member spanning between the two chute sides 8 . This structural member can be made from but not limited to typical sheets of particle board, plywood, High Density Polyethylene or other suitable plastic. It also can be made from moldable High Density Polyethylene or other suitable plastic. The light source 14 is directed upwards through a circular opening 17 in the top of the electronic container 12 directly above the light source 14 . This floods the interior of the return chute 3 with the appropriate amount of light for the proper functioning of the chronograph 15 and allows for heat disipitate from the light source. The chronograph 15 is positioned in the electronic container 12 with the front light gate sensor 18 and rear light gate sensor 19 pointing down. The bottom panel of the electronic container 12 common to the chronograph 15 is made of tempered glass or clear acrylic to allow light through to the sensors. The face of these two sensors is positioned so the sensors are parallel with the elliptical surface 4 directly below them and perpendicular with the chute sides 8 . As the puck passes underneath the front light gate sensor 18 , the front light gate sensor 18 detects the puck and starts a timer until puck is detected by the rear light gate sensor 19 and the timer is stopped. This time is recorded by the electronics in the chronograph 15 . The speed is calculated by dividing the distance traveled (distance between the two light gate sensors) by the time it takes to travel this distance. The other listed feedback is data and form of data readily available and apparent to those skilled in this art, when incorporating the use of a microprocessor. The power source for both the light and the chronograph can be from but not limited to a standard 110 AC house hold power. This power will have to be converted to appropriate dc power for the chronograph 15 . Timers are included in line with the power (or incorporated into the electronics of the chronograph), to the light and the chronographs so they will shut off at defined time set by user. This helps extending the life of both, especially the light, in case user forgets to shut the power off to them.
The accumulated velocity is a unique feedback which is most helpful to track one's development. It is the sum of individual velocities. When this value is summed up over a defined time (defined as Total Velocity), ((Speed of shot 1 +Speed of shot 2 + Speed of shot 3 . . . )/time) is a very useful value to compare for not just the velocity of the shooters shot is defined, but the speed of how many shots are completed over a period of time. This provides a true reading for the rate a shooter can deliver a shot weighted with the speed of the shot. A quickly delivered shot is most helpful skill in the game of hockey, not only for shooting to score, but also for passing to a fellow team mate.
A typical layout for the monitor is shown in FIG. 3 . It consists of numerous touch pads. It should be understood this is one of many possible configurations of the touch pads and their arrangement.
The above has defined the invention in a preferred embodiment, it should be understood that this is only an example and not as a limitation to the scope of this invention. | Hockey Shooting and Return System Training Devise used by hockey players which provides a very time and space efficient method for practicing ones shot. It is efficient for it returns the shot hockey puck back to the shooter relying only on the speed of the puck and the geometry of the return chute to accomplish this. In addition, the devise records and displays the current shot speed, and stores data of shots, so additional statistical data can be later viewed. The devise can be used for on ice training, and also for off ice training. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is a self contained, trailer mounted system with condenser for cooling and condensing those oil well gases that can be condensed and with a separator for separating the condensed portion from the non-condensable portion of the gas stream so that they can be recovered as liquid hydrocarbons. The system is powered by the gas pressure from the well and operates without any outside utilities so that it can be used at new well sites where infrastructure has not been built to support the well.
2. Description of the Related Art
In today's era of oil and gas well drilling, often wells will be drilled in remote locations where there are no utilities and no gas gathering pipelines. In shale areas such as the Baaken, Marcellus, Utica, and Eagle Ford areas, the wells are known to produce significant quantities of very light gravity crude oil, condensate (also known as natural gas liquids or NGLs) and natural gas in abundance. Since the completion technologies are relatively new, and these fields are quite large in geographical area, they lack the infrastructure necessary to bring all of the hydrocarbons into the commercial stream. At these wells, it has not been feasible to condense those hydrocarbons that exit the wellhead in gaseous state that might otherwise have been condensed to a liquid state and pumped to an oil tank. Therefore, large quantities of valuable hydrocarbon liquid rich natural gas are being released into the atmosphere, either directly or through venting or flaring. Often the condensable hydrocarbons are being burned with the non-condensable gases in flares at the wellhead, resulting in the loss of a large amount of recoverable hydrocarbons. With the high price of petroleum, this loss can add up to a considerable loss of revenue.
Also, the state and locate EPA offices in North Dakota, Pennsylvania, Ohio and Texas are now requiring that all wellhead gas be conditioned to remove as much of the valuable natural gas liquids as possible. This adds to the need for a new technology to remove the natural gas liquids prior to venting or flaring.
At the majority of these new wells, all gas and valuable natural gas liquids are being flared and completely destroyed by burning. The present system condenses and captures a portion of the valuable hydrocarbon liquids before they are sent to the flare, increasing the amount of hydrocarbon liquids entering the economic stream, and minimizing the waste and pollution associated with burning these valuable and much-needed products.
Also, burning hydrocarbon liquids generates considerable air pollution. This sort of air pollution was targeted in the Clean Air Act of 1970 as a known carcinogen. The present invention not only returns valuable hydrocarbons to the economic stream, it also generates a “green” benefit by reducing smog and the health hazards associated with it.
The present invention addresses this problem by providing a trailer mounted condensate collection system that is capable of using the pressure from the well to operate the system without the need for outside utilities. The system is a trailer mounted condensate optimization system designed to capture otherwise flared or lost hydrocarbon liquids. The system includes a trailer mounted condenser and a trailer mounted separator. It is specifically designed to be rugged enough for transportation to any well site on what are typically rough lease roads.
The present system treats the gases flowing from the well to condense, separate, and recover those gases that are capable of being condensed to a liquid from those gases that are non-condensable. Once on site, the system is connected to the well's flow line on the inlet end of the system and to the oil storage tank. The system is also connected on its outlet end to a flare, a vent stack or a gas pipeline when a gas pipeline is available.
The system uses pressure from the well to operate a fan that blows ambient air across a heat exchanger where those hydrocarbons from the wellhead that can be condensed will cool sufficiently to condense to a liquid state.
From the heat exchanger, the mixed gaseous and liquid effluent then flows through a separator where the effluent is initially used to heat the separator and then the effluent is introduced into the separator where the liquid portion is separated from the gaseous portion. The separated liquid portion is discharged to an oil storage tank where the liquids that flowed from the well are stored, and the separated gaseous portion is discharged to a flare to be burned or to a gas pipeline when one is available.
As any oil and gas producing area matures, the infrastructure grows to accommodate the need to gather, refine, and process the hydrocarbons to the greatest benefits of the owners. As this infrastructure is put in place the need for wellhead gas liquids condensation systems will shift to areas still outside the influence of infrastructure systems. Wells still remote to new gas gathering pipeline systems and gas plants will still need mobile condensation collection systems like the present invention, at least until the entire field is blanketed by the necessary pipeline networks. In the known shale oil areas of the United States, these plays are so large it may be a century or more before the infrastructure development is truly complete. That assures the present invention a full and fertile future for many decades ahead.
With over 160 drilling rigs currently running in the Baaken within a 50 mile radius of Williston, N. Dak., and with the price of crude oil still rising steadily, the opportunities for the present system continue to grow. And the Baaken is just one basin and one area. The same conditions exist in other shale reserves.
Rigs are completing wells at a rate of about one per month from spud to completion of fracturing. Therefore, in the Baaken alone, nearly 2000 new wells were completed and brought on line in 2012. The extrapolation of this into a nationwide new shale oil and gas well development makes it clear that there is a great need for the present invention.
SUMMARY OF THE INVENTION
The present invention is a trailer mounted condensate collection system that is capable of using the pressure from the well to operate the system without the need for outside utilities. The system is a trailer mounted condensate optimization system designed to capture otherwise flared or lost hydrocarbon liquids. The system includes a trailer mounted condenser and a trailer mounted separator. It is specifically designed to be rugged enough for transportation to any well site on what are typically rough lease roads.
The present system treats the gases flowing from the well to condense, separate, and recover those gases that are capable of being condensed to a liquid from those gases that are non-condensable. Once on site, the system is connected to the well's flow line on the inlet end of the system and to the oil storage tank. The system is also connected on its outlet end to a flare, a vent stack or a gas pipeline when a gas pipeline is available.
As the gaseous stream from the well enters the system, the pressure is first reduced through a gas operated back pressure regulator valve to control the inlet pressure to the system. The system uses a stream of gas from the well to operate a gas powered fan that blows ambient air across an air heat exchanger where those hydrocarbons from the wellhead that can be condensed will cool sufficiently to condense to a liquid state. Once the pressure of the gaseous stream has been reduced, the gaseous stream then enters the air heat exchanger where the inlet gas is cooled to a temperature within 5-10 degrees from ambient air temperature. The air exchanger is a specially designed industrial horizontal in-fan with an under-mounted large diameter multi-blade fan below several horizontal passes of small diameter high pressure finned process gas/fluid containing tubes. The fan driven cooler moves ambient air across the various layers of finned tubes, cooling the tubes and thus the gases/liquids within the tubes, causing the once gaseous stream that entered the heat exchanger to condense to liquid and forming a mixture of gas and liquid within the tubes. This typically produces a temperature reduction of from 50-100 degrees Fahrenheit, depending on ambient conditions. The air exchanger is unique to this application in that its fan is driven by an air powered (or in this case gas powered) motor, eliminating the need for a conventional electric motor, since more often than not, electricity is not available on the target new well sites.
The cooled liquids and gases exit the exchanger and then enter into a horizontal chiller-separator mounted on the trailer. This specially designed separator has a finned process cooling coil in the lower liquid phase portion of the separator tank. The Jules Thompson cooling effect of the upstream components creates a rain-like environment inside the separator allowing otherwise lost hydrocarbon fractions to condense out of the gas phase into the liquid phase within the separator tank.
The finned process cooling coil in the bottom of the separator maintains the cool liquid temperature, stabilizing the liquid temperature to prevent re-evaporation. The result is a dramatic increase in recoverable hydrocarbon liquids.
As the stable hydrocarbon liquid volume grows inside the separator, a gas operated liquid level controller senses the liquid level and sends a signal to a special freeze-proof oil valve to open, allowing the recovered liquid oil to move on to storage. The much enhanced volume of recovered hydrocarbon liquid then flows through a long-life battery powered and highly accurate turbine flow meter that counts each barrel of oil in increments of 1/1000ths of a barrel and electronically totalizes the flow on a continuously readable LCD display. The oil then exits the trailer mounted system and the separated liquid oil portion is discharged to an oil storage tank where the liquids that flowed from the well are stored and is ready for sale as crude oil.
The remaining well stream or separated gaseous portion is now lean gas, free of condensable hydrocarbons. It is released or discharged from the trailer mounted system through a second gas operated back pressure valve from which it flows on to the lease flare stack to be burned, or alternately, to a gas pipeline when one is available.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing the component parts of the present invention in relationship to an oil well and in relationship to a gas flare, an oil tank and a waste water tank that are located at the well site.
FIG. 2 is an enlarged view of the area within dashed line 10 of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2 , there is illustrated a trailer mounted condensate collection system 10 constructed in accordance with a preferred embodiment of the present invention. FIG. 1 is a diagram of the component parts of the system 10 that are mounted on a trailer 11 , with the components of the system 10 shown within the dashed line enclosure associated with numeral 10 . FIG. 1 shows the trailer mounted system 10 in relationship to an oil and gas producing well 12 and in relationship to a gas flare 14 , an oil storage tank 16 and a waste water tank 18 that are located at the well site.
The trailer mounted condensate collection system 10 is capable of using the gas pressure from the well 12 to operate the system 10 without the need for outside utilities. The trailer mounted condensate optimization system 10 is designed to capture otherwise flared or lost hydrocarbon liquids that would be exiting from the well 12 in the gas stream. The system 10 includes a trailer 11 on which is mounted a condenser 20 and a separator 22 and associated valves and equipment as will be described hereafter. It is specifically designed to be rugged enough for transportation to any well site over rough lease roads.
Referring now to the drawing, the system 10 will be described. The present system 10 treats the gases flowing from the well 12 to condense those gases that are capable of being condensed to a liquid, to separate the condensed liquids from those gases that are not condensed, and to recover those condensed liquids. Once on site, the system 10 is connected to the well's gas flow line 24 on the inlet end 26 of the system 10 . On the outlet end 26 of the system 10 , connections are made to an oil storage tank 16 , to a waste water tank 18 and to either a flare 14 , a vent stack (not illustrated) or a gas pipeline (also not illustrated), if a gas pipeline is available at the well site.
As the gaseous stream from the well 12 enters the system 10 , the pressure is first reduced through a gas operated inlet back pressure regulator valve 30 to control the inlet pressure to the system 10 . The system 10 uses a stream of gas from the well 12 to operate a pneumatic powered fan 32 that blows ambient air across an air heat exchanger 34 of the condenser 20 . The air heat exchanger 34 is where those gaseous hydrocarbons from the well 12 that can be condensed will be cooled sufficiently to condense to a liquid state.
Once the pressure of the gaseous stream has been reduced, the gaseous stream then enters the air heat exchanger 34 of the condenser 20 where the inlet gas is cooled to a temperature that is within approximately 5-10 degrees from ambient air temperature. The condenser 20 is a specially designed industrial horizontal fin-fan air exchanger 34 with an under-mounted large diameter multi-blade fan 32 located below several horizontal passes of small diameter high pressure finned process gas containing heat exchanger tubes 36 containing the gaseous stream from the well 12 . The fan driven cooler or condenser 20 moves ambient air across the various layers of finned tubes 36 , cooling the tubes 36 and thus the gas within the tubes 36 , causing a portion of the gaseous stream that entered the heat exchanger 34 to condense to liquid and forming a mixture of gas and liquid within the tubes 36 . This typically produces a temperature reduction of the gas and liquid stream from 50-100 degrees Fahrenheit, depending on ambient conditions.
The air heat exchanger 34 is unique to this application in that its fan 32 is driven by an air powered fan motor 38 . In this case the gas that powers the motor 38 is not air, but is instead the pressurized gas from the well 12 . Use of this type of fan motor eliminates the need for a conventional electric motor, since more often than not, electricity is not available on the target new well sites.
The cooled mixture of liquids and gases exits the exchanger 34 and then enters into a horizontal chiller-separator 22 that is also mounted on the trailer 11 along with the air exchanger 34 . This specially designed separator 22 has a finned process cooling coil 40 contained in the lower liquid phase portion of the separator 22 . The Jules Thompson cooling effect of the upstream components creates a rain-like environment inside the separator 22 allowing otherwise lost hydrocarbon fractions to condense out of the gas phase into the liquid phase within the separator 22 .
The finned process cooling coil 40 in the bottom of the separator 22 maintains the cool liquid temperature, stabilizing the liquid temperature to prevent re-evaporation. The result is a dramatic increase in recoverable hydrocarbon liquids.
The temperature within the separator 22 is monitored by a temperature controller 42 that opens a separate bypass control valve 44 to bypass the system 10 with the well's gas stream if the temperature within the separator 22 approaches temperatures low enough that the entrained water that was contained in the gas and liquid stream and is separated from the hydrocarbons in the separator 22 might be in danger of freezing within the separator 22 before it can be discharged to the waste water tank 18 .
The separator 22 is provided with a gas operated water level controller 46 that senses the level of water within the separator 22 and sends a signal to activate a freeze-proof water dump valve 48 to open, allowing water to be discharged from the bottom of the separator 22 to maintain the proper water level in the separator 22 . The discharged water flows from the system 10 and into the waste water tank 18 .
As the stable hydrocarbon liquid volume grows inside the separator 22 , a gas operated liquid level controller 50 senses the liquid level and sends a signal to a special freeze-proof oil valve 52 to open, allowing the recovered liquid oil to exit the separator 22 . The much enhanced volume of recovered hydrocarbon liquid then flows through a long-life battery powered and highly accurate turbine flow meter 54 that counts each barrel of oil passing through the meter 54 in increments of 1/1000ths of a barrel and electronically totalizes the flow on a continuously readable LCD display 56 . The separated liquid oil portion then exits the trailer mounted system 10 and flows to the oil storage tank 16 where the liquid hydrocarbons that initially flowed from the well 12 are stored and ready for sale as crude oil.
Referring back to the separator 22 , a drip trap 58 is provided in-line on the gas line 60 that supplies control gas to the separator's temperature controller 42 , to the oil liquid level controller 50 and to the water level controller 46 to protect these instruments by preventing liquids from reaching them in the control gas.
The remaining well stream or separated gaseous portion is now lean gas that is free of condensable hydrocarbons. It is released or discharged from the trailer mounted system 10 through a second gas operated back pressure valve 62 from which it flows on to the lease flare 14 to be burned, or alternately, to a gas pipeline when one is available at the well site. FIG. 1 shows the gaseous portion being conducted to a gas flare 14 .
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for the purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled. | A self contained, trailer mounted condensation collection system for an oil and gas well. The system has a condenser for cooling and condensing those oil well gases that can be condensed and a separator for separating the condensed portion from the non-condensable portion of the gas stream so that the condensed gases can be recovered as liquid hydrocarbons. The system is powered by the gas pressure from the well and operates without any outside utilities so that it can be used at new well sites where infrastructure has not been built to support the well. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. provisional Application Ser. No. 61/061,814, filed Jun. 16, 2008.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention generally relates to medical devices such as deflectable sheaths. More particularly, the present invention relates to a steerable sheath catheter for positioning in a desired orientation and location in the human body.
SUMMARY OF THE INVENTION
[0003] Many current deflectable sheaths are designed to deflect in different directions to reach locations within the human body. These sheaths are composed of overlapping monolithic polymer layers that form continuous lumen(s). A wire mesh is typically placed between the monolithic polymer layers to provide added rigidity. Pull wire(s) are typically incorporated along the length of the sheath to provide a means of deflection.
[0004] Current sheaths however, have a limited deflection radius. When these sheaths are bent, the radius of curvature at the point of deflection is constant and symmetric about a deflection point. The sheath's arc of deflection is constant which therefore results in limited freedom of motion. This limitation substantially hinders the accessibility of the catheter to gain access to the desired location within the human body. Therefore, what is needed is a deflectable sheath that overcomes the shortcomings of previous designs by allowing the radius of curvature at the point of deflection to change, i.e. allow for asymmetric curvature about a point of deflection. This would allow the physician to gain access more easily in the human body particularly in the diseased vasculature which has been constricted with blockages.
[0005] The present invention is an improved deflectable sheath catheter that is capable of deflecting over a wider range of curvatures, i.e. is capable of deflecting over an asymmetric or non symmetrical range of curvatures. The improvement is directed to the use of a combination of materials with multiple durometers or hardness's that reside within the outer lumen of the sheath.
[0006] In manufacturing the catheter, a step or void is created in the region of intended deflection in the outer lumen layer. The step is then filled with a polymer(s) consisting of differing durometer(s). This creates a matrix of differing durometer polymers. Single or multiple steps can be made in the distal region of the outer lumen. These steps are also filled with a polymer(s) of differing durometer(s) to create a matrix of materials.
[0007] Conventional sheath catheters do not have a step region that incorporates a combination of differing durometer materials. Instead, they are composed of lumen layers with each lumen layer composed of a monolithic polymer with a single and continuous durometer from one end to the other. The integration of a step region of differing durometer materials within an individual lumen enables the sheath catheter to deflect over a much wider range of curvatures than that provided by conventional deflectable sheaths. This asymmetric deflection functionality results in a sheath that is capable of a wider range of motion than previous deflectable sheaths.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a bi-directional steerable sheath assembly according to the present invention.
[0009] FIG. 2 depicts the preferred composition of the different polymer regions with different durometers in the outer layer lumen of the distal portion.
[0010] FIGS. 3A to 3C depict the various annular extensions of the different polymer regions that comprise the distal portion of the outer lumen as they wrap around the sheath and adjoin at the step interface.
[0011] FIG. 4 depicts an alternate composition of the different polymer regions with different durometers in the outer layer lumen of the distal portion.
[0012] FIG. 5 depicts an alternate composition of the different polymer regions with different durometers in the outer layer lumen of the distal portion.
[0013] FIG. 6 depicts examples of the different radius of curvatures capable of the sheath at the distal region.
[0014] FIG. 7 is a perspective view showing the addition of a ring 72 on the inner lumen.
[0015] FIG. 8 is a perspective view that shows the placement of the pull wires 80 and 82 along the inner lumen.
[0016] FIG. 9 is a perspective view that shows the method of attachment of the pull wires 80 , 82 to the outer ring 72 .
[0017] FIG. 10 is a perspective view that shows the placement of the wire mesh 140 over the sheath assembly of the inner lumen 70 and attached pull wires 80 , 82 .
[0018] FIG. 11 is a perspective view that shows the wire mesh 140 placed over the pull wires 80 , 82 and inner lumen 70 .
[0019] FIG. 12 is a perspective view that shows the placement of the second outer lumen 160 over the inner lumen, wire mesh and pull wire assembly depicted in FIG. 13 .
[0020] FIG. 13 is a perspective view of the placement of the shrink wrap layer 170 over the sheath assembly comprising the wire mesh, pull wires, and inner and outer polymer lumens.
[0021] FIG. 14 is a perspective view of the entire sheath assembly comprising the inner and outer lumens, wire mesh, pull wires and shrink wrap.
[0022] FIG. 15 is a depiction of the sheath assembly being heat treated in a furnace 190 .
[0023] FIG. 16 is a perspective view showing an exemplary deflectable sheath of the present invention having different durometer polymer regions that comprise the distal portion of the outer lumen.
[0024] FIG. 17 is an exploded cross-sectional view along line 17 - 17 of FIG. 16 .
[0025] FIG. 18 is an exploded cross-sectional view along line 18 - 18 of FIG. 16 .
[0026] FIG. 19 is an exploded cross sectional view along line 19 - 19 of FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] As used herein, the term “durometer” relates to the hardness of a material defined as a material's resistance to permanent indentation. In the hardness measurement of polymers, elastomers and rubbers according to the present invention, durometer is measured according to ASTM D2240 type A scale.
[0028] As used herein, a “step” is a transition from a first polymeric material to a second polymeric material where the first and second materials do not meet each other at an annular transition that forms a plane aligned generally perpendicular to a longitudinal axis of the sheath. An example is where the first polymeric material can range from 45° to 315° of the annular extent of the sheath member with the second polymeric material being the remainder of the annular extent along a cross-section aligned perpendicular to a longitudinal axis of the sheath. Multiple polymeric materials can be adjoined together around the catheter so as long as they together form a complete 360° annular extent around the sheath.
[0029] The present invention is a deflectable sheath 10 which is comprised of an elongated tubular structure that is flexible yet substantially non-compressible along its length. The deflectable sheath 10 extends from a deflectable distal portion 16 having a distal end 18 , which is adapted to be disposed within a patient to a proximal portion 14 . The sheath 10 is comprised of an outer tubular lumen member 160 formed of a polymeric material, such as of PEBAX. An inner tubular member 70 composed of a polymeric material, such as PTFE forms the inner lumen of the sheath. The PTFE inner lumen provides the sheath 10 with sufficient lubricity so that medical instruments, devices, and the like, slide through the sheath 10 with a minimal amount of force. A wire mesh 140 and pull wires 80 and 82 both formed of stainless steel, reside between the two lumen layers 70 and 160 . A handle assembly 12 , in turn, provides for selective deflection of a distal portion 16 of the sheath 10 into anyone of a number of disparate orientations, as will be further described in detail herein below. However, it is the incorporation of multiple durometer polymeric materials in the distal portion 16 of the outer lumen 160 that creates the extended asymmetric deflection of the sheath catheter as described in more detail below.
[0030] FIG. 1 illustrates a bi-directional asymmetric sheath assembly 10 according to the present invention. The deflectable sheath 10 has a length extending from a proximal portion 14 supported by the handle assembly 12 to a distal portion 16 and distal end 18 . The distal portion 16 , a section within the outer lumen 160 , in turn is composed of at least two distal regions that are contiguous with each other at a step.
[0031] For example, FIG. 2 illustrates the distal portion 16 of the sheath 10 comprising a first distal region 20 composed of a polymeric material of a different durometer than the proximal portion 14 . Preferably the first distal region 20 is composed of PEBAX of a 65 durometer that extends annularly about 360° around the sheath. The first distal region 20 meets a second distal region 22 composed of a polymeric material of a different durometer than the first region 20 , such as 55 durometer PEBAX. The first distal region 20 meets the second distal region 22 and third distal region 24 at an annular transition 28 that forms a plane aligned generally perpendicular to a longitudinal axis of the sheath. The second distal region 22 extends annularly about 180° around the sheath and meets a third distal region 24 at a step 26 . The third distal region 24 is composed of yet another polymeric material of a different durometer than the first and second distal regions 20 and 22 , such as 35 durometer PEBAX. The third distal region 24 has a proximal portion 24 A that extends annularly about 180° around the sheath and a distal portion 24 B that extends to the end 18 of the distal portion 16 of the sheath 10 .
[0032] In the exemplary construction shown in FIG. 2 , materials with three different and distinct durometers compose the outer layer lumen of the sheath 10 . However a combination of as few as two or a multitude of three or more distinct distal regions of a multitude of geometric shapes could also be used as long as the adjacent distal regions are composed of adjoining polymeric materials of differing durometers. Preferably the durometer of the polymeric material from one region differs by at least 10 durometers from the adjacent region. In that respect, for the sake of clarity the various regions of different durometers in a contiguous relationship with each other will be designated “first distal region”, “second distal region”, “third distal region”, etc. as they extend from a most proximal distal region to the end of the distal portion 16 of the sheath 10 .
[0033] More particularly with respect to FIG. 2 , the deflectable sheath 10 of the present invention comprises the distal portion 16 extending for a length of about two inches to as much as about thirty-five inches with a diameter between about 0.1 inches to about 3 inches. The distal portion 16 is comprised of the first distal region 20 having a cylindrical shape that meets a second distal region 22 at an annular transition 28 . If desired, the first distal region 20 is the proximal portion 14 supported by handle 12 . In that case, there is no “middle sheath portion”. In any event, the second distal region 22 meets the third distal region 24 at a step 26 . Step 26 as depicted in FIG. 2 shows a 90° transition of the second distal region 22 to the third distal region 24 where it adjoins together and assumes a completely cylindrical shape extending to a distal end 18 of the distal sheath portion 16 . Although depicted as a 90° angle as shown in step 26 , the step transition can assume a multitude of different angles such as 45° and 180° or be of a curved transition boundary.
[0034] In that respect, the polymeric materials can have a wide range of annular extents, as long as they combine to have an annular extent of 360°. For example, the cross-section designated by line 3 A- 3 A of FIG. 2 shows an embodiment where polymeric material 22 extends about 45° around the annular extent of the sheath while polymeric material 24 is the remainder of about 315°. In FIG. 2 , cross-sectional line 3 B- 3 B shows an embodiment where both materials 22 and 24 extend about 180° around the annular extent of the sheath. In FIG. 2 , cross-sectional line 3 C- 3 C shows an embodiment where polymeric material 22 extends about 315° around the annular extent of the sheath while polymeric material 24 is the remainder of about 45°. In each case, delineation between the respective materials 22 and 24 is designated by the abrupt transition line 21 .
[0035] As further shown in FIG. 4 , an alternate embodiment of the present deflectable sheath invention comprises a first distal region 30 of a durometer polymeric material having a cylindrical shape extending 360°. The first distal region 30 extends to and meets with a second distal region 32 of a polymeric material. The first distal region 30 can be composed of a PEBAX polymer of a durometer ranging from about 80 to about 65. The first distal region 30 meets the second distal region 32 at an annular transition at an annular transition that forms a plane aligned generally perpendicular to a longitudinal axis of the sheath 31 . The second distal region 32 is comprised of a proximal portion 32 A having a cylindrical shape extending 360° to a distal portion 32 B extending somewhat less than that, for example 180°.
[0036] The second distal region 32 and a third distal region 34 are each of different durometer polymeric materials than that of the first distal region 30 . The proximal portion 32 A of the second distal region 32 extends to a step 33 where it meets the third distal region 34 having a cylindrical shape extending 180 about the periphery of the sheath.
[0037] The distal portion 32 B of the second region 32 and the third distal region 34 in turn meet a fourth distal region 36 at a transition 37 . The forth distal region 36 extends about 180° around the periphery of the sheath as a complementary portion to the distal portion 32 B of the second region 32 and the third distal region 34 .
[0038] The third distal region 34 in turn meets the proximal portion 38 A of a fifth distal region 38 at a step 39 . In turn, the distal portion 38 B of the fifth distal region 38 meets the fourth distal region 36 at a step 41 . Both distal regions 36 and 38 are of a different durometer. The proximal portion 38 A of the fifth distal region 38 extends annularly about 180° around the sheath until it transitions into the distal portion 38 B which has a cylindrical shape extending 360° to the distal end thereof. The fourth distal region 36 can be of a polymeric material having a durometer that is the same or different than that of the first and second distal regions 30 and 32 . The fifth distal portion 38 meets a sixth distal region 40 at an annular transition that forms a plane aligned generally perpendicular to a longitudinal axis of the sheath, which in turn extends to the end 18 of the sheath 10 .
[0039] In another embodiment, the second distal region 32 can be composed of a polymeric material such as PEBAX with a durometer ranging from about 75 to about 60. The third distal region 34 can be composed of a polymeric material such as PEBAX with a durometer ranging from about 70 to about 55. The fourth distal region 36 can be composed of a polymeric material such as PEBAX with a durometer ranging from about 65 to about 45, the fifth distal region 38 can be composed of a polymeric material such as PEBAX with a durometer ranging from about 55 to about 35 and the sixth distal region 40 having a durometer of from about 60 to about 50. The first distal region and the third or fourth distal regions 30 , 34 or 36 can be of the same durometer material as long as adjoining distal regions are not of the same durometer.
[0040] Preferably, the durometer parameter decreases as the various polymeric materials extend to the distal end 18 of the sheath. However, that is not an absolute. In some designs, it may be desired to have a first polymeric material of a first durometer meeting a second polymeric material of a second durometer that in turn meets a third polymeric material of a third durometer. The third durometer can be less than both the first and second polymers or it can be less than one of them, but greater than the other.
[0041] FIG. 5 shows another alternate embodiment of the deflectable sheath invention. This alternate embodiment comprises a first distal region 50 which extends annularly about 360° about the sheath and meets the first portion 52 A of the second distal region 52 . Distal region 52 consists of a polymeric material of a different durometer than distal region 50 and extends annular about 180° about the sheath. Distal portion 52 A extends to distal portion 52 B of distal region 52 . The distal portion 52 A meets distal portion 54 A, a distal portion of the third distal region 54 , at step 53 . Distal portion 52 B meets distal portion 54 B, an extension of distal portion 54 A at step 55 . A fourth distal region 56 which extends annularly about 360° about the sheath, meets distal portion 54 B at an annular transition 57 . Distal region 56 extends to the end of the sheath 18 . Durometers of the polymeric material within the different distal regions can range from about 75 to about 25 with each adjacent distal region having a different durometer.
[0042] FIG. 8 shows the resulting extended asymmetrical deflection range of motion. With the added distal regions that are adjoined at annular transitions and interface steps of differing durometer polymeric materials, resulting in the asymmetric curvature of the distal portion 16 to 315° and more or as little as 45°. The deflectable sheath can bend at different or asymmetric angles about the deflection point; the larger angle of 315° is shown by numerical designation 172 while the smaller curvature of as little as 45° is shown by numerical designation 174 .
[0043] As illustrated in FIG. 7 , the manufacturing process of the deflectable sheath begins with an inner lumen 70 which consists of a monolithic PTFE material of a constant durometer. The lumen 70 is sized and shaped to receive, for example, instruments, fluids, media and the like. The length of this lumen is about twelve inches to about seventy inches long with a diameter of about 0.10 inches to about 1 inch.
[0044] A support ring 72 as shown in FIG. 7 is placed over the distal end of the inner PTFE lumen 70 and forms a tight fit. The distal support ring 72 is preferably made of stainless steel. The ring 72 can also be made of a different rigid material including but is not limited to, a rigid polymeric material, ceramic, titanium, copper, gold, silver, platinum, palladium, NITINOL®, or other metal alloy. The purpose of the support ring 72 is to provide stability to the distal end as well as provide a support for attachment of the pull wire 80 , 82 .
[0045] Next pull wires 80 and 82 depicted in FIG. 8 are placed at opposing sides of the inner lumen. For maximum deflection the push/pull wires should be placed 90° from the complementary distal region. In other words, to provide maximum deflection, the opposing pull wires need to placed so that each of them lays across different durometer distal regions. Preferably the pull wires should be placed opposing each other and 90° from the transition steps of the previously described distal regions of varying durometers to create maximum deflection. These pull wires provide mechanical support to the sheath as well as a means for the operator to push and pull and consequently bend the catheter's distal region. The pull wires 80 and 82 extend from the support ring 72 at the distal end to the handle 12 where they connect to mechanisms for providing tension and compression to consequently deflect the distal portion 16 of the sheath 10 in one direction or another as previously described with respect to FIG. 6 . Such push/pull mechanisms are well known by those skilled in the art and do not necessarily form a differentiating aspect of the present invention. The push/pull wires 80 and 82 are made of stainless steel material. However other materials including but not limited to copper, titanium, gold, silver, platinum, palladium, NITINOL®, or flexible polymers and textile materials such as VECTRAN® or Spectra can also be used.
[0046] Push/pull wires 80 and 82 , are then affixed to the distal support ring 72 by means of welding 90 such as laser or resistance welding 90 as depicted in FIG. 9 . Alternate means of fixation include, but not limited to, chemical bonding, brazing, and soldering. The resulting attachment bond created either through welding, brazing, soldering or other means is depicted as 92 .
[0047] Following attachment of the pull wires 80 , 82 as shown in FIG. 9 , a stainless steel wire mesh 140 is placed over the assembly as shown in FIG. 10 . The wire mesh 140 is pulled over the inner lumen/pull wire assembly and forms a tight fit over the inner PTFE lumen 70 and opposing pull wires 80 and 82 as shown in FIG. 11 . The steel wire mesh 140 provides additional mechanical support to the sheath. The addition of the wire mesh 140 is also known to those skilled in the art and the addition of the wire mesh does not form a differentiating aspect of the present invention. Preferably the wire mesh is composed of stainless steel. Alternate wire braid mesh materials may include NITINOL®′ titanium, copper, nickel, gold, silver, palladium, platinum, ceramic or rigid polymer.
[0048] Following the addition of the stainless steel wire mesh 140 as shown in FIG. 11 , a second polymeric lumen of PEBAX is placed over the sheath assembly as shown in FIG. 12 . The lumen is composed of a high durometer polymeric material, preferably of PEBAX, having a durometer from about 50 to about 150. The preferred durometer of the proximal region is between 70 and 75. The length of the outer lumen corresponds to that of the inner lumen and can be about twelve inches to about seventy inches long with a diameter of about 0.10 inches to about 3 inches.
[0049] A step or steps are cut in the area of intended deflection in the distal portion 16 of the outer lumen material typically by splitting the outer lumen. The removal of the material from the outer lumen creates the space for the different durometer polymeric material. The step or steps are then filled with a geometrically matching piece of material of differing durometer as shown in FIGS. 2 , 4 , and 5 . This results in the creation of the different distal regions that comprise the distal portion of the outer lumen of the sheath. The filling material is PEBAX with a durometer that is typically less than 75. Other polymeric materials could also be used provided that the alternate polymeric material has a different durometer and readily fuses together with the outer lumen layer 160 material.
[0050] The entire assembly of the PTFE inner lumen 70 , push/pull wires 80 and 82 , wire mesh 140 and outer lumen 160 is then encased in a shrink wrap material 170 as shown in FIG. 13 . The sheath assembly with the shrink wrap material 170 ready for heat treating is shown in FIG. 14 . The assembly is then heat treated in a furnace 190 as shown in FIG. 15 at a preferred temperature of between about 350° F. to about 450° F. for about 5 to about 10 minutes in ambient atmosphere and pressure to create the final assembly. After heat treating, the remaining shrink wrap material 170 is removed from the surface of the sheath 10 .
[0051] FIG. 16 shows an exemplary embodiment of a finished bi-directional asymmetric steerable sheath 10 according to the present invention. The illustration depicts the sheath 10 from the proximal region 14 through the distal portion 16 and shows the inner PTFE lumen 70 , distal support ring 72 , wire mesh 140 and push/pull wires 80 and 82 which attachment weld 92 also included in the illustration are distal regions 50 , 52 , and 54 similar to that which is depicted in FIG. 5 . The first distal region 50 extends annularly 360 around the sheath 10 . Distal region 50 adjoins distal region 52 which then adjoins distal region 54 at annular transition 55 which then extends to the end of the sheath. FIG. 17 illustrates the cross section at point 17 - 17 which is prior to the distal portion 16 section which shows the inner lumen 70 , monolithic outer lumen 160 , wire mesh 140 and push/pull wires 80 and 82 . FIG. 18 illustrates cross section 18 - 18 which depicts the outer lumen distal regions of 54 and 52 , annular transition 55 , the inner lumen 70 , wire mesh 140 and push/pull wires 80 and 82 . Finally FIG. 19 depicts the cross section 19 - 19 of the above sheath assembly at the distal end. The cross section shown in FIG. 19 consists of the inner PTFE lumen layer 70 , distal end support ring 72 , and pull wires 80 and 82 which are welded to the opposing sides.
[0052] Thus, it can be seen that the present invention provides a physician with a sheath assembly 10 that is capable of readily deflecting the distal portion 16 in any one of a myriad of direction, both upwardly and downwardly with respect to a longitudinal axis thereof as shown in FIG. 16 . This provides the physician with a great degree of flexibility in maneuvering the distal end 16 of the sheath 10 for performing a medical procedure inside the vasculature of a patient.
[0053] It is appreciated that various modifications to the inventive concepts described herein may be apparent to those of ordinary skill in the art without departing from the spirit and scope of the present invention as defined by the appended claims. | A deflectable sheath with increased range of curvature for human use is provided. The improvement focuses on the use of different durometer polymers that compose the lumen in the portion of deflection. The use of differing durometer polymers allow the deflectable sheath to be bent in a multitude of asymmetric curvature radii therefore providing the physician with a sheath that can traverse different regions of the body than with previous sheaths. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims priority under 35 U.S.C. §120 to U.S. application, U.S. Ser. No. 14/387,033, filed Sep. 22, 2014, which is a national stage filing under 35 U.S.C. §371 of international PCT application, PCT/US2013/031311, filed Mar. 14, 2013, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application, U.S. Ser. No. 61/614,954, filed Mar. 23, 2012, each of which is hereby incorporated herein by reference.
STATEMENT AS TO RIGHTS UNDER FEDERALLY-SPONSORED RESEARCH
[0002] This invention was made with Government support under Contracts Nos. GM57966 and CA158474, awarded by the National Institutes of Health. Accordingly, the U.S. Government has certain rights in this invention.
FIELD OF THE INVENTION
[0003] The invention relates to 5-acyl-6,7-dihydrothieno[3,2-c]pyridines that are useful for treating pancreatic cancer and other types of cancers that are associated with aberrant expression of Hedgehog proteins.
BACKGROUND OF THE INVENTION
[0004] Pancreatic cancer is the fourth most common cause of cancer death in the world, and it has a poor prognosis. For all stages combined, the 1- and 5-year relative survival rates are 25% and 6%, respectively; the median survival for locally advanced and for metastatic disease, which collectively represent over 80% of individuals, is about 10 and 6 months respectively. It is estimated that in the United States in 2012 there will be 43,920 new cases and 37,390 deaths.
[0005] Hedgehog (Hh) and Sonic Hedgehog (Shh) are signaling proteins that mediate growth and patterning during embryonic development. These proteins act as morphogens to form long and short range signaling gradients. Hh is expressed in flies, while vertebrates express 3 family members: Sonic, Indian and Desert, of which Shh is the best studied. Shh regulates limb development, cell proliferation and differentiation. In adult tissues, aberrant Shh expression or signaling is implicated in the biogenesis of multiple human cancers, including medulloblastoma, basal cell carcinoma, liver, pancreatic and urogenital tumors [See Pasca di Magliano, M., and Hebrok, M. (2003) Hedgehog signalling in cancer formation and maintenance, Nat Rev Cancer 3, 903-911.]
[0006] Hedgehog proteins undergo a unique set of post-translational processing reactions. Shh is synthesized as a 45 kDa precursor that traffics through the secretory pathway. After the signal sequence is removed, Shh undergoes autocleavage to generate a 19 kDa N-terminal signaling molecule, ShhN. During this reaction, cholesterol is attached to the C-terminus of ShhN. In addition, the N-terminal cysteine residue of ShhN is modified by palmitoylation. Unlike nearly all other known palmitoylated proteins, palmitate is attached via an amide bond to the N-terminus of ShhN. Palmitoylation of Hh and Shh is critical for effective long- and short-range signaling Mutation of the N-terminal Cys to Ser or Ala results in a mutant protein with little or no activity in vivo or in vitro. Attachment of palmitate to Shh is catalyzed by the multipass membrane protein Hhat (Hedgehog acyltransferase). Hhat is a member of the membrane-bound O-acyl transferase (MBOAT) family. Most MBOAT family members catalyze transfer of long chain fatty acids to hydroxyl groups of lipids; however, Hhat is one of three MBOAT proteins that transfer fatty acids to protein substrates. In each case, fatty acid modification of the substrate protein is essential for its signaling function.
[0007] The normal adult pancreas does not express Shh. However, aberrant Shh expression can occur in the mature pancreas, where it plays a critical role in promoting pancreatic cancer [See Morton, J. P., and Lewis, B. C. (2007) “Shh signaling and pancreatic cancer: implications for therapy?”, Cell Cycle 6, 1553-1557.] Aberrant expression of Shh drives proliferation of pancreatic cancer cells and formation of pancreatic intraepithelial neoplasms, and Hedgehog signaling is one of the core pathways altered in all human pancreatic cancers. Mouse models of pancreatic cancer reveal that Shh functions synergistically with activated K-Ras to promote and maintain tumorigenesis, while inhibition of Shh signaling blocks pancreatic cancer invasion and metastasis [See Olive et al. (2009) “Inhibition of Hedgehog signaling enhances delivery of chemotherapy in a mouse model of pancreatic cancer”, Science 324, 1457-1461 and Feldmann et al. (2007) “Blockade of hedgehog signaling inhibits pancreatic cancer invasion and metastases: a new paradigm for combination therapy in solid cancers”, Cancer Res. 67, 2187-2196.]
[0008] There is an urgent need for novel therapeutics to treat pancreatic cancer. We describe herein Hhat inhibitors that block Shh palmitoylation, and thus provide opportunities for efficacious treatment of pancreatic cancer.
SUMMARY OF THE INVENTION
[0009] The compounds of the invention are useful as anticancer agents, particularly in the treatment of Shh-driven cancers such as pancreatic cancer, gastric cancer, colon cancer, prostate cancer, osteosarcoma and small cell lung cancer.
[0010] In one aspect, the invention relates to a compound of formula I
[0000]
[0000] wherein
R 1 and R 2 are independently selected from H, halogen, (C 1 -C 4 )hydrocarbyl, (C 1 -C 4 )alkoxy, trifluoromethyl, trifluoromethoxy, cyano and nitro;
R 3 is selected from (C 1 -C 10 )hydrocarbyl, (C 1 -C 6 )oxaalkyl and heterocyclylalkyl; and
R 4 is selected from H, methyl, halomethyl, dihalomethyl, and trihalomethyl.
[0011] In another aspect, the invention relates to a pharmaceutical composition comprising a pharmaceutically acceptable carrier and a compound of formula I.
[0012] In another aspect, the invention relates to a method for treating an Shh-driven cancer comprising administering to a patient having such a cancer a therapeutically effective amount of a compound of formula I.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 depicts a graph of tumor volume versus time comparing cells in which Shh and Hhat have been suppressed with control cells.
[0014] FIG. 2 depicts a bar graph showing counts per minute of radiolabeled palmitate residue incorporated into Shh peptide with controls and in the presence and absence of compounds 13 and 14.
[0015] FIG. 3 depicts a bar graph showing cell counts of human pancreatic cancer cells in the presence and absence of compound 13.
DETAILED DESCRIPTION OF THE INVENTION
[0016] In a composition aspect, the invention relates to a compound of formula I
[0000]
[0000] as described above. In some embodiments, A is chosen from pyrrolidine, furan, thiophene and pyridine. In some embodiments, R 1 may be H and R 2 may be H or methyl. In other embodiments, A is phenyl. In these embodiments, R 1 may be ortho relative to the point of attachment of phenyl to the thieno[3,2-c]pyridine and R 2 may be para to the point of attachment of phenyl to the thieno[3,2-c]pyridine. Such compounds would be represented by formula II:
[0000]
[0017] In some of these compounds, R 1 may be H or methyl and R 2 may be chosen from H, methyl, methoxy, chloro and fluoro. In others, R 1 and R 2 may be the same and may be chosen from H and halogen.
[0018] In some embodiments, R 3 may be selected from (C 1 -C 10 )alkyl, (C 1 -C 6 )oxaalkyl and heterocyclylalkyl. In some embodiments, R 3 may be chosen from (C 3 -C 6 )alkyl, (C 3 -C 6 )alkenyl, (C 3 -C 6 )cycloalkyl, (C 1 -C 6 )oxaalkyl, furanyl(C 1 -C 4 )alkyl, thienyl(C 1 -C 4 )alkyl, pyrrolyl(C 1 -C 4 )alkyl, pyrrolidinyl(C 1 -C 4 )alkyl and tetrahydrofuranyl(C 1 -C 4 )alkyl. In particular examples, R 3 is methoxyethyl, methoxypropyl, ethoxypropyl, isopropyl, cyclopropyl, allyl or furanylmethyl.
[0019] In some embodiments, R 4 is hydrogen.
[0020] Throughout this specification the terms and substituents retain their definitions.
[0021] Alkyl is intended to include linear or branched saturated hydrocarbon structures. Examples of alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, s- and t-butyl, 1-methyl-3-ethyloctyl and the like. Preferred alkyl groups are those of C 20 or below.
[0022] Cycloalkyl is for the purposes herein distinguished from alkyl and includes cyclic hydrocarbon groups of from 3 to 10 carbon atoms. Examples of cycloalkyl groups include c-propyl, c-butyl, c-pentyl, norbornyl, decahydronaphthyl and the like.
[0023] Alkoxy or alkoxyl refers to groups of from 1 to 8 carbon atoms of a straight or branched configuration attached to the parent structure through an oxygen. Examples include methoxy, ethoxy, propoxy, isopropoxy and the like.
[0024] Aryl and heteroaryl generally refer to a 5- or 6-membered aromatic or heteroaromatic ring containing 0-3 heteroatoms selected from O, N, or S; a bicyclic 9- or 10-membered aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S; or a tricyclic 13- or 14-membered aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S. In the embodiments described herein, the ring A is limited to 5- or 6-membered aromatic or heteroaromatic rings such as benzene, pyrrole, imidazole, pyridine, thiophene, thiazole, isothiazole, oxazole, isoxazole, furan, pyrimidine, pyrazine, tetrazole and pyrazole.
[0025] Arylalkyl means an aryl ring attached to an alkyl residue in which the point of attachment to the parent structure is through the alkyl. Examples are benzyl, phenethyl and the like. Heteroarylalkyl means an alkyl residue attached to a heteroaryl ring. Examples include, e.g., pyridinylmethyl, pyrimidinylethyl and the like.
[0026] C 1 to C 10 hydrocarbon (or, when describing a substituent, hydrocarbyl) means a linear, branched, or cyclic residue comprised of hydrogen and carbon as the only elemental constituents. The term includes alkyl, cycloalkyl, polycycloalkyl, alkenyl, alkynyl, aryl and combinations thereof. Examples include benzyl, phenethyl, cyclohexylmethyl, cyclopropylmethyl, cyclobutylmethyl, allyl, camphoryl and naphthylethyl.
[0027] Oxaalkyl refers to alkyl residues in which one or more carbons (and their associated hydrogens) have been replaced by oxygen. Examples include methoxypropoxy, 3,6,9-trioxadecyl and the like. The term oxaalkyl is intended as it is understood in the art [see Naming and Indexing of Chemical Substances for Chemical Abstracts, published by the American Chemical Society, 196, but without the restriction of 127(a)], i.e. it refers to compounds in which the oxygen is bonded via a single bond to its adjacent atoms (forming ether bonds); it does not refer to doubly bonded oxygen, as would be found in carbonyl groups.
[0028] Unless otherwise specified, the term “carbocycle” is intended to include ring systems in which the ring atoms are all carbon but of any oxidation state. Thus (C 3 -C 10 ) carbocycle refers to both non-aromatic and aromatic systems, including such systems as cyclopropane, benzene and cyclohexene; (C 8 -C 12 ) carbopolycycle refers to such systems as norbornane, decalin, indane and naphthalene. Carbocycle, if not otherwise limited, refers to monocycles, bicycles and polycycles.
[0029] Heterocycle means a cycloalkyl or aryl residue in which one to two of the carbons is replaced by a heteroatom such as oxygen, nitrogen or sulfur. Heteroaryls form a subset of heterocycles. Examples of heterocycles include pyrrolidine, pyrazole, pyrrole, imidazole, indole, quinoline, isoquinoline, tetrahydroisoquinoline, benzofuran, benzodioxan, benzodioxole (commonly referred to as methylenedioxyphenyl, when occurring as a substituent), tetrazole, morpholine, thiazole, pyridine, pyridazine, pyrimidine, pyrazine, thiophene, furan, oxazole, oxazoline, isoxazole, dioxane, tetrahydrofuran and the like.
[0030] As used herein, the term “optionally substituted” may be used interchangeably with “unsubstituted or substituted”. The term “substituted” refers to the replacement of one or more hydrogen atoms in a specified group with a specified radical. Substituted alkyl, aryl, cycloalkyl, heterocyclyl etc. refer to alkyl, aryl, cycloalkyl, or heterocyclyl wherein one or more H atoms in each residue are replaced with halogen, haloalkyl, alkyl, acyl, alkoxyalkyl, hydroxyloweralkyl, hydroxy, loweralkoxy, haloalkoxy, oxaalkyl, carboxy, nitro, amino, alkylamino, and/or dialkylamino. In one embodiment, 1, 2 or 3 hydrogen atoms are replaced with a specified radical. In the case of alkyl and cycloalkyl, more than three hydrogen atoms can be replaced by fluorine; indeed, all available hydrogen atoms could be replaced by fluorine.
[0031] The compounds described herein may contain, in a substituent R x , double bonds and may also contain other centers of geometric asymmetry; unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers. Likewise, all tautomeric forms are also intended to be included. The compounds possess an asymmetric center at C-4 and may contain, in a substituent R x , additional asymmetric centers and may thus give rise to enantiomers, diastereomers, and other stereoisomeric forms that may be defined, in terms of absolute stereochemistry, as (R)- or (S)-. The present invention is meant to include all such possible isomers, as well as their racemic and optically pure forms. Optically active (R)- and (S)-isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques.
[0032] As used herein, and as would be understood by the person of skill in the art, the recitation of “a compound”—unless expressly further limited—is intended to include salts of that compound. In a particular embodiment, the term “compound of formula I” refers to the compound or a pharmaceutically acceptable salt thereof.
[0033] The term “pharmaceutically acceptable salt” refers to salts whose counter ion (anion) derives from pharmaceutically acceptable non-toxic acids including inorganic acids and organic acids. Suitable pharmaceutically acceptable acids for salts of the compounds of the present invention include, for example, acetic, adipic, alginic, ascorbic, aspartic, benzenesulfonic (besylate), benzoic, boric, butyric, camphoric, camphorsulfonic, carbonic, citric, ethanedisulfonic, ethanesulfonic, ethylenediaminetetraacetic, formic, fumaric, glucoheptonic, gluconic, glutamic, hydrobromic, hydrochloric, hydroiodic, hydroxynaphthoic, isethionic, lactic, lactobionic, laurylsulfonic, maleic, malic, mandelic, methanesulfonic, mucic, naphthylenesulfonic, nitric, oleic, pamoic, pantothenic, phosphoric, pivalic, polygalacturonic, salicylic, stearic, succinic, sulfuric, tannic, tartaric acid, teoclatic, p-toluenesulfonic, and the like.
[0034] It will be recognized that the compounds of this invention can exist in radiolabeled form, i.e., the compounds may contain one or more atoms containing an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Alternatively, a plurality of molecules of a single structure may include at least one atom that occurs in an isotopic ratio that is different from the isotopic ratio found in nature. Radioisotopes of hydrogen, carbon, phosphorous, fluorine, chlorine and iodine include 2 H, 3 H, 11 C, 13 C, 14 C, 15 N, 35 S, 18 F 36 Cl, 125 I, 124 I and 131 I respectively. Compounds that contain those radioisotopes and/or other radioisotopes of other atoms are within the scope of this invention. Tritiated, i.e. 3 H, and carbon-14, i.e., 14 C, radioisotopes are particularly preferred for their ease in preparation and detectability. Compounds that contain isotopes 11 C, 13 N, 15 O, 124 I and 18 F are well suited for positron emission tomography. Radiolabeled compounds of formula I of this invention and prodrugs thereof can generally be prepared by methods well known to those skilled in the art. Conveniently, such radiolabeled compounds can be prepared by carrying out the procedures disclosed in Schemes 1 and 2 by substituting a readily available radiolabeled reagent for a non-radiolabeled reagent.
[0035] Although this invention is susceptible to embodiment in many different forms, preferred embodiments of the invention are shown. It should be understood, however, that the present disclosure is to be considered as an exemplification of the principles of this invention and is not intended to limit the invention to the embodiments illustrated. In a first aspect, the invention relates to compounds; in a second aspect the invention relates to pharmaceutical compositions; in a third aspect, the invention relates to methods. Both the second aspect of the invention and the third aspect envision the use of any and all compounds of the formula I in the method of treatment. However, due to the peculiarities of patent law, and having nothing whatever to do with the scope of the inventors' conception of the invention, certain compounds appear from a preliminary search of the literature ineligible to be claimed as compounds. Thus, for example, compounds in which R 3 is cyclopropyl, R 4 is H and A is 4-t-butylphenyl, 4-methoxyphenyl, 4-methylphenyl, 2-methylphenyl, 4-chlorophenyl, phenyl, 4-fluorophenyl or 2,4-dichlorophenyl appear to be known. Similarly, compounds in which R 3 is cyclohexyl, R 4 is H and A is 2-methylphenyl or 2,4-dichlorophenyl appear to be known. In all of these cases, the compounds are disclosed in Chemical Abstracts only as members of a library, with no disclosed utility. Therefore, while these compounds are part of the inventive concept, they have been excluded from the claims to compounds, per se. It may be found upon further examination that certain members of the claimed genus are not patentable to the inventors in this application. In this event, subsequent exclusions of species from the compass of applicants' claims are to be considered artifacts of patent prosecution and not reflective of the inventors' concept or description of their invention; the invention encompasses all of the members of the genus I that are not already in the possession of the public.
[0036] While it may be possible for the compounds of formula I to be administered as the raw chemical, it is preferable to present them as a pharmaceutical composition. According to a further aspect, the present invention provides a pharmaceutical composition comprising a compound of formula I or a pharmaceutically acceptable salt or solvate thereof, together with one or more pharmaceutically carriers thereof and optionally one or more other therapeutic ingredients. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof. The compositions may be formulated for oral, topical or parenteral administration. For example, they may be given intravenously, intraarterially, intraperitoneally, intratumorally or subcutaneously.
[0037] Formulations include those suitable for oral, parenteral (including subcutaneous, intradermal, intramuscular, intravenous and intraarticular), rectal and topical administration. The compounds are preferably administered orally or by injection (intravenous, intramuscular, intraperitoneally, intratumorally or subcutaneous). The precise amount of compound administered to a patient will be the responsibility of the attendant physician. However, the dose employed will depend on a number of factors, including the age and sex of the patient, the precise disorder being treated, and its severity. Also, the route of administration may vary depending on the condition and its severity. The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. In general, the formulations are prepared by uniformly and intimately bringing into association the active ingredient with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
[0038] Formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be presented as a bolus, electuary or paste.
[0039] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, lubricating, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide sustained, delayed or controlled release of the active ingredient therein.
[0040] Formulations for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient. Formulations for parenteral administration also include aqueous and non-aqueous sterile suspensions, which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example sealed ampoules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of a sterile liquid carrier, for example saline, phosphate-buffered saline (PBS) or the like, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kind previously described.
[0041] Preferred unit dosage formulations are those containing an effective dose, as herein below recited, or an appropriate fraction thereof, of the active ingredient.
[0042] It should be understood that in addition to the ingredients particularly mentioned above, the formulations of this invention may include other agents conventional in the art having regard to the type of formulation in question, for example those suitable for oral administration may include flavoring agents.
[0043] As used herein, “treatment” or “treating,” or “palliating” or “ameliorating” are used interchangeably herein. These terms refer to an approach for obtaining beneficial or desired results including but not limited to therapeutic benefit and/or a prophylactic benefit. By therapeutic benefit is meant eradication or amelioration of the underlying disorder being treated. Also, a therapeutic benefit is achieved with the eradication or amelioration of one or more of the physiological symptoms associated with the underlying disorder such that an improvement is observed in the patient, notwithstanding that the patient may still be afflicted with the underlying disorder. For prophylactic benefit, the compositions may be administered to a patient reporting one or more of the physiological symptoms of a disease, even though a diagnosis of this disease may not have been made.
[0044] A comprehensive list of abbreviations utilized by organic chemists (i.e. persons of ordinary skill in the art) appears in the first issue of each volume of the Journal of Organic Chemistry . The list, which is typically presented in a table entitled “Standard List of Abbreviations” is incorporated herein by reference.
[0045] The compounds employed in the methods and pharmaceutical compositions described above are commercially available or may be synthesized by processes known in the art. In general, the synthesis may be schematically described as in Schemes 1 and 2. An aromatic aldehyde is reacted with an aminoethylthiophene under Pictet-Spengler conditions to provide an 4-aryl-4,5,6,7-tetrahydrothieno[3,2-c]pyridine. Alternatively, an aromatic acid may be reacted with an aminoethylthiophene to provide the amide and the amide reacted under Bischler-Napieralski conditions to provide the 4-aryl-6,7-dihydrothieno[3,2-c]pyridine, which is reduced with a borohydride reagent to provide the 4-aryl-4,5,6,7-tetrahydrothieno[3,2-c]pyridine. Both these routes are described in Madsen et al. Bioorg. Med. Chem. 8, 2277-2289 (2000), which is incorporated herein by reference.
[0046] The 4-aryl-4,5,6,7-tetrahydrothieno[3,2-c]pyridine may then be reacted with an activated glycine derivative (the acyl component) by any of the many means well known in the art, particularly in the art of the synthesis of peptides. Such agents include carbodiimides of various sorts, mixed anhydrides, EEDQ, HATU, and the like. It is also possible to pre-react the carboxylic acid with an appropriate leaving group to form an activated ester. Activated esters denote esters which are capable of undergoing a substitution reaction with the secondary amine to form an amide. The term includes esters “activated” by neighboring electron withdrawing substituents. Examples include esters of phenols, particularly electronegatively substituted phenol esters such as pentafluorophenol esters; O-esters of isourea, such as arise from interaction with carbodiimides; O-esters of N-hydroxyimides and N-hydroxy heterocycles; specific examples include S-t-butyl esters, S-phenyl esters, S-2-pyridyl esters, N-hydroxypiperidine esters, N-hydroxysuccinimide esters, N-hydroxyphthalimide esters and N-hydroxybenzotriazole esters. The carboxyl may also be activated by pre-reaction to provide acyl halides, such as acid chlorides and fluorides.
[0047] During condensation, the activated glycine will usually be protected with one of the common protecting groups, R 10 , known in the peptide art. The protecting group, when present, will then be cleaved with a suitable cleaving agent to provide the 5-acyl-6,7-dihydrothieno[3,2-c]pyridines of formula I. Protecting groups for the amine are discussed in standard textbooks in the field of chemistry, such as Protective Groups in Organic Synthesis by T. W. Greene and P. G. M. Wuts [John Wiley & Sons, New York, 1999], which is incorporated herein by reference. Particular attention is drawn to the chapter entitled “Protection for the Amino Group” (pages 494-614). Common protecting groups include, t-Boc, Fmoc and the like. Cleavage of t-Boc is accomplished by treatment with an acid, usually trifluoroacetic acid; cleavage of Fmoc is usually accomplished by treatment with a nucleophile such as piperidine or tetrabutylammonium fluoride.
[0000]
[0000]
[0048] Fourteen examples of compounds of the genus I have been prepared and tested according to the protocol described below.
[0049] Radioiodination of iodo-palmitate with [ 125 I] NaI and synthesis of 125 I-iodo-palmitoyl and 3H-palmitoyl CoA derivatives using CoA synthetase were carried out as described by Berthiaume, L., et al. “Synthesis and use of iodo-fatty acid analogs”. Methods Enzymol. 250, 454-466 (1995) and Peseckis, S. M., et al. (1993) “Iodinated fatty acids as probes for myristate processing and function. Incorporation into pp60v-src”. J. Biol. Chem. 268, 5107-5114. The final concentrations of purified 125 I-iodo-palmitoyl CoA and 3 H-palmitoyl CoA, were determined from the absorbance at 260 nm using the extinction coefficient for palmitoylCoA.
[0050] A cell based assay was used to monitor Shh palmitoylation. COS-1 cells expressing Shh, Fyn, or ShhGFP fusions and Hhat were starved for 1 hr in DMEM containing 2% dialysed fetal calf serum, followed by incubation with 10-20 μCi/mL [ 125 I] IC16 or 4 hrs at 37 C. Cells were washed twice with 2 ml of ice cold STE (100 mM NaCl, 10 mM Tris, 1 mM EDTA [pH 7.4]) and lysed in 500 μl of RIPA Buffer (150 mM NaCl, 50 mM Tris, pH 7.4, 1% Triton X-100, 0.5% sodium deoxycholate, 0.1% SDS, 1 mM EDTA). Lysates were clarified by ultracentrifugation at 100,000×g for 15 min in a T100.2 rotor (Beckman, Fullerton, Calif.). Protein levels were determined by SDS-PAGE and Western blot analysis. Immunoprecipitations were performed by incubating clarified lysates with 5 μl of the appropriate antibody and 50 μl of protein A/G+ agarose beads (Santa Cruz Biotechnology) at 4° C. for 16 hrs. The beads were washed twice with 500 μl of RIPA buffer. The final bead pellets were resuspended in 40 μl of 2×SDS-PAGE sample buffer containing 40 mM DTT. Immunoprecipitated samples were run on a 12.5% SDS-PAGE gel, dried, and exposed by phosphorimaging for 2-3 days. Screens were analyzed on a FLA-7000 phosphorimager (Fuji). Labelings were performed in duplicate and repeated three times. For hydroxylamine treatment, gels were soaked in either 1M Tris or hydroxylamine, pH 8.0 for 1 hr, then dried and analyzed as above.
[0051] Expression and purification of recombinant Shh were carried out as described in Buglino, J. A. and Resh, M. D. “Hhat is a palmitoylacyl transferase with specificity for N-palmitoylation of sonic hedgehog”. J. Biol. Chem. 283, 22076-22088 (2008) and Buglino, J. A. and Resh, M. D. “Identification of conserved regions and residues within Hedgehog acyltransferase critical for palmitoylation of Sonic Hedgehog”. PLoS One 5, e11195 (2010). N-terminally 6× His tagged human Shh 24-197 with an enterokinase cleavage site immediately upstream of residue 24 was amplified using full length Shh as a template. The purified PCR product was ligated in NcoI and BamHI cut PET19b (Novagen). C24S and C24A constructs were generated by site directed mutagenesis using the Quick Change mutagenesis kit. All mutations were confirmed by sequencing. His-tagged Shh24-197 constructs were expressed in E. coli BL21(DE3)codon plus (Novagen), purified on Ni-NTA-agarose resin (Qiagen), and dialyzed (20 mM Tris-HCl, pH 8.0, 350 mM NaCl, 1 mM β-mercaptoethanol) in the presence of enterokinase (New England Biolabs). The dialyzed product was further purified by size exclusion chromatography on a Superdex 75 column (GE Heathcare). Pooled fractions after size exclusion chromatography were concentrated to 3.0-3.5 mg/ml in 20 mM HEPES, pH 7.3, 100 mM NaCl, 1 mM DTT. Protein concentration was measured using the DC protein assay (BioRad). The N-terminii of both wild type and mutant proteins were confirmed by Edman degradation.
[0052] HhatHAFlagHis was purified as follows. 20×100 mm plates of 293FT cells were transfected with HhatHAFlagHis or pcDNA3.1 empty vector. 48 hrs post transfection, the cells were placed on ice, washed twice with 5 ml of ice cold STE, and then scraped into 5 ml of STE per plate. Cells were pelleted by centrifugation at 1000×G for 10 min. Cell pellets were resuspended in 8 ml of cold hypotonic lysis buffer (0.2 mM MgCl2, 10 mM HEPES, pH 7.3). After 15 min incubation on ice, cells were lysed by 30 up/down strokes in a Dounce homogenizer with a tight fitting pestle. After lysis, 2 ml of 1.25M sucrose was added to yield 10 ml of total cell lysate. The lysate was separated into soluble (S100) and membrane (P100) fractions by ultracentrifugation at 100,000×G for 45 min in a Ti 70.1 fixed angle rotor (Beckman) After centrifugation, the supernatant was saved and the P100 pellets were resuspended in 10 ml of Hypotonic Lysis Buffer plus 0.25M sucrose and recentrifuged as above. The resultant supernatant was combined with the supernatant from the first spin for a total of 20 ml S100. The P100 membranes were again resuspended in 10 ml hypotonic lysis buffer+0.25M sucrose and recentrifuged as above. The supernatant was discarded and the pellets were resuspended in 10 ml of wash/solubilization buffer (20 mM HEPES, pH 7.3, 350 mM NaCl, 1% octylglucoside, 1% glycerol) and incubated on ice for 1 hr, followed by centrifugation at 100,000×g. The resultant pellet was discarded and the supernatant (detergent soluble fraction) was transferred to a 15 ml tube and 500 ml of Flag M2 resin (Sigma) was added. Following a 1 hr incubation, the Flag resin was pelleted by centrifugation at 1000×g and washed 4 times with 5 ml of solubilization/wash buffer. HhatHAFlagHis was eluted with 1.5 ml of solubilization/wash buffer supplemented with 300 ng/ml 3× FlagPeptide. The purified sample was concentrated and buffer exchanged to a final volume of 0.5-1.0 ml in 20 mM HEPES, pH 7.3, 100 mM NaCl, 1% octylglucoside, 1% glycerol. Protein concentrations were determined using the DC Protein Assay. The concentration of the final Flag eluate was determined from the absorbance at 280 nm using an extinction coefficient of 193045 cm −1 M −1 . Samples of the final purified fraction were subjected to SDS-PAGE and silver staining.
[0053] In vitro palmitoylation was assayed according to Buglino, J. A. and Resh, M. D. “Hhat is a palmitoylacyl transferase with specificity for N-palmitoylation of sonic hedgehog”. J. Biol. Chem. 283, 22076-22088 (2008) The in vitro assay was performed by incubating 10 μL of HhatHAFlagHis in 20 mM HEPES, pH 7.3, 100 mM NaCl, 1% octylglucoside, 1% glycerol with 10 μl of recombinant Shh (0.2-0.4 mg/mL in 20 mM MES, pH 6.5, 1 mM EDTA, 1 mM DTT), followed by the addition of 30 μL of reaction buffer (167 mM MES, pH 6.5, 1.7 mM DTT, 0.083% Triton X-100, 167 μM 125 I-iodo-palmitate CoA). The reaction was stopped by the addition of 50 μL of 2× sample buffer with 40 mM DTT. Samples were electrophoresed on 12.5% SDS-PAGE gels, which were stained with Coomassie Blue, dried and exposed to phosphorimager for 12-18 hrs. After phosphorimaging, each Shh containing gel band was excised. 125 I-iodo-palmitate incorporation was measured by counting in a Perkin-Elmer Gamma counter. Non-enzymatic incorporation of 125 I-iodo-palmitate into Shh was corrected for by subtraction of counts from matched pcDNA 3.1 mock purification controls.
[0054] C-terminally biotinylated peptides corresponding to the first 10 amino acids of Shh (CGPGRGFGKR), N-terminal acetylated Shh (Acetyl-CGPGRGFGKR) and C24A Shh (AGPGRGFGKR) were synthesized by the Sloan-Kettering Microchemistry Core Facility. Purified peptides were palmitoylated in vitro as outlined above except that the final Shh peptide concentration was 100 μM. After incubation, 400 μL of RIPA buffer and 50 μl of Streptavidin-agarose beads were added, and the mixture was incubated for 1 hr at 4° C. with continuous mixing. Biotinylated peptides were pelleted by centrifugation at 1000×g for 5 minutes. Pellets were washed twice with 500 mL RIPA buffer. 125 I-iodo-palmitate incorporation was determined by Gamma counting. Samples were incubated in either 1M Tris, pH8.0, or hydroxylamine, pH 8.0 for 1 hr at room temperature followed by 2 washes in RIPA buffer.
[0055] To show knockdown of Shh and Hhat in human pancreatic cancer cells, shRNAs directed against human Shh or Hhat were cloned into the pLKO1 vector. Human pancreatic cancer cell lines Panc1 and AsPC1 were transfected and selected for 10-14 days in puromycin. Analyses of Shh and Hhat mRNA levels were performed by RT-qPCR. The results established that knockdown of either Shh or Hhat inhibits both anchorage-dependent and anchorage-independent cell growth.
[0056] Xenograft experiments were performed under Animal Protocol #11-02-003. Panc-1 cells were transfected with pLK0.1 encoding shRNAs directed against Shh, Hhat, or a scrambled (Scr) control. pLK0.1 is a lentivirus-based vector (Open Biosystems) that does not replicate, is self-inactivating, and is designed to deliver silencing shRNAs to tissue culture cells. Cells were grown in tissue culture for 10 days to allow for knockdown of the designated gene. Aliquots of cells were analyzed by RT-qPCR analysis to verify that >80% knockdown of Shh or Hhat had been achieved. A separate culture of Panc-1 cells that were not treated (Untr) with pLK0.1 were maintained as a control for any effect of pLK0.1 on tumor growth. Fifteen million Panc-1 cells were injected into the flanks of athymic (nude) female mice. Tumor measurements were taken with a caliper twice a week and plotted. The results are shown in FIG. 1 . At the end of 71 days, tumor mass in the Shh or Hhat-depleted cells was less than 30% of control, showing that inhibition of Shh or Hhat correlates with tumor suppression.
[0057] Hhat activity assay: Five μl of 10 mM MES, pH 6.5 buffer was dispensed within each well of a 384-well white/clear-bottom plate (Greiner Bio-One, Kremsmuenster, Austria) using a Thermo Multi-Drop Combi dispenser. Compounds (12.5 μM final concentration) were dispensed using a Janus “Varispan” automated syringe pipette. Next, 3 μL of P100 membranes from HA-Hhat transfected 293FT cells were dispensed with the Thermo Multi-Drop Combi dispenser, and incubated for 20 min at room temperature. The reaction was started by the addition of 12 μL of reaction buffer (167 mM MES, pH 6.5, 2 mM DTT, 0.083% Triton X-100, 8.3 μM 125-I-iodo-palmitoylCoA, 5.21 μM Shh biotinylated peptide). Following a 1 hour incubation at room temperature, the reaction was stopped by the addition of 70 μL SPA beads solution (7.14 mg/mL in RIPA buffer), and the signal was detected on a Microbeta Trilux reader. Each plate included high control (DMSO only) and low control (0.125% TFA final concentration) rows. Percent inhibition for each experimental point was determined by the formula: [(high control-compound)/(high control-low control)]*100.
[0058] Human pancreatic adenocarcinoma cell assay: 5000 AsPC1 (human pancreatic adenocarcinoma) cells were plated in each well of a 384-well black/clear-bottom tissue culture plate (Greiner Bio-One, Kremsmuenster, Austria), using Thermo Multi-Drop Combi dispenser. The plates were incubated at 37° C. for 24 h before compounds were dispensed using a Janus “Varispan” automated syringe pipette at 50 μM final concentration. High control (DMSO only) and low control (cell media only) rows were included in each plate. After 48 h incubation, Alamar Blue (Invitrogen) was added to each well in 1:100 ratio. 4 h later, cell viability was assessed by measuring fluorescence on a Perkin-Elmer EnVision plate reader.
[0059] Compounds tested and found effective were:
[0000]
%
Inhibition
of Hhat
Example
RU
at 12.5
number
number
Structure
μM
1
RU- 0072298
100.8
2
RU- 0072503
98.9
3
RU- 0072407
97.8
4
RU- 0072417
96.2
5
RU- 0072436
95.6
6
RU- 0072279
94.7
7
RU- 0072513
94.3
8
RU- 0072523
94.3
9
RU- 0072130
92.8
10
RU- 0072467
91.6
11
RU- 0072268
87.2
12
RU- 0072288
17.1
13
RU-SKI 101
14
RU-SKI 201
[0060] Each of compounds 13 and 14 (20 μM) was incubated with purified Hhat in the presence of saturating concentrations of 125 I-Iodopalmitoyl CoA+Shh peptide as described above. Radiolabeled peptides were pulled down with streptavidin agarose and the cpm incorporated into the peptide was quantified in a gamma counter. As shown in FIG. 2 , compounds 13 and 14 are good inhibitors of Hhat activity, showing greater than 75% reduction in cpm.
[0061] Compound 13 was tested in the human pancreatic adenocarcinoma cell assay. The results are shown graphically in FIG. 3 . At 10 μM it reduced the proliferation of human pancreatic cancer cells 50% at day six. At 20 μM it reduced the proliferation of human pancreatic cancer cells by 70% at day six.
[0062] IC50 values were generated for compound 13 (RU-SKI 101) and compound 14 (RU-SKI 201) in an in vitro Hhat activity assay at saturating substrate concentrations, using purified enzyme, 0.7 μM ShhN recombinant protein and 18 μM 125 I-iodo-palmitoylCoA. The samples were incubated and incorporation into ShhN protein was quantified. Each experiment was repeated twice. The IC50 value for compound 13 was 2.05 μM and for compound 14 was 0.68 μm. | Methods for inhibiting the growth of pancreatic cancer cells or other cancer cells driven by Sonic hedgehog are disclosed. The method involves exposing the cells to 5-acyl-6,7-dihydrothieno[3,2-c]pyridines of formula I | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to application of roofing shingles, and more particularly to apparatus movable along a roof and operable to sequentially and automatically dispense shingles from a stack into laid positions on the roof, and also to fasten them to the roof.
Shingling of roofs is commonly done by roofers who walk upon the roof and hand carry the shingles into position for laying; they then position the shingles by hand, and fasten or nail them to the roof, by hand. These operations are time consuming and very expensive so that the cost of re-roofing homes is commonly prohibitive. There is need for automated roofing techniques and apparatus that will substantially reduce such costs, and greatly speed up the time required to shingle a roof.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide apparatus and methods to meet the above needs.
Basically, the apparatus of the invention comprises:
(a) a longitudinally elongated blade having a laterally presented sharp edge section adapted to initially penetrate between two stacked shingles, and a laterally presented thickened edge section adapted to spread the two shingles as the blade further penetrates laterally therebetween,
(b) and means to separate one of the two relatively spread shingles from the other by movement of the one shingle in a direction generally parallel to the other.
The blade to accomplish such inter-shingle penetration and spreading typically incorporatesmeans for heating the blade so as to enable transfer of heat from the blade to the shingles to ease penetration and spreading, as when the stacked shingles are cold. Also, shingle spreading is facilitated by making the thickened section of the blade forwardly convex, as will appear.
The means to separate the shingles one from another may typically include a pusher to push said one shingle in said direction after the blade has initially penetrated between the two shingles, and a carriage carrying said pusher and said blade, the pusher supported for cyclic movement on a carriage, and laterally relative to the longitudinal direction of carriage movement on the roof. Thus, the pusher and blade may be interconnected so that when the pusher is moved in one lateral direction, the blade moves in the opposite lateral direction, whereby the blade retracts relative to the shingles as the pusher pushes said one shingle laterally to discharge off one side of the carriage.
The carriage typically includes means such as a roller supporting the frame for transport longitudinally along a roof. The roller may have an elastomeric surface to frictionally grip the sloping roof; and a shingle stapler is carried by the frame in a position to staple to the roof said one shingle after it has been pushed by the pusher in said direction to free the one shingle from the frame.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a perspective view of a roof, with roofing apparatus of the invention moving thereon, to lay shingles;
FIG. 2 is an enlarged perspective view of the roofing apparatus;
FIG. 3 is another view of the FIG. 2 device with some parts removed to show operation of other parts;
FIG. 4 is a side view of the apparatus, looking in the direction 4--4 of FIG. 3;
FIG. 5 is a perspective view of a blade component of the FIG. 2 apparatus;
FIGS. 6, 7, 7a and 8a-8d are schematic views of blade operation to separate and spread shingles in a stack; and
FIG. 9 is a side elevational view of a shingle pusher, and associated mechanism;
FIG. 10 is a perspective view showing pusher means movable laterally to push shingles along support bars; and
FIGS. 11 and 12a-12e are further schematic views.
DETAILED DESCRIPTION
In FIG. 1, the roofing apparatus is shown at 10 movable along a roof 11, in longitudinal direction 12. It discharges rectangular shingles 13 laterally to the roof, in positions to be attached to the roof. As will later appear, the apparatus may also attach the shingles to the roof, as by stapling. Shingles are also referred to as tiles, herein.
Referring to FIGS. 2, 3 and 7, the apparatus 10 is shown to include a carriage frame including two laterally spaced U-shaped members 14 extending in upright, longitudinal planes. Each member includes a lower horizontal rod or bar 15 and bars 16 extending upright from opposite ends of bars 15. Handles 17 are provided at the upper ends of bars 16. Multiple plates 18 are carried by the lower bars and extend laterally in upright parallel planes so that the top edges 18a of the plates define a slide plane along which shingels are slidable, laterally, one after another. A roller 20 is supported at the underside of the frame to extend laterally as shown. Axles 21 at opposite ends of the roller may be supported by bars 15. The roller may have an elastomeric surface to frictionally engage the roof and prevent lateral sliding of the apparatus, as it is moved longitudinally.
Extending between one pair of upright bars 16 in a rod 23 that carries a longitudinally extending stop plate 24. The latter has depending tongues 25 that slidably interfit laterally extending grooves 26 sunk in the top surface of a longitudinally elongated blade 27 that is supported for lateral movement. See for example blade supports 28 that extends downwardly at its opposite ends. Guide rollers 29 on the support 28 engage a laterally extending rail 30 that is in turn carried by the frame. Thus the blade is movable laterally back and forth. The blade has a laterally presented sharp edge section 27a adapted to initially penetrate between two stacked tiles 31a, and 31b, as shown in FIG. 6, as the blade moves leftwardly.
The blade also has a laterally presented thickened edge section 27b adapted to spread the two shingles as the blade further penetrate laterally between them. Section 27b is advantageously forwardly convex, as appears in FIG. 5, and the convexity i.e. sharpness of curvature gradually increases in a direction toward section 27a until it becomes sharp edged, at section 27a. Convex section 27b tends to lift the upper stack 31 of tiles away from the lowermost tile 31a enabling the latter to progressively separate and drop down onto bar or plate edges 18a, i.e. in position to be displaced laterally, and off the apparatus. Edge 27a may also be tapered, as shown in FIG. 6.
A tile stack support plate is shown at 35, to slidably support the stack as the plate moves horizontally laterally under lowest tile 31a, during blade advancement laterally. See FIG. 6. Thus, a tile discharge slot 36 formed between the forward edge 27 of the blade and the rearward door 35a on plate 35, moves laterally to progressively pass or discharge the tile 31a downwardly, per FIG. 8 (a). During such movement, the stack of tiles is retained against a fixed upright plate 37 carried by a rod 38 connected between upright bars 16, as shown. Fixed plate 37 has lower depending tongues 37a that interfit grooves 40 in the upper surface of movable plate 35, whereby tiles cannot wedge between plates 35 and 37; and the same non-wedging relationship exists as between fixed plate 24 and movable blade 27. The plate 35 is mounted on supports 44 that extend downwardly to carry guide rollers 45. The latter also engage the rail 30, so that the plate is movable back and forth, laterally.
After a tile 31a has dropped onto lateral edges 18a, (see FIG. 8(b) it is displaced laterally by a pusher or pushers 38. See also FIGS. 7 and 10. The pushers are mounted on a longitudinal support 39, to project upwardly between plates or bars 18, and to engage the edge 31a' of the tile 31a dropped down onto the edges 18a. The pusher or pushers move in synchronism with blade movement, laterally, so that the pusher is in position to displace the tile laterally once it has completely freed itself from the stack, and dropped onto the edge 18a. To this end, the opposite ends of the pusher support 39 carry slide blocks 40 slidable. along guide rods 41 that extend laterally between the frames as seen in FIGS. 2 and 10.
The pusher 38 and blade are interconnected so that when the pusher is moved in one lateral direction, the blade moves in the opposite lateral direction, whereby the blade retracts relative to the shingles as the pusher pushes the dropped (one) shingle laterally to discharge off the side of the carriage. For this purpose, a cable or line 50 turned about two pulleys 51 and 52 is connected to the blade, pusher and plate 35 as shown at 53, 54 and 55. Pulleys 51 and 52 are suitably carried by the fixed frame. Thus, as the blade and plate 35 travel to the left in FIGS. 2, 8(a) and 8(b), the pusher moves to the right, into position to engage the rightward edge of the dropped tile, as seen in FIG. 8(b); and as the blade retracts to the right in FIGS. 8(c) and 8(d), along with carriage movement to the right, the pusher moves or displaces the dropped tile to the left, to discharge off the carriage. FIG. 8(d) shows completed discharge.
A drive for these components is seen to include motor 56, shaft 57, gears 58 and 59, and gears 60 and 61, the drive actually moving the plate 35 which in turn moves the cable system. The plate 35 and blade 27 may be directly connected by structure or link 68, seen in FIG. 2. Trigger switches 70 are located on the handles to start and stop the motor.
The system may also be used to displace tiles off the opposite side of the carriage or frame; and to this end the pushers 38 are inverted 180° to hand downwardly, as the pusher is moved leftwardly under a dropped tile, so as the become inactive. To this end, pusher rod 39 is rotatable 180° in the guide blocks 40 at its opposite ends. Note that the guide and transport structure shown at the end of th carriage nearest the viewer in FIG. 2 is duplicated at the opposite end of the carriage, furthest from the viewer.
A projection or projections 110, pivotally attched to the door 35a, are now swing downwardly as in FIGS. 11 and 12. The blade movement sequence in FIGS. 12(a)-12(e) is the same as in FIGS. 7 and 8(a) to 8(d); however, the projection 110 now becomes the effective pusher. Note that it moves in synchronism with the blade, and in the same direction therewith, to push the dropped tile rightwardly off the edges 18a, as in FIGS. 12(d) and 12(e). FIG. 11 shows a cam plate to raise and lower the door 35a.
Finally, shingle staplers 75 are carried by the frame in a position to staple the displaced shingle to the roof after it is freed from the apparatus. When lowered from raised position seen in FIG. 2, as by rotation of stapler mounting rods 76, the staplers are positioned just above the discharged shingles, to staple them to the roof. Rods 76 are rotatably end connected at 77 to the uprights 16.
Heated balde 27 is well suited to separating tiles or shingles that are stuck together. Blade 27 may be electrically heated, as by internal wires 85. | Roofing apparatus comprises:
(a) a longitudinally elongated blade having a laterally presented sharp edge section adapted to initially penetrate between two stacked shingles, and a laterally presented thickened edge section adapted to spread the two shingles as the blade further penetrates laterally therebetween,
(b) and structure to separate one of the two relatively spread shingles from the other by movement of the one shingle in a direction generally parallel to the other.
Other mechanism allows feeding of the shingles, successively, off the apparatus and onto a roof. | 4 |
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to sulfonic acids and derivatives thereof and to pharmaceutical compositions containing them, which are used in the prevention and treatment of tissue damage due to the exacerbated recruitment of polymorphonucleated neutrophils (PMN leukocytes) at inflammation sites.
STATE OF THE ART
Particular blood cells (macrophages, granulocytes, neutrophils, polymorphonucleated) respond to a chemical stimulus (when stimulated by substances called chemolines) by migrating along the concentration gradient of the stimulating agent, through a process called chemotaxis. The main known stimulating agents or chemokines are represented by the breakdown products of complement C5a, some N-formyl peptides generated from lysis of the bacterial surface or peptides of synthetic origin, such as formyl-methionyl-leucyl-phenylalanine (f-MLP) and mainly by a variety of cytolines, including Interleukin-8 (IL-8, also referred to as CXCL8). Interleukin-8 is an endogenous chemotactic factor produced by most nucleated cells such as fibroblasts and macrophages.
In some pathological conditions, marked by exacerbated recruitment of neutrophils, a more severe tissue damage at the site is associated with the infiltration of neutrophilic cells. Recently, the role of neutrophilic activation in the determination of damage associated with post ischemia reperfusion and pulmonary hyperoxia was widely demonstrated.
The biological activity of IL-8 is mediated by the interaction of the interleukin with CXCR1 and CXCR2 membrane receptors which belong to the family of seven transmembrane receptors, expressed on the surface of human neutrophils and of certain types of T-cells (L. Xu et al., J. Leukocyte Biol., 57, 335, 1995). Selective ligands are known which can distinguish between CXCR1 and CXCR2: GRO-α is an example of a CXCR2 selective chemotactic factor.
Although CXCR1 activation is known to play a crucial role in IL-8-mediated chemotaxis, it has been recently supposed that CXCR2 activation could play a pathophysiological role in cronic inflammatory diseases such as psoriasis. In fact, the pathophysiological role of IL-8 in psoriasis is also supported by the effects of IL-8 on keratinocyte functions.
Indeed, IL-8 has been shown to be a potent stimulator of epidermal cell proliferation as well as angiogenesis, both important aspects of psoriatic pathogenesis (A. Tuschil et al. J Invest Dermatol, 99, 294, 1992; Koch A E et al, Science, 258, 1798, 1992).
In addition, there is accumulating evidence that the pathophysiological role of IL-8 in melanoma progression and metastasis could be mediated by CXCR2 activation (L. R. Bryan et al., Am J Surg, 174, 507, 1997).
The potential pathogenic role of IL-8 in pulmonary diseases (lung injury, acute respiratory distress syndrome, asthma, chronic lung inflammation, and cystic fibrosis) and, specifically, in the pathogenesis of COPD (chronic obstructive pulmonary disease) through the CXCR2 receptor pathway has been widely described (D. WP Hay and H. M. Sarau., Current Opinion in Pharmacology 2001, 1:242-247).
Studies on the contribution of single (S) and (R) enantiomers of ketoprofen to the anti-inflammatory activity of the racemate and on their role in the modulation of the chemokine have demonstrated (P. Ghezzi et al., J. Exp. Pharm. Ther., 287, 969, 1998) that the two enantiomers and their salts with chiral and non-chiral organic bases can inhibit in a dose-dependent way the chemotaxis and increase in intracellular concentration of Ca 2+ ions induced by IL-8 on human PMN leukocytes (Patent Application U.S. Pat. No. 6,069,172). It has been subsequently demonstrated (C. Bizzarri et al., Biochem. Pharmacol. 61, 1429, 2001) that Ketoprofen shares the property to inhibit the IL-8 biological activity with other molecules belonging to the class of non-steroidal anti-inflammatory NSAIDs) such as flurbiprofen, ibuprofen and indomethacin. The cyclo-oxygenase enzyme (COX) inhibition activity typical of NSAIDs limits the therapeutical application of these compounds in the context of the treatment of neutrophil-dependent pathological states and inflammatory conditions such as psoriasis, idiopathic pulmonary fibrosis, acute respiratory failure, damages from reperfusion and glomerulonephritis. The inhibition of prostaglandin synthesis deriving from the action on cyclo-oxygenase enzymes involves the increase of the cytokine production which, like TNF-α, play a role in amplifying the undesired pro-inflammatory effects of neutrophils.
Novel classes of potent and selective inhibitors of IL-8 biological activities suitable for “in vivo” administration have been discovered. R-2-arylpropionic acid amides and N-acylsulfonamides have been described as effective inhibitors of IL-8 induced neutrophils chemotaxis and degranulation (WO 01/58852; WO 00/24710). Furthermore, novel R and S-2-phenylpropionic acids have been recently described as potent IL-8 inhibitors completely lacking the undesired COX inhibitory effect (PCT/EP02/12939).
DETAILED DESCRIPTION OF THE INVENTION
We have now found that a class of sulfonic acids and derivatives thereof show the ability to effectively inhibit IL-8 induced neutrophils chemotaxis and degranulation.
The present invention thus provides use of sulfonic acids and derivatives of formula (I):
and pharmaceutically acceptable salts thereof,
wherein
Ar is a phenyl group, unsubstituted or substituted by one to three substituents, independently selected from halogen, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, hydroxy, C 1 -C 4 -acyloxy, phenoxy, cyano, nitro, amino, C 1 -C 4 -acylamino, halogen-C 1 -C 3 -alkyl, halogen C 1 -C 3 -alkoxy, benzoyl, or Ar is a substituted or unsubstituted 5-6 membered heteroaryl ring;
X represents either a —CH 2 — or a —CH(CH 3 )— group or an ethylenic group of formula (II) in the E configuration, wherein R′ is H or CH 3 ;
Y is selected from O (oxygen) and NH; and
when Y is O (oxygen), R is H (hydrogen); when Y is NH, R is selected from H, C 1 -C 5 -alkyl, C 1 -C 5 -cycloalkyl, C 1 -C 5 -alkenyl, C 1 -C 5 -acyl; a residue of formula —CH 2 —CH 2 —Z—(CH 2 —CH 2 O)nR″ wherein R″ is H or C 1 -C 5 -alkyl, n is an integer from 0 to 2 and Z is oxygen or sulfur; a residue of formula —(CH2)n-NRaRb wherein n is an integer from 0 to 5 and each Ra and Rb, which may be the same or different, are C 1 -C 6 -alkyl, C 1 -C 6 -alkenyl or, alternatively, Ra and Rb, together with the nitrogen atom to which they are bound, form a heterocycle from 3 to 7 members of formula (III)
wherein W represents a single bond, CH2, O, S, N—Rc, Rc being H, C 1 -C 6 -alkyl or C 1 -C 6 -alkylphenyl, in the preparation of a medicament for the inhibition of IL-8 induced human PMNs chemotaxis.
The term “substituted” in the above definition means substituted with a group selected from C 1 -C 5 -alkyl, halogen, hydroxy, C 1 -C 5 -alkoxy, amino, C 1 -C 5 -alkylamino, nitro, or a cyano group.
Ar is a substituted phenyl group selected from 3′-benzoylphenyl, 3′-(4-chloro-benzoyl)-phenyl, 3′-(4-methyl-benzoyl)-phenyl, 3′-acetyl-phenyl, 3′-propionyl-phenyl, 3′-isobutanoyl-phenyl, 4′-trifluoromethanesulfonyloxy-phenyl, 4′-benzenesulfonyloxy-phenyl, 4′-trifluoromethanesulfonylamino-phenyl, 4′-benzenesulfonylamino-phenyl, 4′-benzenesulfonylmethyl-phenyl, 4′-acetoxyphenyl, 4′-propionyloxy-phenyl, 4′-benzoyloxy-phenyl, 4′acetylamino-phenyl, 4′propionylamino-phenyl, 4′-benzoylamino-phenyl, or a heteroaromatic ring selected from pyridine, pyrrole, thiophene, furane, indole.
When Y is NH, preferred R groups are
H, C 1 -C 5 alkyl, C 1 -C 5 acyl; a residue of formula —CH 2 —CH 2 —O—(CH 2 —CH 2 O)R″ wherein R″ is H or C 1 -C 5 -alkyl; a residue of formula —(CH2)n-NRaRb wherein n is an integer from 2 to three, more preferably 3 and the group NRaRb is N,N-dimethylamine, N,N-diethylamine, 1-piperidyl, 4-morpholyl, 1-pyrrolidyl, 1-piperazinyl, 1-(4-methyl)piperazinyl;
The present invention further provides novel sulfonic acids and derivative compounds of formula (1), as defined above, selected from:
1-(4-isobutylphenyl) ethanesulfonic acid 1-(4-isobutylphenyl) ethanesulfonic acid 1-[4-(1-oxo-2-isoindolinyl)phenyl]ethanesulfonic acid 1-[4-(1-oxo-2-isoindolinyl)phenyl]ethanesulfonic acid 2-(4-phenylsulfonyloxy)ethanesulfonic acid 2-(4-phenylsulfonyloxy)ethanesulfonic acid (1-methyl-5-acetylpyrrolyl)-1-methanesulfonic acid 2-(3-benzoylphenyl)ethanesulfonic acid 2-(3-isopropylphenyl)ethanesulfonic acid E-2-(4-isobutylphenyl)ethenesulfonic acid E-2-(3-benzoylphenyl)ethenesulfonic acid E-2-(4-methanesulfonylamainophenyl)ethenesulfonic acid E-2-(4-trifluoromethanesulfonyloxyphenyl)ethenesulfonic acid E-2-(4-isobutylphenyl)ethenesulfonamide E-2-(3-benzoylphenyl)ethenesulfonamide E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethenesulfonamide E-2-[4-(methanesulfonylamino)phenyl]ethenesulfonamide E-2-(4-isobutylphenyl)ethene-N-(N,N-dimethylaminopropyl)sulfonamide E-2-(3-benzoylphenyl)ethene-N-(N,N-dimethylaminopropyl)sulfonamide E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethene-N-(N,N-dimethylaminopropyl) sulfonamide E-2-[4-(methanesulfonylamino)phenyl]ethene-N-(N,N-dimethylaminopropyl)sulfonamide E-2-(4-isobutylphenyl)ethene-N-methyl sulfonamide E-2-(3-benzoylphenyl)ethene-N-methyl sulfonamide E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethene-N-methyl sulfonamide E-2-[4-(methanesulfonylamino)phenyl]ethene-N-methyl sulfonamide E-2-(4-isobutylphenyl)ethene-N-(2″-methoxyethyl)sulfonamide E-2-(3-benzoylphenyl)ethene-N-(2″-methoxyethyl)sulfonamide E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethene-N-(2″-methoxyethyl)sulfonamide E-2-[4-(methanesulfonylamino)phenyl]ethene-N-(2″-methoxyethyl)sulfonamide (1-methyl-5-isobutirrylpyrrolyl)-1-methanesulfonamide (1-methyl-5-acetylpyrrolyl)-1-methanesulfonamide 1-(4-isobutylphenyl)ethanesulfonamide 1-(4isobutylphenyl)ethanesulfonamide 1-(3-isopropylphenyl)ethanesulfonamide 1-(4isobutylphenyl)ethane-N-(N,N-dimethylaminopropyl)sulfonamide 1-(3-benzoylphenyl)ethane-N-(N,N-dimethylaminopropyl)sulfonamide 1-[4-(trifluoromethanesulfonyloxy)phenyl]ethane-N-(N,N-dimethylaminopropyl) sulfonamide 1-[4-(methanesulfonylamino)phenyl]ethane-N-(N,N-dimethylaminopropyl)sulfonamide 1-(4-isobutylphenyl)ethane-N-(2-methoxyethyl)sulfonamide 1-(3-benzoylphenyl)ethane-N-(2-methoxyethyl)sulfonamide 1-[4-(trifluoromethanesulfonyloxy)phenyl]ethane-N-(2-methoxyethyl)sulfonamide 1-[4(methanesulfonylamino)phenyl]ethane-N-2-methoxyethyl)sulfonamide 1-(4-isobutylphenyl)ethane-N-methyl sulfonamide 1-(3-benzoylphenyl)ethane-N-methyl sulfonamide 1-[4-(trifluoromethanesulfonyloxy)phenyl]ethane-N-methyl sulfonamide 1-[4-(methanesulfonylamino)phenyl]ethane-N-methyl sulfonamide 1-[4-isobutylphenyl]ethane-N-acetyl sulfonamide E-2-(3-benzoylphenyl)-2-methyl-ethenesulfonamide E-2-(3-isopropylphenyl)-2-methyl-ethenesulfonamide E-2-(4-isobutylphenyl)-2-methyl-ethanesulfonamide
and pharmaceutically acceptable salts thereof.
Preferably the salt is sodium salt
The ethanesulfonamide described above are chiral compounds and the invention provides both the racemic and the single (+) and (−) enantiomers.
The compounds of the invention of formula (I), when bearing acidic or basic groups, are generally isolated in the form of their addition salts with both organic and inorganic pharmaceutically acceptable acids or bases.
Examples of such acids are selected from hydrochloric acid, sulfuric acid, phosphoric acid, metansolfonic acid, fumaric acid, citric acid.
Examples of such bases are selected from sodium hydroxide, potassium hydroxide, calcium hydroxide, (D,L)-Lysine, L-Lysine, tromethamine.
Compounds of formula (I) wherein YR is OH are obtained by reacting corresponding compounds of formula (IV) wherein J is H or COCH 3 with a suitable oxidizing agent such as H 2 O 2 , HClO and peroxyacids preferably m-chloroperbenzoic acid.
Compounds of formula (I) wherein Y is NH and X is —CH 2 — are obtained by reacting corresponding sulfonylhalides, such as sulfonylchlorides, with one or two equivalents of an amine of formula NH 2 R in presence of a suitable organic or inorganic base if necessary.
Compounds of formula (I) wherein Y is NH and X is —CH(CH) 3 — are obtained by reacting corresponding thiols of formula (IV) with a suitable N-bromoimmide such as N-bromoftalimmide and subsequent oxidation of the sulfur atom followed by deprotection of the sulfonamide derivative as specifically detailed in the examples.
Compounds of formula (I) wherein Y is NH and X is a group of formula (II) are obtained by reacting corresponding sulfonylhalides, such as sulfonylchlorides, with the amine of formula NH 2 R.
The compounds of the present invention are particularly useful as inhibitors of IL-8 induced human PMNs chemotaxis.
It is a further object of the present invention to provide the novel sulfonic acids and derivative compounds, mentioned above, for use as medicanents.
The compounds of formula (I) were evaluated in vitro for their ability to inhibit chemotaxis of polymorphonucleate leukocytes (hereinafter referred to as PMNs) and monocytes induced by the fractions of IL-8 and GRO-α. For this purpose, in order to isolate the PMNs from heparinized human blood, taken from healthy adult volunteers, mononucleates were removed by means of sedimentation on dextran (according to the procedure disclosed by W. J. Ming et al, J. Immunol., 138, 1469, 1987) and red blood cells by a hypotonic solution. The cell vitality was calculated by exclusion with Trypan blue, whilst the ratio of the circulating polymorphonucleates was estimated on the cytocentrifugate after staining with Diff Quick.
Human recombinant IL-8 (Pepro Tech) was used as stimulating agents in the chemotaxis experiments, giving practically identical results: the lyophilized protein was dissolved in a volume of HBSS containing 0.2% bovin serum albumin (BSA) so thus to obtain a stock solution having a concentration of 10 −5 M to be diluted in HBSS to a concentration of 10 −9 M, for the chemotaxis assays.
During the chemotaxis assay (according to W. Falket et al., J. Immunol. Methods, 33, 239, 1980) PVP-free filters with a porosity of 5 μm and microchambers suitable for replication were used.
The compounds of formula (I) were evaluated at a concentration ranging between 10 −6 and 10 −10 M; for this purpose they were added, at the same concentration, both to the lower pores and the upper pores of the microchamber. Evaluation of the ability of the compounds of the invention of formula I to inhibit IL-8-induced chemotaxis of human monocytes was carried out according to the method disclosed by Van Damme J. et al. (Eur. J. Immunol., 19, 2367, 1989).
Biological results of some representative compounds in the IL-8 induced PMN chemotaxis test are reported in table II (inhibition data, C=10 −8 M).
Particularly preferred is the use of compounds of formula (I) in which Ar groups are 3′-benzoylphenyl, 3′-(4-chloro-benzoyl)-phenyl, 3′-(4-methyl-benzoyl)-phenyl, 3′-acetyl-phenyl, 3′-propionyl-phenyl, 3′-isobutanoyl-phenyl, 4′-trifluoromethanesulfonyloxy-phenyl, 4′-benzenesulfonyloxy-phenyl, 4′-trifluoromethanesulfonylamino-phenyl, 4′-benzenesulfonylamino-phenyl, 4′-benzenesulfonylmethyl-phenyl, 4′-acetoxyphenyl, 4′-propionyloxy-phenyl, 4′-benzoyloxy-phenyl, 4′acetylamino-phenyl, 4′propionylamino-phenyl, 4′-benzoylamino-phenyl, which show the additional property to effectively inhibit the GROα induced PMN chemotaxis; this activity allows the therapeutical use of these compounds in IL-8 related pathologies where the CXCR2 pathway is involved specifically or in conjunction with the CXCR1 signaling.
The dual inhibitors of the IL-8 and GRO-α induced biological activities are strongly preferred in view of the therapeutical applications of interest, but the described compounds selectively acting on CXCR1 IL-8 receptor or CXCR2 GRO-α/IL-8 receptor can find useful therapeutical applications in the management of specific pathologies as below described.
The compounds of formula (I), evaluated ex vivo in the blood in toto according to the procedure disclosed by Patrignani et al., in J. Pharmacol. Exper. Ther., 271, 1705, 1994, were found to be totally ineffective as inhibitors of cyclooxygenase (COX) enzymes.
In most cases, the compounds of formula (I) do not interfere with the production of PGE 2 induced in murine macrophages by lipopolysaccharides stimulation (LPS, 1 μg/mL) at a concentration ranging between 10 −5 and 10 −7 M. Inhibition of the production of PGE 2 which may be recorded, is mostly at the limit of statistical significance, and more often is below 15-20% of the basal value. The reduced effectiveness in the inhibition of the CO constitutes an advantage for the therapeutical application of compounds of the invention in as much as the inhibition of prostaglandin synthesis constitutes a stimulus for the macrophage cells to amplify synthesis of TNF-α (induced by LPS or hydrogen peroxide) that is an important mediator of the neutrophilic activation and stimulus for the production of the cytokine Interleukin-8.
In view of the experimental evidence discussed above and of the role performed by Interleukin-8 (IL-8) and congenetics thereof in the processes that involve the activation and the infiltration of neutrophils, the compounds of the invention are particularly useful in the treatment of a disease such as psoriasis (R. J. Nicholoff et al., Am. J. Pathol., 138, 129, 1991). Further diseases which can be treated with the compounds of the present invention are intestinal chronic inflammatory pathologies such as ulcerative colitis (Y. R. Mahida et al., Clin. Sci., 82, 273, 1992) and melanoma, chronic obstructive pulmonary disease (COPD), bullous pemphigo, rheumatoid arthritis (M. Selz et al., J. Clin. Invest., 87, 463, 1981), idiopathic fibrosis (E. J. Miller, previously cited, and P. C. Carré et al., J. Clin. Invest., 88, 1882, 1991), glomerulonephritis (T. Wada et al., J. Exp. Med., 180, 1135, 1994) and in the prevention and treatment of damages caused by ischemia and reperfusion.
Inhibitors of CXCR1 and CXCR2 activation find useful applications, as above detailed, particularly in treatment of chronic inflammatory pathologies (e.g. psoriasis) in which the activation of both IL-8 receptors is supposed to play a crucial pathophysiological role in the development of the disease.
In fact, activation of CXCR1 is known to be essential in IL-8-mediated PMN chemotaxis (Hammond M et al, J Immunol, 155, 1428, 1995). On the other hand, activation of CXCR2 activation is supposed to be essential in IL-8-mediated epidermal cell proliferation and angiogenesis of psoriatic patients (Kulke R et al., J Invest Dermatol, 110, 90, 1998).
In addition, CXCR2 selective antagonists find particularly useful therapeutic applications in the management of important pulmonary diseases like chronic obstructive pulmonary disease COPD (D. WP Hay and H. M. Sarau., Current Opinion in Pharmacology 2001, 1:242-247).
It is therefore a further object of the present invention to provide the use of compounds of formula (I) in the preparation of a medicament for the treatment of psoriasis, ulcerative colitis, melanoma, chronic obstructive pulmonary disease (COPD), bullous pemphigo, rheumatoid arthritis, idiopathic fibrosis, glomerulonephritis and in the prevention and treatment of damages caused by ischemia and reperfusion, as well as the use of such compounds. Pharmaceutical compositions comprising a compound of the invention and a suitable carrier thereof, are also within the scope of the present invention.
The compounds of the invention, together with a conventionally employed adjuvant, carrier, diluent or excipient may, in fact, be placed into the form of pharmaceutical compositions and unit dosages thereof, and in such form may be employed as solids, such as tablets or filled capsules, or liquids such as solutions, suspensions, emulsions, elixirs, or capsules filled with the same, all for oral use, or in the form of sterile injectable solutions for parenteral (including subcutaneous) use. Such pharmaceutical compositions and unit dosage forms thereof may comprise ingredients in conventional proportions, with or without additional active compounds or principles, and such unit dosage forms may contain any suitable effective amount of the active ingredient commensurate with the intended daily dosage range to be employed.
When employed as pharmaceuticals, the acids of this invention are typically administered in the form of a pharmaceutical composition. Such compositions can be prepared in a manner well known in the pharmaceutical art and comprise at least one active compound. Generally, the compounds of this invention are administered in a pharmaceutically effective amount. The amount of the compound actually administered will typically be determined by a physician, in the light of the relevant circumstances, including the condition to be treated, the chosen route of administration, the actual compound administered, the age, weight, and response of the individual patient, the severity of the patient's symptoms, and the like.
The pharmaceutical compositions of the invention can be administered by a variety of routes including oral, rectal, transdermaldermal, subcutaneous, intravenous, intramuscular, and intranasal. Depending on the intended route of delivery, the compounds are preferably formulated as either injectable or oral compositions. The compositions for oral administration can take the form of bulk liquid solutions or suspensions, or bulk powders. More commonly, however, the compositions are presented in unit dosage forms to facilitate accurate dosing. The term “unit dosage forms” refers to physically discrete units suitable as unitary dosages for human subjects and other mammals, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect, in association with a suitable pharmaceutical excipient. Typical unit dosage forms include prefilled, premeasured ampoules or syringes of the liquid compositions or pills, tablets, capsules or the like in the case of solid compositions. In such compositions, the acid compound is usually a minor component (from about 0.1 to about 50% by weight or preferably from about 1 to about 40% by weight) with the remainder being various vehicles or carriers and processing aids helpful for forming the desired dosing form.
Liquid forms suitable for oral administration may include a suitable aqueous or nonaqueous vehicle with buffers, suspending and dispensing agents, colorants, flavors and the like.Liquid forms, including the injectable compositions described herebelow, are always stored in the absence of light, so as to avoid any catalytic effect of light, such as hydroperoxide or peroxide formation. Solid forms may include, for example, any of the following ingredients, or compounds of a similar nature: a binder such as microcrystalline cellulose, gum tragacanth or gelatine; an excipient such as starch or lactose, a disintegrating agent such as alginic acid, Primogel, or corn starch; a lubricant such as magnesium stearate; a glidant such as colloidal silicon dioxide; a sweetening agent such as sucrose or saccharin; or a flavoring agent such as peppermint, methyl salicylate, or orange flavoring.
Injectable compositions are typically based upon injectable sterile saline or phosphate-buffered saline or other injectable carriers known in the art. As above mentioned, the acid derivative of formula I in such compositions is typically a minor component, frequently ranging between 0.05 to 10% by weight with the remainder being the injectable carrier and the like. The mean daily dosage will depend upon various factors, such as the seriousness of the disease and the conditions of the patient (age, sex and weight). The dose will generally vary from 1 mg or a few mg up to 1500 mg of the compounds of formula (I) per day, optionally divided into multiple administrations. Higher dosages may be administered also thanks to the low toxicity of the compounds of the invention over long periods of time.
The above described components for orally administered or injectable compositions are merely representative. Further materials as well as processing techniques and the like are set out in Part 8 of “Remington's Pharmaceutical Sciences Handbook”, 18 th Edition, 1990, Mack Publishing Company, Easton, Pa., which is incorporated herein by reference.
The compounds of the invention can also be administered in sustained release forms or from sustained release drug delivery systems. A description of representative sustained release materials can also be found in the incorporated materials in the Remington's Handbook as above.
The present invention shall be illustrated by means of the following examples which are not construed to be viewed as limiting the scope of the invention.
EXAMPLE 1
General Procedure for the Synthesis of Arylmethanesulfonic Acids, 1-arylethanesulfonic Acids of Formula R—Ar—C(CH 3 )H—SO 3 H and Related Enantiomers
To a cooled (T=0-4° C.) solution of the substituted benzene (17 mmol) and acetyl chloride (18 mmol) in dry CH 2 Cl 2 (25 mL), AlCl 3 (18 mmol) is added portionwise under vigorous stirring. The ice bath is then removed and the solution is refluxed until complete disappearance of the starting material is evident (2-3 hours). After cooling at room temperature, the mixture is poured into cooled 2N HCl and left stirring for 30′. The acid solution is then transferred into a separator funnel and extracted with CH 2 Cl 2 (3×20 mL). The collected organic extracts are washed with a NaCl saturated solution (2×25 mL), dried over Na 2 SO 4 and evaporated under vacuum to give the pure arylacetophenone (14.45-16.15 mmol) in high yield (85-95%).
To a stirred solution of arylacetophenone (11.5 mmol) in methyl alcohol (40 mL) sodium borohydride (17.2 mmol) is added portionwise. The mixture is refluxed until the starting material is completely disappeared (3 hours). After cooling at room temperature, 1M HCl is added to the mixture and the alcohol is distilled off. The aqueous phase is extracted with ethyl acetate (3×15 mL) and the collected organic extracts are washed with a NaCl saturated solution (2×15 mL), dried over Na 2 SO 4 and evaporated under vacuum to give the pure 1-arylethyl alcohol (yield around 75%).
To a stirred solution of 1-arylethyl alcohol (4.5 mmol) in dry CHCl 3 (10 mL) thiolacetic acid (5.39 mmol) and zinc iodide (2.24 mmol) are added. The reaction mixture is refluxed for 3 hours; after cooling at room temperature, the mixture is diluted with water (15 mL) and transferred into a separator funnel. The two phases are shaken and separated. The organic phase is washed with a NaHCO 3 saturated solution (3×20 mL), then with a NaCl saturated solution, dried over Na 2 SO 4 and evaporated under vacuum to give the pure 1-arylethylthioacetate (yield around 80%).
A solution of 1-arylethylthioacetate (0.91 mmol) in glacial acetic acid (2 mL) is stirred at 60° C. and treated dropwise with 30% H 2 O 2 (4.56 mmol); the resulting solution is stirred at 60° C. for 24 hours, then the acetic acid is removed azeotropically with toluene. The residue is diluted with water (5 mL), neutralised with 1N NaOH, washed with diethyl ether (2×15 mL) and lyophilised to provide the 1-arylethanesulfonic acid sodium salt as racemic mixture as a white solid (yield around 90%).
Optical Resolution
Racemic 1-arylethanesulfonic acid sodium salt is filtered through a column packed with Amberlite IR-120 resin (H+ form) eluted with water to give the product as pasty oil. The two isomers separation is achieved by crystalisation of the corresponding (+) or (−) α-phenylethylammonium salts in ethanolic solution as described for the optical resolution of arylpropionic acids in Akgun H. et al., Arzneim.-Forsch./Drug Res., 46(II), Nr.9, 891-894 (1996). The pure enantiomers are isolated as sodium salts.
According to the above described method, the following compounds have been prepared:
(−)-1-(4-isobutylphenyl)ethanesulfonic acid sodium salt (1)
The compound has been synthesised starting from commercial isobutylbenzene.
[α]D =−35 (c=1; H 2 O) 1 H-NMR (DMSO-d 6 ): δ 7.25 (d, 2H, J=7 Hz); 7.05 (d, 2H, J=7 Hz); 3.62 (m, 1H); 2.37 (d, 2H, J=7 Hz); 1.86 (m, 1H); 1.40 (d, 3H, J=7 Hz); 0.91 (d, 6H, J=7 Hz).
(+)-1-(4-isobutylphenyl)ethanesulfonic acid sodium salt (2)
The compound has been synthesised starting from commercial isobutylbenzene.
[α] D =+34.5 (c=1; H 2 O) 1 H-NMR (DMSO-d 6 ): δ 7.25 (d, 2H, J=7 Hz); 7.08 (d, 2H, J=7 Hz); 3.62 (m, 1H); 2.37 (d, 2H, J=7 Hz); 1.86 (m, 1H); 1.42 (d, 3H, J=7 Hz); 0.90 (d, 6H, J=7 Hz).
(−)-1-[4-(1-oxo-2-isoindolinyl)phenyl]ethanesulfonic acid sodium salt (3)
The compound has been prepared according to the above described method starting from the intermediate 4-(1-oxo-2-isoindolinyl)acetophenone. This intermediate has been prepared from the commercially available reagents phtalaldehyde and 4-aminoacetophenone on the basis of the method described in ichiro, T. et al., Heterocycles 43: 11, 2343-2346 (1996).
[α] D =−52.4 (c=1; H 2 O) 1 H-NMR (DMSO-d 6 ): δ 7.68 (m, 3H); 7.35 (m, 3H); 7.15 (d, 2H, J=7 Hz); 4.68 (s, 2M); 3.65 (q, 1H, J=7 Hz, J2=3 Hz); 1.28 (d, 3H, J=7 Hz).
(+)-1-[4-1-oxo-2-isoindolinyl)phenyl] ethanesulfonic acid sodium salt (4)
The compound has been prepared according to the above described method starting from the intermediate 4-(1-oxo-2-isoindolinyl)acetophenone. This intermediate has been prepared from the commercially available reagents phtalaldehyde and 4-aminoacetophenone on the basis of the method described in Ichiro, T. et al., Heterocycles 43: 11, 2343-2346 (1996).
[α] D =+50 (c=1; H 2 O) 1 H-NMR (DMSO-d 6 ): δ 7.708 (m, 3H); 7.35 (m, 3H); 7.18 (d, 2H, J=7 Hz); 4.68 (s, 2H); 3.65 (q, 1H, J=7 Hz, J2=3 Hz); 1.30 (d, 3H, J=7 Hz).
(−)-2-(4-phenylsulfonyloxy)ethanesulfonic acid sodium salt (5)
The compound has been prepared according to the above described method starting from the intermediate 4-benzenesulfonyloxyacetophenone obtained from the commercial 4-hydroxyacetophenone following known experimental procedures.
[α] D =−47.5 (c=1; H 2 O) 1 H-NMR (D 2 O): δ 7.90 (d, 2H, J=7 Hz); 7.70 (t, 1H, J=7 Hz); 7.55 (t, 2H, J=7 Hz); 7.32 (d, 2H, J=7 Hz); 6.95 (d, 2H, J=7 Hz); 3.64 (m, 1H); 1.41 (d, 3H, J=7 Hz).
(+)-2-(4-phenylsulfonyloxy)ethanesulfonic acid sodium salt (6)
The compound has been prepared according to the above described method starting from the intermediate 4-benzenesulfonyloxyacetophenone obtained from the commercial 4-hydroxyacetophenone following known experimental procedures.
[α] D =+49 (c=1; H 2 O) 1 H-NMR (D 2 O): δ 7.93 (d, 2H, J=7 Hz); 7.70 (t, 1H, J=7 Hz); 7.55 (t, 2H, J=7 Hz); 7.32 (d, 2H, J=7 Hz); 6.91 (d, 2H, J=7 Hz); 3.67 (m, 1H); 1.41 (d, 3H, J=7 Hz).
(1-methyl-5-acetylpyrrolyl)1-methanesulfonic acid sodium salt (7)
The synthesis of (7) has been carried out starting from the commercial reagent methyl-1-methyl-2-pyrrole acetate that, by Friedel Cafts acylation with acethyl chloride, has afforded the (1-methyl-5-acetylpyrrolyl)-1-methaneacetate. The ester group then has been hydrolysed. Following the experimental procedure described in WO 02/0704095 the related (1-methyl-5-acetylpyrrolyl)-1-methanesulfonic acid sodium salt has been obtained.
1 H-NMR (DMSO-d 6 ): δ 7.5 (s, 1H); 6.18 (s, 1H); 3.60 (s, 3H); 3.51 (s, 2H); 2.10 (s, 3H).
(±)-2-(3-benzoylphenyl) ethanesulfonic acid sodium salt (8)
The synthesis of (8) has been carried out starting from the commercial reagent 3-(1-cyanoethyl)benzoic acid that, by Friedel Crafts acylation in benzene, has afforded the 2-(3′-benzoylphenyl)propionitrile. Following the experimental procedure described in WO 02/0704095 the related 2-(3′-benzoylphenyl)ethanesulfonic acid sodium salt has been obtained.
1 H-NMR (D 2 O): δ 7.80 (d, 2H, J=7 Hz); 7.70 (s, 1H); 7.62 (d, 1H, J=7 Hz); 7.51 (m, 2H); 7.30 (m, 3); 3.62 (m, 1H); 1.40 (d, 3H, J=7 Hz).
(±)-2-(3-isopropylphenyl)ethanesulfonic acid sodium salt (9)
The synthesis of (9) has been carried out starting from the available reagent 3-(1-cyanoethyl)acetophenone that, by Wittig reaction and reduction of the methylene group according well known methods, has afforded the 2-(3-isopropylphenyl)propionitrile. Following the experimental procedure described in WO 02/0704095 the related 2-(3-isopropylphenyl)ethanesulfonic acid sodium salt has been obtained.
1 H-NMR (D 2 O): δ 7.30 (m, 2H); 7.10 (m, 2H); 3.92 (m, 1H); 3.63 (m, 1H); 1.42 (d, 3H, J=7 Hz); 1.25 (d, 6H, J=8 Hz).
EXAMPLE 2
Preparation of E-arylethenesulfonic acids (sodium salts)
The arylethanesulfonic acid is dissolved in thionyl chloride (5 mL) and the solution is left under reflux overnight. After cooling at room temperature, thionyl chloride is evaporated under vacuum and the crude arylethanesulfonyl chloride is diluted with dry THF (5 mL) and cooled at T=0° C. in an ice-water bath; 1N aqueous NaOH (0.64 mmol) is added at T=4° C.; the ice-water bath is removed and the reaction mixture is left still until it reaches room temperature in about one hour, while a white solid precipitates. The organic sodium salt is filtered under vacuum, washed with THF and dried in oven under vacuum at 40° C. to give the pure E-arylethenesulfonic acid sodium salt (0.32-0.51 mmol) (yield 50-80%) as white powder.
According to the above described procedure, the following compounds have been prepared:
E-2-(4-isobutylphenyl)ethenesulfonic acid sodium salt (10)
1 H-NMR (D 2 O): δ 7.60 (d, 1H, J=8 Hz); 7.55-7.32 (m, 4H); 7.05 (d, 1H, J=14 Hz); 2.62 (m, 2H); 1.90 (m, 1H); 0.97 (d, 6H, J=7 Hz).
E-2-(3-benzoylphenyl)ethenesulfonic acid sodium salt (11)
1 H-NMR (D 2 O): δ 7.80 (d, 2H, J=7 Hz); 7.70 (s, 1H); 7.65 (d, 1H, J=8 Hz); 7.62 (d, 1H, J=7 Hz); 7.51 (m, 2H); 7.30 (m, 3H); 7.00 (d, 1H, J=14 Hz).
E-2-(4-methanesulfonylaminophenyl)ethenesulfonic acid sodium salt (12)
1 H-NMR (DMSO-d 6 ): δ 7.60 (d, 1H, J=8 Hz); 7.35 (d, 2H, J=8 Hz); 7.20 (d, 2H, J=8 Hz); 7.07 (d, 1H, J=14 Hz); 6.51 (bs, 1H, SO 2 NH); 3.00 (s, 3H).
E-2-(4-trifluoromethanesulfonyloxyphenyl)ethenesulfonic acid sodium salt (13)
1 H-NMR (CDCl 3 ): δ 7.62 (d, 1H, J=8 Hz); 7.50 (d, 2H, J=7 Hz); 7.25 (d, 2H, J=7 Hz); 7.05 (d, 1H, J=14 Hz).
EXAMPLE 3
General Procedure for the Synthesis of E-arylethenesulfonamides
A solution of the arylethanesulfonic acid (0.64 mmol) is dissolved in thionyl chloride (5 mL) and the solution is left under reflux overnight After cooling at room temperature, thionyl chloride is evaporated under vacuum and the crude arylethanesulfonyl chloride is diluted with dry THF (5 mL) and cooled at T=0° C. in an ice-water bath; the selected amine (1.28 mmol) is added dropwise. The ice-water bath is removed and the reaction mixture is left to reach room temperature. After the complete disappearance of the starting reagent the solvents are evaporated under vacuum and CHCl 3 (10 mL) and water (10 mL) are added to the residue; the two phases are shaken and separated, the organic phase is washed with water (3×15 mL), dried over Na 2 SO 4 and evaporated under vacuum to give a crude which is purified by flash chromatography. Pure E/Z-aryl ethenesulfonamides (0.32-0.51 mmol) (yield 50-80%) are isolated as colourless oils.
According to the above described method, and using ammonia (0.5 M in 1,4-dioxane) as the amine, the following compounds have been prepared:
E-2-(4-isobutylphenyl)ethenesulfonamide (14)
1 H-NMR (CDCl 3 ): δ 7.55 (d, 1H, J=14 Hz); 7.38 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz); 6.88 (d, 1H, J=14 Hz); 4.75 (bs, 2H, SO 2 NH 2 ); 2.55 (d, 2H, J=7 Hz); 1,94 (m, 1H); 1.02 (d, 6H, J=7 Hz).
E-2-(3-benzoylphenyl)ethenesulfonamide (15)
1 H-NMR (CDCl 3 ): δ 7.80 (d, 2H, J=7 Hz); 7.72 (s, 1H); 7.62 (d, 1H, J=8 Hz); 7.52 (d, 1H, J=14 Hz); 7.50 (m, 2H); 7.30 (m, 3H); 6.88 (d, 1H, J=14 Hz); 4.75 (bs, 2H, SO 2 NH 2 ).
E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethenesulfonamide (16)
1 H-NMR (CDCl 3 ): δ 7.60 (d, 1H, J=8 Hz); 7.52 (d, 2H, J=7 Hz); 7.28 (d, 2H, J=7 Hz); 7.10 (d, 1H, J=14 Hz); 4.85 (bs, 2H, SO 2 NH 2 ).
E-2-[4-(methanesulfonylamino)phenyl]ethenesulfonamide (17)
1 H-NMR (CDCl 3 ): δ 7.55 (d, 1H, J=14 Hz); 7.37 (d, 2H, J=8 Hz); 7.22 (d, 2H, J=8 Hz); 6.90 (d, 1H, J=14 Hz); 6.45 (bs, 1H, SO 2 NH); 4.80 (bs, 2H, SO 2 NH 2 ); 2.98 (s, 3H).
According to the above described method, and using 3-(dimethylamino)propylamine as the amine, the following compounds have been prepared:
E-2-(4-isobutylphenyl)ethene-(N,N-dimethylaminopropyl)sulfonamide (18)
1 H-NMR (CDCl 3 ): δ 7.45 (m, 3H); 7.20 (d, 2H, J=7 Hz); 6.70 (d, 1H, J=14 Hz); 6.40 (bs, 1H, SO 2 NH); 3.18 (m, 2H); 2.55 (m, 4H); 2.30 (s, 6H); 1.92 (m, 1H); 1.75 (m, 2H); 0.97 (d, 6H, J=7 Hz).
E-2-(3-benzoylphenyl)etheneN-(N,N-dimethylaminopropyl)sulfonamide (19)
1 H-NMR (CDCl 3 ): δ 7.82 (d, 2H, J=7 Hz); 7.74 (s, 1H); 7.60 (d, 1H, J=8 Hz); 7.50 (d, 1H, J=14 Hz); 7.45 (m, 2H); 7.26 (m, 3H); 6.70 (d, 1H, J=14 Hz); 6.45 (bs, 1H, SO 2 NR); 3.15 (m, 2H); 2.50 (m, 4H); 2.35 (s, 6H).
E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethene-(N,N-dimethylaminopropyl)sulfonamide (20)
1 H-NMR (CDCl 3 ): δ 7.62 (d, 1H, J=14 Hz); 7.48 (d, 2H, J=7 Hz); 7.25 (d, 2H, J=7 Hz); 7.00 (d, 1H, J=14 Hz); 6.50 (bs, 1, SO 2 NH); 3.17 (m., 2H); 2.48 (m, 4H); 2.35 (s, 6H).
E-2-[4-(methanesulfonylamino)phenyl]ethene-(N,N-dimethylaminopropyl)sulfonamide (21)
1 H-NMR (CDCl 3 ): δ 7.57 (d, 1H, J=14 Hz); 7.37 (d, 2H, J=8 Hz); 7.22 (d, 2H, J=8 Hz); 6.75 (d, 1H, J=14 Hz); 6.50 (bs, 2H, SO 2 NH); 3.15 (m, 2H); 2.98 (s, 3H); 2.50 (m, 4H); 2.40 (s, 6H).
According to the above described method, and using methylamine (2M in THF) as the amine the following compounds have been prepared:
E-2-(4-isobutylphenyl)ethene-N-methyl sulfonamide (22)
1 H-NMR (CDCl 3 ): δ 7.55 (d, 1H, J=14 Hz); 7.38 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz); 6.88 (d, 1H, J=14 Hz); 4.80 (bs, 1H, SO 2 NH); 2.75 (d, 3H, J=4 Hz); 2.55 (d, 2H, J=7 Hz); 1.95 (m, 1H); 1.04 (d, 6H, J=7 Hz).
E-2-(3-benzoylphenyl)ethene-N-methyl sulfonamide (23)
1 H-NMR (CDCl 3 ): δ 7.81 (d, 2H, J=7 Hz); 7.70 (s, 1H); 7.62 (d, 1H, J=8 Hz); 7.55 (d, 1H, J=14 Hz); 7.45 (m, 2H); 7.30 (m, 3H); 6.90 (d, 1H, J=14 Hz); 4.60 (bs, 1H, SO 2 NH); 2.70 (d, 3H, J=4 Hz).
E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethene-N-methyl sulfonamide (24)
1 H-NMR (CDCl 3 ): δ 7.60 (d, 1H, J=8 Hz); 7.52 (d, 2H, J=7 Hz); 7.28 (d, 2H, J=7 Hz); 7.10 (d, 1H, J=14 Hz); 4.85 (bs, 1H, SO 2 NH); 2.70 (d, 3H, J=4 Hz).
E-2-[4-(methanesulfonylamino)phenyl]ethene-N-methyl sulfonamide (25)
1 H-NMR (CDCl 3 ): δ 7.56 (d, 1H, J=14 Hz); 7.35 (d, 2H, J=8 Hz); 7.20 (d, 2H, J=8 Hz); 6.92 (d, 1H, J=14 Hz); 6.50 (bs, 1H, SO 2 NH); 4.70 (bs, 1H, SO 2 NH); 3.00 (s, 3H), 2.75 (d, 3H, J=4 Hz).
According to the above described method, and using 2-methoxyethylamine as the amine the following compounds have been prepared:
E-2-(4isobutylphenyl)ethene-N-2-methoxyethyl)sulfonamide (26)
1 H-NMR (CDCl 3 ): δ 7.57 (d, 1H, J=14 Hz); 7.38 (d, 2H, J=7 Hz.); 7.20 (d, 2H, J=7 Hz); 6.90 (d, 1H, J=14 Hz); 4.80 (bs, 1H, SO 2 NH); 3.74 (m, 2H); 3.55 (m, 2H); 3.45 (s, 3H); 2.52 (d, 2H, J=7 Hz.); 1.95 (m, 1H); 1.05 (d, 6H, J=7 Hz).
E-2-(3-benzoylphenyl)ethene-N-(2-methoxyethyl)sulfonamide (27)
1 H-NMR (CDCl 3 ): δ 7.80 (d, 2H, J=7 Hz); 7.72 (s, 1H); 7.62 (d, 1H, J=8 Hz); 7.55 (d, 1H, J=14 Hz); 7.40 (m, 2H); 7.30 (m, 3H); 6.95 (d, 1H, J=14 Hz); 4.62 (bs, 1H, SO 2 NH); 3.75 (m, 2H); 3.50 (m, 2H); 3.40 (s, 3H).
E-2-[4-(trifluoromethanesulfonyloxy)phenyl]ethen-N-(2-methoxyethyl)sulfonamide (28)
1 H-NMR (CDCl 3 ): δ 7.62 (d, 1H, J=8 Hz); 7.50 (d, 2H, J=7 Hz); 7.30 (d, 2H, J=7 Hz); 7.15 (d, 1H, J=14 Hz); 4.80 (bs, 1H, SO 2 NH); 3.77 (m, 2H); 3.52 (m, 2H); 3.40 (s, 3H).
E-2-[4-(methanesulfonylamino)phenyl]ethen-N-(2-methoxyethyl)sulfonamide (29)
1 H-NMR (CDCl 3 ): δ 7.58 (d, 1H, J=14 Hz); 7.35 (d, 2H, J=8 Hz); 7.25 (d, 2H, J=8 Hz); 6.90 (d, 1H, J=14 Hz); 6.52 (bs, 1H, SO 2 NH); 4.75 (bs, 1H, SO 2 NH); 3.70 (m, 2H); 3.50 (m, 2H); 3.40 (s, 3H); 3.05 (s, 3H).
EXAMPLE 4
General Procedure for the Synthesis of arylmethanesulfonamides
(1-methyl-5-isobutirrylpyrrolyl)-1-methanesulfonamide (30)
The synthesis of (30) has been carried out starting from the commercial reagent methyl-1-methyl-2-pyrrole acetate that, by Friedel Crafts acylation with isobuturryl chloride, has afforded the (1-methyl-5-isobutirrylpyrrolyl)-1-methaneacetate. The ester group then has been hydrolysed. Following the experimental procedure described in WO 02/0704095, the related (1-methyl-5-isobutirrylpyrrolyl)-1-methanesulfonic acid sodium salt has been obtained.
A solution of (1-methyl-5-isobutirrylpyrrolyl)-1-methanesulfonic acid sodium salt (0.64 mmol) is dissolved in thionyl chloride (5 mL) and the solution is left under reflux overnight. After cooling at room temperature, thionyl chloride is evaporated under vacuum and the crude (1-methyl-5-isobutirrylpyrrolyl)-1-methanesulfonyl chloride is diluted with dry THF (5 mL) and cooled at T=0° C. in an ice-water bath; the solution of ammonia (1.28 mmol) is added dropwise. The ice-water bath is removed and the reaction mixture is left to reach room temperature. After the complete disappearance of the starting reagent the solvents are evaporated under vacuum and CHCl 3 (10 mL) and water (10 mL) are added to the residue; the two phases are shaken and separated, the organic one is washed with water (3×15 mL), dried over Na 2 SO 4 and evaporated under vacuum to give a crude which is purified by flash chromatography. Pure (1-methyl-5-isobutirrylpyrrolyl)-1-methanesulfonamide (0.60 mmol) (yield 93%) are isolated as a yellow oil.
1 H-NMR (DMSO-d 6 ): δ 7.5 (s, 1H); 6.18 (s, 1H); 4.65 (bs, 2H, SO 2 NH 2 ); 3.60 (s, 3H); 3.51 (s, 2H); 3.38 (m, 1H); 1.25 (d, 6H, J=8 Hz).
According to the above described method, and using (1-methyl-5-acetylpyrrolyl)-1-methanesulfonic acid sodium salt (7) (prepared according to the above described method of general procedure for the synthesis of arymethanesulfonic acids) the following compound has been prepared:
(1-methyl-5-acetylpyrrolyl)-1-methanesulfonamide (31)
1 H-NMR (DMSO-d 6 ): δ 7.5 (s, 1H); 6.18 (s, 1H); 4.40 (bs, 2H, SO 2 NH 2 ); 3.60 (s, 3H); 3.51 (s, 2H); 2.10 (s, 3H).
Enantioselective Synthesis of (+) and (−) Enantiomers of Compounds 32 and 33
The enantioselective synthesis of (+) and (−) enantiomers of 1-(4-isobutylphenyl)ethanesulfonamide has been performed as described in Davis F. A. et al., J. Org. Chem., 58, 4890-4896, (1993). The procedure involves the diastereoselective C-methylation of N-sulfonylcamphorimine generated from 4-isobutylbenzylsulfonamide (27) and N,N-diisopropyl-(1S)-(+)-10-camphorsulfonamide or N,N-diisopropyl-(1R)-(−)-10-camphorsulfonamide. The diastereoisomers acid hydrolysis allows to obtain the desired compounds, both as transparent oils.
(−)-1-(4-isobutylphenyl)ethanesulfonamide (32)
[α] D =−8.5 (c=1.2; CHCl 3 ) 1 H-NMR (CDCl 3 ): δ 7.30 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz); 4.25 (m, 1H+bs SONH 2 ); 2.45 (d, 2H, J=7 Hz); 1.87 (m, 4H); 0.97 (d, 6H, J=7 Hz).
(+)-1-(4-isobutylphenyl)ethanesulfonamide (33)
[α] D =+15 (c=1; CHCl 3 ) 1 H-NMR (CDCl 3 ): δ 7.30 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz); 4.25 (m, 1H+bs SONH 2 ); 2.45 (d, 2H, J=7 Hz); 1.87 (m, 4H); 0.97 (d, 6H, J=7 Hz).
EXAMPLE 5
Alternative Synthesis of Arylethanesulfonamides
Synthesis of (+)-1-(3-isopronylphenyl)ethanesulfonamide (34)
The title compound has been prepared starting the commercial reagent 3-(1-cyanoethyl)benzoic acid which, following the experimental procedures described in Kindler K. et al., Chem. Ber., 99, 226 (1966) and in Kindler K. et al., Liebigs Ann. Chem., 26, 707 (1967), has afforded the intermediate 3-isopropyl benzoic acid. Reduction to benzylalcohol derivative by LiAlH 4 and subsequent treatment of the alcohol with thiolacetic acid has given the intermediate ethylthioacetate. The subsequent hydrolysis to the thiol derivative has been carried out as described in Corey E. J. et al., Tet. Lett., 33, 4099 (1992).
To a suspension of 3-isopropylbenzyl thiol (3.85 g; 23.2 mmol) and potassium ter-butoxide (2.6 g; 23.2 mmol) in CH 2 Cl 2 (15 mL), 18-Crown-6 (0.6 g; 2.3 mmol) is added. After stirring for 15′ at T=0°-4° C. N—Br-phtalimide (5.24 g; 23.2 mmol) is added. After the adding the ice-water bath is removed and the solution is left stirring at room temperature for 1 h; then the organic phase is washed with water (3×15 mL), dried over Na2SO4 and evaporated under vacuum to give an oily residue purified by flash chromatography to give 3-isopropylbenzylthiophtalimide (6.05 g; 18.56 mmol) as a pale yellow oil (yield 80%). The following methylation to give the racemic 1-(3-isopropylphenyl)ethyl thiophtalimide has been carried out as described in Davis F. A. et al., J. Org. Chem., 58, 4890-4896, (1993). The final compound 1-(3-isopropylphenyl)ethanesulfonamide (31) has been obtained by oxidation with 3-chloroperbenzoic acid (2 equivalents) and cleavage of the phtalimido moiety by treatment with hydrazine according to methods well known in the art.
1 H-NMR (CDCl 3 ): δ 7.28 (m, 2H); 7.05 (m, 2H); 4.40 (bs, 2H, SO 2 NH 2 ); 3.90 (m, 1H); 3.65 (m, 1H); 1.35 (d, 3H, J=7 Hz); 1.20 (d, 6H, J=8 Hz).
Alkylation of the corresponding 1-arylethanesulfonamides (prepared according to the above described method) by 3-dimethylaminopropyl chloride as alkylating reagent has been carried out in phase transfer conditions as described in Gajda T. et al., Synthesis, 1005 (1981) and Burke P.O. et al., Synthesis, 935 (1985). The following compounds have been prepared:
(±)-1-(4-isobutylphenyl)ethane-N-(N,N-dimethylaminopropyl)sulfonamide (35)
1 H-NMR (CDCl 3 ): δ 7.32 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz.); 4.26 (m, 1H); 4.10 (bs, 1H, SONH); 3.18 (m, 2H); 2.55 (m, 4H); 2.45 (d, 2H, J=7 Hz); 2.40 (s, 6H); 1.85(m, 4H); 1.00 (d, 6H, J=7 Hz).
(±)-1-(3-benzoylphenyl)ethane-N-(N,N-dimethylaminopropyl)sulfonamide (36)
1 H-NMR (CDCl 3 ): δ 7.80 (d, 2H, J=7 Hz); 7.70 (s, 1H); 7.62 (d, 1H, J=7 Hz); 7.51 (m, 2H); 7.30 (m, 3H); 4.35 (bs, 1H, SO 2 NH); 3.62 (m, 1H); 3.18 (m, 2H); 2.55 (m, 4H); 2.40 (s, 6H); 1.30 (d, 3H, J=7 Hz).
(±)-1-[4-(trifluoromethanesulfonyloxy)phenyl]ethane-N-(N,N-dimethylaminopropyl)sulfonamide (37)
1 H-NMR (CDCl 3 ): δ 7.50 (d, 2H, J=7 Hz); 7.25 (d, 2H, J=7 Hz); 4.30 (bs, 1H, SO 2 NH); 3.85 (m, 1H); 3.20 (m, 2H); 2.60 (m, 4H); 2.45 (s, 6H); 1.25 (d, 3H, J=7 Hz).
(±) 1-[4-(methanesulfonylamino)phenyl]ethane-N-(N,N-dimethylaminopropyl)sulfonamide (38)
1 H-NMR (CDCl 3 ): δ 7.37 (d, 2H, J=8 Hz); 7.22 (d, 2H, J=8 Hz); 6.45 (bs, 1H, SO2NH); 4.80 (bs, 1H, SO 2 NH); 3.82 (m, 1H); 3.25 (m, 2H); 2.98 (s, 3H); 2.65 (m, 4H); 2.45 (s, 6H); 1.05 (d, 3H, J=7 Hz).
Alkylation of the corresponding 1-arylethanesulfonamides (prepared according to the above described method) by 2-bromoethylmethyl ether as alkylating reagent has been carded out in phase transfer conditions as described in Gajda T. et al., Synthesis, 1005 (1981) and Burke P.O. et al., Synthesis, 935 (1985). The following compounds have been prepared:
(±)-1-(4-isobutylphenyl)ethane-N-(2-methoxyethyl)sulfonamide (39)
1 H-NMR (CDCl 3 ): δ 7.30 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz); 4.25 (m, 1H); 4.80 (bs, 1H, SO 2 NH); 3.74 (m, 2H); 3.55 (m, 2H); 3.45 (s, 3H); 2.45 (d, 2H, J=7 Hz); 1.87 (m, 1H); 1.65 (d, 3H, J=7 Hz); 0.97 (d, 6H, J=7 Hz).
(±)-1-(3-benzoylphenyl)ethane-N-(2-methoxyethyl)sulfonamide (40)
1 H-NMR (CDCl 3 ): δ 7.82 (d, 2H, J=7 Hz); 7.75 (s, 1H); 7.62 (d, 1H, J=7 Hz); 7.55 (m, 2H); 7.30 (m, 3H); 4.25 (bs, 1H, SO 2 NH); 3.75 (m, 2H); 3.60 (m, 1H); 3.55 (m, 2H); 3.48 (s, 3H); 1.55 (d, 3H, J=7 Hz).
(±)-1-[4-(trifluoromethanesulfonyloxy)phenyl]ethane-N-(2-methoxyethyl)sulfonamide (41)
1 H-NMR (CDCl 3 ): δ 7.50 (d, 2H, J=7 Hz); 7.25 (d, 2H, J=7 Hz); 4.30 (bs, 1H, SO 2 NH); 3.85 (m, 1H); 3.60 (m, 2H); 3.55 (m, 2H); 3.48 (s, 3H); 1.35 (d, 3H, J=7 Hz).
(±)-1-[4-(methanesulfonylamino)phenyl]ethane-N-(2-methoxyethyl)sulfonamide (42)
1 H-NMR (CDCl 3 ): δ 7.52 (d, 2H, J=7 Hz); 7.28 (d, 2H, J=7 Hz); 6.45 (bs, 1H, SO 2 NH); 4.32 (bs, 1H, SO 2 NH); 3.85 (m, 1H); 3.62 (m, 2M); 3.55 (m, 2H); 3.48 (s, 3H); 3.00 (s, 3H); 1.35 (d, 3H, J=7 Hz).
Monomethylation of the corresponding 1-arylethanesulfonamides (prepared according to the above described method) by diazomethane has been carried out as described in Muller E. et al., Liebigs Ann. Chem., 623, 34 (1959) and Saegusa T. et al., Tet Lett., 6131 (1966). The following compounds have been prepared:
(±)-1-(4-isobutylphenyl)ethane-N-methyl sulfonamide (43)
1 H-NMR (CDCl 3 ): δ 7.25 (d, 2H, J=7 Hz); 7.18 (d, 2H, J=7 Hz); 4.80 (bs, 1H, SO 2 NH); 4.20 (m, 1H); 2.70 (d, 3H, J=4 Hz); 2.45 (d, 2H, J=7 Hz); 1.87 (m, 1H); 1.65 (d, 3H, J=7 Hz); 0.97 (d, 6H, J=7 Hz).
(±)-1-(3-benzoylphenyl)ethane-N-methyl sulfonamide (44)
1 H-NMR (CDCl 3 ): δ 7.82 (d, 2H, J=7 Hz); 7.75 (s, 1H); 7.62 (d, 1H, J=7 Hz); 7.55 (m, 2H); 7.30 (m, 3H); 4.25 (bs, 1H, SO 2 NH); 4.15 (m, 1H); 2.70 (d, 3H, J=4 Hz); 1.55 (d, 3H, J=7 Hz).
(±)-1-[4-(trifluoromethanesulfonyloxy)phenyl]ethane-N-methyl sulfonamide (45)
1 H-NMR (CDCl 3 ): δ 7.52 (d, 2H, J=7 Hz); 7.28 (d, 2H, J=7 Hz); 4.10 (bs, 1H, SO 2 NH); 3.80 (m, 1H); 2.75 (d, 3H, J=4 Hz); 1.20 (d, 3H, J=7 Hz).
(±)-1-[4-(methanesulfonylamino)phenyl]ethane-N-methyl sulfonamide (46)
1 H-NMR (CDCl 3 ): δ 7.50 (d, 2H, J=7 Hz); 7.27 (d, 2H, J=7 Hz); 6.50 (bs, 1H, SO 2 NH); 4.30 (bs, 1H, SO 2 NR); 3.90 (m, 1H); 3.05 (s, 3H); 2.70 (d, 3H, J=4 Hz); 1.32 (d, 3H, J=7 Hz).
(±)-1-(4-isobutylphenyl)ethane-N-acetyl sulfonamide (47)
The compound has been synthesised, as above described, by acylation with acetyl chloride of the related 1-(4-isobutylphenyl)ethanesulfonamide.
1 H-NMR (CDCl 3 ): δ 7.28 (d, 2H, J=7 Hz); 7.20 (d, 2H, J=7 Hz); 4.82 (bs, 1H, SO 2 NH); 4.30 (m, 1H); 2.45 (d, 2H, J=7 Hz); 1.85 (m, 1H); 1.80 (s, 3H); 1.65 (d, 3H, J=7 Hz); 0.97 (d, 6H, J=7 Hz).
EXAMPLE 6
General Procedure for the Synthesis of E/Z 2-aryl-2-methylethensulfonamides
A solution of the appropriate arylacetophenone (20 mmol) (prepared according to the above described method of general procedure for the synthesis of 1-arylethanesulfonic acids) in 10 mL of t-butyl alcohol is added dropwise over 20 min, to a commercial ylide, Iodomethylenetriphenylphosphorane (25 mmol), maintaining the reaction temperature below 25° C. and the resulting mixture is stirred for 4 h at room temperature. At the end of the reaction, the mixture is shaken with 50 ml of pentane and 50 ml of water, filtered, and the layers are separeted. The aqueous layer is extracted with 3×50 ml of pentane and dried over sodium sulfate to afford, after purification by flash chromatography, the pure 2-(aryl) propene iodide (E/Z isomers mixture), (yield around 70%). The above Wittig olefination of a carbonyl compound has been utilized as described in Sotaro Miyano et al., Bull. Chem. Soc. J., 1197, 52 (1979).
The 2-(aryl) propene iodide (2 mmol) is dissolved in acetonitrile (5 mL) and is added to solution of potassium thioacecetate (4 mmol) in acetonitrile (2 ml) at room temperature; the reaction mixture is stirred for 4 hours. The mixture is quenced with water and extracted by EtOAc; the separated organic layers are dried, filtered and concentrated to give 2-arylpropenthioacetate (E/Z isomers mixture) (almost quantitative yield).
A solution of 2-aryl-2-methylethenthioacetate (1.00 mmol) in glacial acetic acid (2 mL) is stirred at 60° C. and treated dropwise with 30% H 2 O 2 (4.56 mmol); the resulting solution is stirred at 60° C. for 24 hours, then the acetic acid is azeotropically removed with toluene. The residue is diluted with water (5 mL), neutralised with 1N NaOH, washed with diethyl ether (2×15 mL) and lyophilised to provide the 2-aryl-2-methylethenesulfonic acid sodium salt as E/Z isomers mixture as white solid (yield around 90%).
The E/Z 2-aryl-2-methylethensulfonamides are prepared according to the above described method of general procedure for the synthesis of E-arylethenesulfonamides to obtain E/Z-2-aryl-2-methyl-ethensulfonamides (0.75-0.85 mmol) (yield 85-95%) as colourless oils.
Following the above described procedure the following compounds have been synthesised:
E-2-(3-benzoylphenyl)-2-methyl ethenesulfonamide (48)
1 H-NMR (CDCl 3 ): δ 7.75 (m, 3H); 7.62 (m, 2H); 7.53 (m, 4H); 6.15 (d, 1H, J=1.4 Hz), 5.96 (d, 1H, J=1.3 Hz); 4.38 (bs, 2H, SONH 2 ); 2.10 (d, 3H, J=1.4 Hz); 2.0 (d, 3H, J=1.3 Hz).
E-2-(3-isopropylphenyl)-2-methyl ethenesulfonamide (49)
1 H-NMR (CDCl 3 ): δ 7.28 (m, 1H); 7.15 (m, 1H); 7.05 (m, 2H); 6.15 (d, 1H, J=1.4 Hz), 5.96 (d, 1H, J=1.3 Hz); 4.38 (bs, 2H, SONH 2 ); 3.15 (m, 1H); 2.10 (d, 3H, J=1.4 Hz); 2.0 (d, 3H, J=1.3 Hz); 1.25 (d, 6H, J=7 Hz).
E-2-(4isobutylphenyl)-2-methyl ethenesulfonamide (50)
1 H-NMR (CDCl 3 ): δ 7.32 (d, 2H, J=7 Hz); 7.23 (d, 2H, J=7 Hz); 6.15 (q, 1H, J=1.4 Hz); 5.96 (q, 1H, J=1.3 Hz); 4.35 (bs, 2H, SONH 2 ); 2.45 (d, 2H, J=7 Hz); 2.10 (d, 3H, J=1.4 Hz); 2.0 (d, 3H, J=1.3 Hz); 1.88 (m, 1H); 0.97 (d, 6H, J=7 Hz).
A list of chemical names and structures of the compounds in Examples 1-6 is reported in TABLE I.
TABLE I
N.
NAME
STRUCTURE
1
(−)-1-(4-isobutylphenyl) ethanesulfonic acid sodium salt
2
(+)-1-(4-isobutylphenyl) ethanesulfonic acid sodium salt
3
(−)-1-[4-(1-oxo-2-isoindolinyl)phenyl] ethanesulfonic acid sodium salt
4
(+)-1-[4-(1-oxo-2-isolndolinyl)phenyl] ethanesulfonic acid sodium salt
5
(−)-2-(4-phenylsulfonyloxy) ethanesulfonic acid sodium salt
6
(+)-2-(4-phenylsulfbnyloxy) ethanesulfonic acid sodium salt
7
(1-methyl-5-acetylpyrrolyl)-1-methanesulfonic acid sodium salt
8
(±)-2-(3-benzoylphenyl) ethanesulfonic acid sodium salt
9
(±)-2-(3-isopropylphenyl) ethanesulfonic acid sodium salt
10
E-2-(4-isobutylphenyl)ethenesulfonic acid sodium salt
11
E-2-(3-benzoylphenyl)ethenesulfonic acid sodium salt
12
E-2-(4-methanesulfonylaminophenyl) ethenesulfonic acid sodium salt
13
E-2-(4-trifluoromethanesulfonyloxy phenyl)ethenesulfonic acid sodium salt
14
E-2-(4-isobutylphenyl) ethenesulfonamide
15
E-2-(3-benzoylphenyl) ethenesulfonamide
16
E-2-[4-(trifluoromethanesulfonyloxy phenyl]ethenesulfonamide
17
E-2-[4-(methanesulfonylamino)phenyl] ethenesulfonamide
18
E-2-(4-isobutylphenyl)ethene(N,N- dimethylaminopropyl) sulfonamide
19
E-2-(3-benzoylphenyl)etheneN-(N,N- dimethylaminopropyl) sulfonamide
20
E-2-[4-(trifluoromethanesulfonyloxy) phenyl]ethene-(N,N-dimethylamino propyl)sulfonamide
21
E-2-[4-(methanesulfonylamino)phenyl] ethene- (N,N-dimethylaminopropyl) sulfonamide
22
E-2-(4-isobutylphenyl)ethene-N-methyl sulfonamide
23
E-2-(3-benoylphenyl)ethene-N-methyl sulfonamide
24
E-2-[4-(trifluoromethanesulfonyloxy) phenyl]ethene-N-methyl sulfonamide
25
E-2-[4-(methanesulfonylamino)phenyl] ethene- N-methyl sulfonamide
26
E-2-(4-isobutylphenyl)ethene-N-(2- methoxyethyl) sulfonamide
27
E-2-(3-benzoylphenyl)ethene-N-(2- methoxyethyl) sulfonamide
28
E-2-[4-(trifluoromethanesulfonyloxy) phenyl]ethen-N-(2-methoxyethyl) sulfonamide
29
E-2-[4-(methanesulfonylamino) phenyl]ethen-N- (2-methoxyethyl) sulfonamide
30
(1-methyl-5-isobutirrylpyrrolyl)-1- methanesulfonamide
31
(1-methyl-5-acetylpyrrolyl)-1- methanesulfonamide
32
(−)-1-(4-isobutylphenyl)ethane sulfonamide
33
(+)-1-(4-isobutylphenyl)ethane sulfonamide
34
(+)-1-(3-isopropylphenyl)ethane sulfonamide
35
(±)-1-(4-isobutylphenyl)ethane-N-(N,N- dimethylaminopropyl) sulfonamide
36
(±)-1-(3-benzoylphenyl)ethane-N-(N,N- dimethylaminopropyl) sulfonamide
37
(±)-1-(4-(trifluoromethanesulfonyloxy) phenyl]ethane-N-(N,N-dimethylaminopropyl) sulfonamide
38
(±)1-[4-(methanesulfonylamino) phenyl]ethane- N-(N,N-dimethylaminopropyl) sulfonamide
39
(±)-1-(4-isobutylphenyl)ethane-N-(2- methoxyethyl) sulfonamide
40
(±)-1-(3-benzoylphenyl)ethane-N-(2- methoxyethyl) sulfonamide
41
(±)-1-[4-(trifluoromethanesulfonyloxy) phenyl]ethane-N-(2-methoxyethyl) sulfonamide
42
(±)-1-[4-(methanesulfonylamino) phenyl]ethane- N-(2-methoxyethyl) sulfonamide
43
(±)-1-(4-isobutylphenyl)ethane-N-methyl sulfonamide
44
(±)-1-(3-benzoylphenyl)ethane-N-methyl sulfonamide
45
(±)-1-[4-(trifluoromethanesulfonyloxy) phenyl]ethane-N-methyl sulfonamide
46
(±)-1-[4-(methanesulfonylamino) phenyl]ethane- N-methyl sulfonamide
47
(±)-1-(4-isobutylphenyl)ethane-N-acetyl sulfonamide
48
E-2-(3-benzoylphenyl)-2-methyl- ethenesulfonamide
49
E-2-(3-isopropylphenyl)-2-methyl- ethenesulfonamide
50
E-2-(4-isobutylphenyl)-2-methyl- ethenesulfonamide
TABLE II
Inhibition (%) of human PMNs chemotaxis induced by IL-8 (100 ng/mL)
IL-8 PMN chemotaxis inhibition %
N.
(c = 10 −8 )
STRUCTURE
1
55 ± 7
2
35 ± 7
7
35 ± 2
8
65 ± 4
10
45 ± 4
14
41 ± 17
15
66 ± 10
17
41 ± 17*
18
40 ± 1
20
60 ± 1
21
31 ± 6
22
41 ± 9*
26
50 ± 4*
30
50 ± 1
31
39 ± 4
36
49 ± 14
43
36 ± 15*
47
40 ± 17
50
32 ± 1
*compounds were tested at c = 10 −7 | Selected sulfonic acids, their derivatives and pharmaceutical compositions containing such compounds are useful in inhibiting the chernotactic activation of neutrophils (PMN leukocytes) induced by the interaction of Interleukin-8 (IL-8) with CXCR1 and CXCR2 membrane receptors. The compounds are used for the prevention and treatment of pathologies deriving from said activation. Notably, the selected sulfonic acids and their derivativas are devoid of cyclo-oxygenase inhibition activity and are particularly useful in the treatment of neutrofil-dependent pathologies such as psoriasis, ulcerative colitis, melanoma, chronic obstructive pulmonary disease (COPD), bullous pemphigoid, rheumatoid arthritis, idiopathic fibrosis, glomerulonephritis and in the prevention and treatment of damages caused by ischemia and reperfusion. | 2 |
This is a continuation of application Ser. No. 379,268, filed Jul. 13, 1989, now abandoned.
BACKGROUND OF THE INVENTION
The present invention is directed to a melting and casting plant for operation under a vacuum, a protective gas atmosphere or normal atmosphere. The plant has a chamber for a melting and casting means, preferably an inductively heated melting crucible and one or more ingot molds loadable onto a turntable and/or elevating platform, the chamber having a bipartite wall with a part of the wall being pivotable.
Melting and casting systems are utilized in vacuum processing technology for research and development and for production. The critical component parts of these systems are a vacuum chamber, a pump and an energy supply system with a control unit. Such systems can be operated under a high-vacuum, under a protective gas atmosphere or in normal atmosphere.
Such a melting and casting plant is described, for example, in the brochure of Leybold AG "IS 001 Labor-Induktions-Schmeltz-und Giess-Anlag", number 31-140.21.
SUMMARY OF THE INVENTION
The present invention has the following objects: easy accessibility to all parts of the chamber is achieved; working with an opened chamber is simplified; the introduction, attachment and mounting and removal of equipment in the chamber is simplified. In very general terms, a simplified handling of all parts is possible.
It is also an object of the present invention to provide for the maintenance and cleaning of the chamber and of the parts accommodated therein in an easy and economical manner. In particular, an easy coil changing is possible. Furthermore, the loading and unloading of the chamber, particularly of the ingot molds located in the chamber, as well as the tamping of a crucible can be carried out quickly, simply and effectively.
The stated objects are inventively achieved by a chamber wall which is fashioned angularly and is composed of a stationary part and of a part that can be swivelled out, the part that can be swivelled out being hinged to the stationary part. The shape of the chamber wall and a linking axis are fashioned and arranged such that, after the moveable part of the chamber wall has been swivelled out, the articles located in the interior of the chamber, to be introduced into the interior of the chamber, to be removed therefrom or to be treated therein can be easily manipulated or are accessible for loading and unloading.
It has proven especially beneficial that the shape of the chamber wall and the link axis are fashioned or arranged such that, after the moveable part of the chamber wall has been swivelled out, the interior of the chamber is accessible from different directions.
An especially easy accessibility of all locations and articles in the interior of the chamber is achieved in that the ground plan of the chamber has a rectangular or approximately rectangular shape. For the same reason the chamber can be fashioned cuboid-like or approximately cuboid-like.
It is a feature of the present invention that all parts located in the chamber are exposed when the five walls of the approximately cuboid-like chamber, which form a trough-shaped unit, is hinged to a sixth wall and is swivelled out around a vertically oriented axis.
In order to achieve an easy loadability and unloadability of the ingot molds, it is a further feature of the present invention that a door (ingot mold door) is located in that part of the wall of the chamber that can be swivelled out, this door also being preferably capable of being swivelled out around a vertically arranged swivelling axis.
The door which is hinged to that part of the wall of the chamber that can be swivelled out is provided with a hinge axis that is positioned in the proximity of the part of the wall of the chamber that is stationary. It occupies this position only when the part of the wall of the chamber that can be swivelled out is not swivelled out.
As an alternative, the door which is hinged to that part of the wall of the chamber that can be swivelled out can have a hinge axis on a wall of the part of the chamber that can be swivelled out which is at a set distance from the stationary wall. This means that when the moveable part of the chamber is swiveled out, the door moves away from the stationary part of the chamber.
The following advantages are achieved with the present invention. The overall handling of the installation, particularly of the chamber and of the articles, individual units, and materials in the chamber, is considerably improved. An easier coil changing is possible. The loading and unloading of the ingot molds can be more reasonably designed. The tamping of the crucible becomes easier. In very general terms, an accessibility to all parts in the chamber is considerably simpler in comparison to the prior art.
Further details of the invention may be derived from the following description of an exemplary embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several Figures in which like reference numerals identify like elements, and in which:
FIG. 1 shows a side view of a prior art induction melting and casting plant;
FIG. 2 shows a side view of an induction melting and casting plant that is equipped with a chamber in accordance with an exemplary embodiment of the present invention;
FIG. 3 shows a simplified illustration of the chamber of FIG. 2 in a view from above and partially cut away;
FIG. 4 is a side view of one embodiment of the chamber of the present invention;
FIG. 5 is a front view of the FIG. 4 chamber;
FIG. 6 is a top view of the FIG. 4 chamber;
FIG. 7 is another top view of the FIG. 3 chamber; and
FIG. 8 is another front view of the FIG. 3 chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention has general applicability, but is most advantageously utilized in an induction melting and casting plant. The present invention is an improvement over the prior art plant of FIG. 1 which is described below and illustrates the problem in the prior art which the present invention overcomes.
A chamber 1 in which an induction coil 2 is accommodated is depicted in FIG. 1. The induction coil 2 surrounds a melting crucible that is not visible because the melting crucible is located inside the coil 2. A table 3 in the chamber 1 supports one or more ingot molds. After the table 3 is loaded, the ingot molds would be situated in position 4. By charging the induction coil 2 with current, material in the melting crucible is melted and is then cast into the ingot molds located on the table, by a special known device.
A vacuum rotary disk pump 5 and a vacuum oil diffusion pump 6 are also provided and establish the vacuum required for the implementation of the melting and casting process. A high-vacuum valve 7 is provided which places the chamber 1 under vacuum. Also included is a temperature measuring means 8, a charging mechanism 9, an operating unit 10 for the overall system and a supply unit 11 which provides the melting power for the plant.
The chamber 1 in the prior art plant is composed of two parts 12, 13. The part 12 can be swivelled away from the stationary part 13. Whereas the chamber 1 depicted in Figure 1 has essentially a spherical form, the chamber 14 in the exemplary embodiment of the present invention (see FIGS. 2, 3, 7 and 8) is angular, being especially fashioned approximately cuboid-shaped. FIGS. 4, 5 and 6 illustrate an alternative embodiment of the chamber of the present invention.
FIG. 3 has been simplified for illustrating the critical chamber parts of the present invention. Those parts not critical to the present invention have been omitted and only the chamber itself has been shown. A view from above has been selected, whereby the cover of the chamber has been mainly omitted in order to permit an unobstructed view into the interior of the chamber.
The approximately rectangular shape of the ground plan of the chamber is evident from FIG. 3. The chamber is defined by the vertically arranged side walls 15, 16, 17, 18, by the floor 19 and by the cover 20 shown in broken fashion. As shall be set forth below, the wall 18 is fashioned as a pivotable ingot mold door.
Together with the floor 19 and the cover 20, the side walls 15, 16, 18 form a trough-shaped unit that is hinged to the stationary wall 17 as a chamber part that can be swivelled out. The swivel axis is referenced 21 and the swivelling direction is indicated by the arrow 40.
In the swivelled-opened position, the four side walls bear the reference numerals 22, 23, 24, 25. The cover in the swivelled-opened position is referenced with reference numeral 26. It may seem that articles inside the chamber can be reached very easily in the swivelled-open position. Merely by way of example, an induction coil with a melting crucible are schematically indicated and referenced 27. An ingot mold 28 is also shown. These and other articles located in the chamber are accessible from five different directions in the opened position of the chamber. That is, it is to be understood that the induction coil and melting crucible 27 and the ingot mold 28 are located on the table 3 which is attached to the stationary wall 17. In the swivelled-open position these objects can be manipulated from above, from the front or back directions, from the side direction and even from the direction of the stationary wall 17 in the sense that they are not positioned directly next to the stationary wall 17.
Such a high degree of accessibility and, thus, such ease of handling are established which has not been achieved in melting and casting plants of the prior art.
The vertical side wall 18 or 22 of the chamber is additionally fashioned as a door. This door can be swivelled out in the direction of the arrow 30 around the swivel axis 29. In the swivelled-opened position, the door is referenced with reference numeral 31.
When the chamber is opened on all sides, all articles in the chamber are freely accessible. A complete chamber cleaning is then possible and loading the chamber with ingot molds is simplified in comparison to the prior art. The same is true of the tamping of the crucible and for changing the coil of the induction furnace.
FIGS. 7 and 8 show additional top and front views of the chamber 14 depicted in FIG. 3, FIGS. 6, 7 and 8 illustrate an alternative embodiment of the present invention in that the chamber 14 is only approximately rectangular in shape (see FIG. 6). In this embodiment the two side walls 15, 16 actually form a curved section of the chamber 14.
As initially set forth, the basic methods and apparatus components of the prior art as shown in FIG. 1 are used in the present exemplary embodiment. Thus, reference numeral 32 in FIG. 2 references an operating unit. The supply unit for the melting power has reference numeral 33 and the system for generating the vacuum and charging the chamber with the vacuum is referenced 34. Also included is a viewing glass 35, a charging mechanism 36 and an apparatus 41 for taking samples.
The side wall 18 which is fashioned as a door may be seen in FIG. 2, and is connected to the stationary chamber part 17 via hinge articulations 37, 38. The hinge articulations 37, 38 lie in the vertical axis 29 indicated with broken lines. Reference numeral 39 references the lower end of a turntable for one or more ingot molds. This table 39 can also be fashioned as an elevator/turntable. The ingot molds are brought into the desired positions with the table 39.
In an alternative exemplary embodiment, the door 18 which is hinged to the part 15, 16, 19, 20 of the chamber 14 can be hinged to wall 15 thereby placing the hinge position of the wall 15 at a set distance from the stationary wall 17, as shown in FIG. 3. The door 18 hinged to the swivellable part of the chamber 14 is provided with a hinge axis 42 that is located at the set distance from the stationary part 17 of the wall of the chamber (that is, the hinge axis 42 is located on the section of the swivellable part opposed from the stationary part 17) such that the door 18 when swivelled away moves away from the stationary part 17 of the wall of the chamber in accordance with the arrow 43 and proceeds into the position 44.
Equipping the chamber with ingot molds can be simply carried out through the opened door 18. The tamping of the crucible and the changing of the coil can also be performed in an easy fashion when the chamber is opened.
The application of the basic ideas of the present invention is not limited to induction melting and casting plants. It can also be used for other systems. For example, employment in systems of sintering process technology and general employment in systems for heat treatment methods is possible. The present invention can be used in vacuum furnaces, furnaces that are operated under a protective gas atmosphere, or furnaces that operate in a normal atmosphere. In addition to the induction heating, other types of heating, for example resistance heating, can be used.
The invention is not limited to the particular details of the apparatus depicted and other modifications and applications are contemplated. Certain other changes may be made in the above described apparatus without departing from the true spirit and scope of the invention herein involved. It is intended, therefore, that the subject matter in the above depiction shall be interpreted as illustrative and not in a limiting sense. | A melting and casting plant for operation at least under a vacuum and having a vacuum chamber. A wall of the vacuum chamber of the plant is angularly fashioned and is composed of a stationary part and of a swivellable part, the swivellable part being hinged to the stationary part. A door (ingot mold door) is provided in the swivellable part. The shape of the chamber wall and a linking axis of the swivellable part are fashioned or arranged, such that, when the chamber is opened, articles situated in the interior of the chamber are readily accessible. In comparison to the prior art, improved operations of the system, particularly regarding the chamber, is possible. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of application Ser. No. 10/818,996, filed Apr. 6, 2004 which is a Continuation of application Ser. No. 10/235,978, filed Sep. 5, 2002 now U.S. Pat. No. 6,729,754, the entire contents of each of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Powered mixers are popular in retail outlets selling paint. When the paint is vended in five gallon buckets (or similar containers), considerable effort required to lift the buckets into and out of the mixers. One form of assistance has been to provide a roller conveyor in front of one version of a paint mixer to raise the bucket to a height at or near that necessary to slide the bucket into the mixer. However, with “drop-in” type paint mixers further lifting effort is still required to move the bucket between the conveyor and mixer. The present invention reduces this effort and provides an attachment that makes it easier to lift five gallon buckets or similar containers of paint into and out of “drop-in” type paint mixers. The present invention will accomplish its function whether or not a conveyor is present in front of the mixer.
BRIEF SUMMARY OF THE INVENTION
[0003] The present invention, in one aspect, includes a lifting apparatus for lifting paint containers into and out of paint mixers, where the lifting apparatus is useable in combination with the paint mixer and includes a generally horizontal surface with at least upright member supporting at least one lifting arm including a proximal end pivotably connected to the upright member and a distal end extending beyond the paint mixer, a mechanical link connected to the lifting arm intermediate the proximal and distal ends for lifting and lowering a paint container into and out of the paint mixer, and a spring means connected to the lifting arm for urging the lifting arm vertically upwards.
[0004] The present invention, in another aspect, includes a method of assisting movement of a paint container into and out of a paint mixer according to the steps of providing a lifting attachment having at least one lifting arm with a proximal end pivotably connected to a support and a distal end extending beyond the paint mixer, a mechanical link connected to the lifting arm intermediate the proximal and distal ends for lifting and lowering a paint container into and out of the paint mixer, and spring means connected to the lifting arm for urging the lifting arm vertically upwards, engaging the mechanical link to the paint container; and assisting movement of the paint container with respect to the mixer by moving the lifting arm with the assistance of the spring means.
[0005] In one aspect the present invention is separate from the paint mixer with its own support structure and may be pivotable or pivotable and slideable with respect to the support structure. The sliding version may utilize a separate support structure or the paint mixer as the support structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a perspective view from the front and above of a conveyor and paint mixer with the lifting attachment of the present invention shown with a paint bucket in the mixer.
[0007] [0007]FIG. 2 is a side elevation view of the mixer and attachment of FIG. 1.
[0008] [0008]FIG. 2 a is an enlarged view of a portion of FIG. 2 showing the lifting attachment assembly.
[0009] [0009]FIG. 2 b is a front elevation view of the mixer and attachment of FIG. 1.
[0010] [0010]FIG. 2 c is an exploded view of a weldment subassembly with associated parts useful in the practice of the present invention.
[0011] [0011]FIG. 2 d is an exploded view of the lifting attachment assembly.
[0012] [0012]FIG. 3 is a view similar to FIG. 1, except with the paint bucket on the conveyor and the lifting attachment connected to the bucket in a first position.
[0013] [0013]FIG. 4 is a view similar to that of FIG. 3, except with the lifting attachment raised to lift the bucket to a second position.
[0014] [0014]FIG. 5 is a view similar to that of FIG. 4, except with the bucket moved laterally and rotated to a position in which the bucket is about to be received in the mixer while still supported by the lifting attachment.
[0015] [0015]FIG. 6 is a view similar to that of FIG. 5, except with the bucket fully received in the mixer and with the lifting attachment lowered to a position just prior to release from the bucket.
[0016] [0016]FIG. 7 is a view similar to FIG. 3 except without a conveyor and with the bucket elevated slightly above the surface supporting the paint mixer.
[0017] [0017]FIG. 8 is a view similar to that of FIG. 5, except with a single handle.
[0018] [0018]FIG. 9 is an alternative embodiment showing a single arm version of the lifting attachment useful in the practice of the present invention.
[0019] [0019]FIG. 10 is another alternative embodiment of the present invention in a free-standing form useful in the practice of the present invention.
[0020] [0020]FIG. 10 a is a simplified plan view of an arrangement for the practice of the present invention.
[0021] [0021]FIG. 10 b is a simplified plan view of an alternative arrangement for the practice of the present invention.
[0022] [0022]FIG. 11 is still another alternative embodiment of the present invention using a sliding and pivoting motion in the practice of the present invention.
[0023] [0023]FIG. 12 is another alternative embodiment of a support structure for the lifting apparatus of the present invention.
DETAILED DESCRIPTION
[0024] Referring now to the Figures, and most particularly to FIG. 1, a paint mixer 10 , together with a lifting attachment 12 useful in the practice of the present invention, may be seen. Paint mixer 10 is preferably a Model 5305, available from Red Devil Equipment Co., 7150 Boone Avenue North, Suite 100, Brooklyn Park, Minn. 55428. In the past, it was necessary to manually lift a five gallon paint container or bucket 14 into and out of the mixer. The lifting attachment 12 of the present invention reduces the effort required to move the paint container 14 into and out of the mixer 10 . Typically, a conveyor 16 is located in front of the mixer and preferably extends from a colorant dispenser or tinting station (not shown) to the mixer 10 to assist in moving the five gallon buckets 14 of paint from the tinting station to a mixing station at the mixer. It is to be understood that additional conveyor segments are typically present to extend the length of the conveyor 16 as desired. It is also to be understood that bucket 14 has a bail 18 and handle 20 . A door or hood 22 is pivotably attached to mixer 10 and is closed prior to operating mixer 10 . As may be seen most clearly in FIG. 2, both the mixer 10 and conveyor 16 are preferably supported on a floor or other horizontal surface 24 . Conveyor 16 preferably is a non-powered conveyor having a plurality of rollers 26 supported by a frame 28 , and may include multiple sections similar or identical to the section shown in the figures to transport paint containers 14 towards and away from mixer 10 , as desired.
[0025] Referring now also to FIGS. 2 a , 2 b , 2 c , and 2 d , the lifting attachment 12 preferably includes an arm weldment 30 having a pair of arms 32 , 34 , and a cross brace 36 welded in an “H” form with two pairs of diagonal offsets 38 , 40 and 42 , 44 . The first pair of diagonal offsets 38 , 40 are arranged in arms 32 , 34 , respectively to conform to a sloping portion 46 of a front side 48 of mixer 10 . As used herein, “side” is to be understood to include the front surface of the mixer 10 , encompassing one or both of the sloping portion 46 and the vertically oriented parts of side 48 . The second pair of diagonal offsets 42 , 44 reduce the width between a pair of manually graspable handles 50 , 52 . Each of arms 32 and 34 are preferably formed of ⅛×1.0×1.0 inch cold rolled hollow steel tubing having a square cross section. The cross brace 36 is preferably formed of 16 gauge 0.50×1.00 inch cold rolled hollow steel tubing. The handles 50 , 52 are preferably formed of ⅞ OD cylindrical steel tubing extend from proximal ends of arms 32 and 34 , respectively, and each has a conventional vinyl handle grip 57 received thereon. A pair of circular cross section pieces of ⅞ OD steel tubing form a pair of journals 58 , 60 at distal ends of the arms 32 , 34 , respectively, to allow the arm weldment 30 to pivot with respect to its mounting, to be described infra. A pair of cross section pieces of ⅞ OD steel tubing form projections 62 , 64 to carry bumpers 65 which limit downward travel of the lifting attachment 12 after installation. A pair of 1 inch wide, 6 gauge steel angle flanges 66 each have an ear 70 formed at an angle of 122 degrees to carry a bumper 69 to limit upward travel of the lifting attachment 12 . Bumpers 65 and 69 are conventional, with bumpers 65 preferably having a shore durometer of 40 and bumpers 69 preferably having a shore durometer of 70. A pair of 1 inch wide, 6 gauge steel gussets 72 each have an aperture 74 therein to receive an end of a gas spring 76 to provide lifting support for lifting attachment 12 . Gas springs 76 are preferably rated at 80 lbs. and preferably have an operating range of 7.09 to 9.09 inches, with metal ball ends, each having a conventional threaded stud for attachment to the lifting attachment 12 using conventional washers and nuts.
[0026] A 2 inch wide strap of nylon webbing 77 carries a hook 78 sized and shaped to receive bail handle 20 on bucket 14 . The hook 78 is preferably formed of 7 gauge steel. As may be seen most clearly in FIG. 2 c , webbing 77 preferably has a pair of loops 79 formed at each end of the strap by stitching the webbing to itself. One loop captures the hook 78 , and the other loop is received over a plate clamp 80 . The hook and webbing subassembly is preferably sized to enable the hook to release from the handle 20 when the lifting attachment is at or near the lowermost position. The hook and webbing subassembly is preferably secured to the cross brace 36 by the plate clamp 80 . As may be seen most clearly in FIGS. 2 c and 2 d , conventional nuts are preferably used to secure bumpers 69 and plate clamp 80 to the lifting attachment 12 .
[0027] Referring now most particularly to FIGS. 2 a and 2 d , a plate 82 has a first pair of tabs 84 welded thereto for securing the gas springs 76 , and further has a second pair of tabs 86 welded to the plate 82 to support the arms 32 , 34 at the journals 58 , 60 . A pair of end walls 90 , 92 are similarly welded to plate 82 . Each of the tabs 84 , 86 and end walls 90 , 92 are to be understood to include conventional projections received in notches (not shown) in plate 82 for maintaining the respective locations of these parts as they are welded together. End walls 90 , 92 each have an aperture 94 aligned with an aperture 96 in tabs 86 to receive a conventional shoulder bolt 98 to form a pivot in each of journals 58 , 60 . A decorative sheet metal cover 100 is preferably received over plate 82 and attached to end walls 90 , 92 via studs 102 received in slotted tabs 104 welded to cover 100 . A conventional nut (not shown) is received over each of studs 102 and tightened to secure cover 100 to the lifting attachment assembly 12 .
[0028] Referring now again most particularly to FIG. 2 a , a plurality of studs 106 preferably project downward from plate 82 and are used to secure the lifting attachment assembly 12 to the mixer 10 in a conventional manner.
[0029] Referring now to FIGS. 3, 4, 5 and 6 , the operation of the lifting attachment will be explained. In FIG. 3, a paint bucket 14 is shown located on the conveyor 16 just prior to insertion into the mixer 10 . At this position, the arms 32 , 34 of the lifting attachment 12 have been manually lowered and the hook 78 has been manually engaged with the bail handle 20 of the bucket 14 . In FIG. 4, the lifting attachment has been manually elevated with the aid of the gas springs 76 , by grasping at least one handle grip 57 and raising assembly 12 until the bucket clears a bucket receptacle 108 in the mixer 10 . It is to be understood that cross brace 36 will move laterally, as well as vertically, as the assembly 12 is elevated, moving bucket 14 closer to receptacle 108 as the assembly is elevated.
[0030] In FIG. 4, the assembly 12 is nearly fully elevated, evidenced by close approach of bumpers 69 to plate 82 . At this time, the bucket 14 is positioned over the receptacle 108 , but is not aligned therewith. In FIG. 5, the bucket 14 is manually aligned with receptacle 108 , while attachment 12 is held in the fully elevated position. The lifting attachment is then lowered to the position shown in FIG. 6, using one or both handle grips 57 , while the bucket 14 slides into receptacle 108 , coming to rest as shown in FIG. 6. The lifting attachment 12 is shown in FIG. 6 positioned slightly above its lowermost position. This allows arms 32 , 34 to be lowered to the lowermost position (not shown) at which time the bail handle 20 is released from hook 78 . The lifting attachment is then released from manual control, at which time it will return to the uppermost position similar to that shown in FIGS. 4 and 5, but with the bucket 14 remaining fully received in receptacle 108 . It is to be understood that the uppermost position will allow the lifting attachment to move (preferably about four inches in travel) higher than that shown in FIGS. 4 and 5, to enable the lifting attachment to rest in a position providing greater clearance to the mixer 10 than that shown in FIGS. 4 and 5. After the lifting attachment is elevated and released, door 22 is closed on mixer 10 and the paint is agitated by mixer 10 , after which the door 22 is opened and the process described above is repeated in reverse order to lift the bucket 14 from the mixer and return it to the conveyor 16 .
[0031] In an alternative arrangement as shown in FIG. 7, a paint bucket 14 may be located on the floor 24 in front of mixer 10 , where the lifting attachment 12 may be used to assist raising the bucket 14 from the floor and into and out of the mixer 10 . The conveyor 16 is absent from this arrangement.
[0032] Referring now most particularly to FIG. 8, an alternative embodiment of the present invention may be seen. In this embodiment, a single elongated handle 54 extends between the arms 32 and 34 . Handle 54 may have a vinyl grip thereon, similar to grip 57 for handles 50 and 52 .
[0033] Referring now to FIG. 9, a still further alternative embodiment of the present invention utilizes a single arm 110 replacing and performing the functions of arms 32 and 34 . Arm 110 may be made of stronger material, if desired, or may be made of larger cross section material, to adequately support the increased loading for a single arm embodiment. An increased capacity spring 112 , preferably doubling the force of spring 76 , (but with the same stroke) may be used in this embodiment. Alternatively a pair of springs 112 , 114 may be used with ratings the same as springs 76 . In this embodiment, a yoke or Y-shaped member 116 may be used to support webbing 77 , and a single handle 118 is preferable, with a vinyl grip, if desired.
[0034] Referring now to FIGS. 10 and 11, it may be seen that the present invention may be practiced with free standing versions of the lifting apparatus. FIG. 10 shows an embodiment for a lifting apparatus 120 which is preferably not permanently attached to a paint mixer, but instead, is designed to have a paint mixer (such as the paint mixer 10 ) resting on it. A support structure or frame 122 includes a base member 124 and a pair of upright members 126 . Each upright member may be reinforced with a gusset 128 . Each upright member 126 has a lifting arm 130 pivotably attached thereto at pivot joints 131 , and a gas spring 132 or other device adapted to provide a lifting force is connected between the respective arm 130 and upright member 126 . A cross member 134 is secured between arms 130 , and carries a lifting strap 136 and hook 138 . It is to be understood that the lifting apparatus 120 may be the same or similar to lifting attachment 12 , except that it is not attached to the paint mixer, either directly or indirectly, but has its own support frame which may take various forms, provided that (in this embodiment) the support frame is free-standing with respect to the paint mixer. The operation of this embodiment is the same as that described for the previous embodiments. Furthermore, it is to be understood that the upright members may be located at the sides or even the front of the mixer, as alternatives to the embodiment shown in FIG. 10, where the upright members are shown in a position where they would be located at the back of the mixer.
[0035] [0035]FIG. 10 a is a simplified plan view of a “footprint” of the lifting apparatus of the present invention in the embodiments (e.g., shown in FIGS. 10 and 11) which are separate from the mixer. The base member 124 is shown as a frame of reference, with rear positions 172 shown to correspond to the positions of the upright members 126 of the embodiment shown in FIG. 10. Alternative locations for the upright members are at the sides of the paint mixer at locations 174 - 180 , or any where between locations 174 to 176 and 178 to 180 . As a still further alternative, the upright members may, if desired be located at the front of the mixer, as indicated at locations 182 . It is to be further understood that one or more upright members 126 may be located at the rear of the mixer between locations 172 , if desired, for example, to support a lifting attachment similar to that shown in FIG. 8 or 9 . Chain line 170 indicates a position for the mixer 10 with respect to the base member 124 of the lifting attachment 120 , with it being understood that clearance is provided either at the sides of mixer 10 or above mixer 10 for the gas springs 132 and their attachments to upright members 126 , which may be similar to tabs 84 (see FIGS. 2 a and 2 d ).
[0036] Referring now to FIG. 10 b , a simplified plan view of a “footprint” of a modified paint mixer 10 ′ may be seen. In this view, mixer 10 ′ may be “notched” or recessed at any of positions 184 to accommodate upright members 126 . The housing of the mixer may be inset as shown, or the housing may be “pushed out” in the regions intermediate “notches” 184 that are used to accommodate the upright members 126 . It is to be understood that, although notches 184 are shown adjacent corners, the notches may be located at alternative positions corresponding to such alternative positions described for the upright members with respect to FIG. 10 a.
[0037] Referring now most particularly to FIG. 11, another version of the present invention shows a lifting apparatus 140 which, as shown, has its own support frame 142 . In an alternative embodiment (not shown) the sliding and pivoting arrangement of this embodiment may be attached to the paint mixer, if desired. Referring to FIG. 11, support frame 142 has a base member 144 and a pair of upright members 146 with gussets 148 . Lifting apparatus 140 has a pair of lifting arms 150 and a pair of gas springs or other lifting force devices 152 . A cross member 154 is secured between lifting arms 150 and supports a strap 156 carrying a hook 158 , as in earlier embodiments. Lifting apparatus 140 differs from the embodiments described above in that each of the arms 150 and lifting force devices 152 are pivotably attached to respective slide rails 160 which are slideably mounted on respective slide supports 162 . As shown the slide supports are mounted on the upright members 146 , but in an alternative version, the slide supports may be mounted to respective lateral sides of the paint mixer 10 . It is to be understood that the slide rails may be similar to drawer slides. Slide rails 160 are free to move by sliding along a predetermined length of slide supports 162 , with end stops 168 limiting travel of the rails or cars 160 at the respective ends of supports 162 .
[0038] In operation, the lifting apparatus 140 may be stored by moving the slide rails 160 fully to the rear or distal end 164 of the slide supports 162 . To lift a paint container, the lifting apparatus 140 is preferably grasped by one or both handles 165 and moved forward by advancing slide rails 160 along slide supports 162 toward proximal end 166 . Stops 168 provided at each of ends 164 , 166 of support 160 prevent separating the slide rail 160 from the slide support 162 during normal operation. Once the lifting apparatus 140 is advanced to the proximal end 166 of the slide supports 162 , the arms 150 are lowered by pulling down on handles 165 and the hook 158 is engaged with a paint container bail (not shown, but similar to either FIG. 3 or FIG. 7). The arms 150 are then raised by pushing or lifting up with handles 165 , with the assist of gas springs 152 , raising the paint container up vertically. Next the lifting apparatus 140 is pushed back away from the proximal end 166 , moving towards the distal end 164 , until the paint container is over the paint container receptacle 108 of the paint mixer 10 , similar to the relation of container 14 and receptacle 108 shown in FIG. 4. The paint container is then tipped or allowed to tip into alignment with the receptacle, as shown in FIG. 5, after which the arms 150 are lowered analogously to the position shown in FIG. 6, allowing the paint container to be fully received in the receptacle 108 . The process is reversed to remove the paint container from the receptacle using this embodiment. It is to be understood that the details of the pivoting connections to the arms and gas springs of FIGS. 10 and 11 may be the same as those shown and described for prior embodiments, as are the details of the strap and hook. It is to be further understood that the embodiments of FIGS. 10 and 11 may be used with or without a conveyor 16 in front of the paint mixer 10 in the practice of the invention using these embodiments. The embodiments of the lifting apparatus of FIG. 8 or 9 may be used with either of the support frames 122 or 142 , shown in FIGS. 10 and 11.
[0039] Referring now to FIG. 12, an alternative support structure 200 for the lifting apparatus of the present invention includes a generally horizontal shelf-like member 202 to which any of the various embodiments of the lifting arms may be attached. Shelf 202 may be integrally formed with a pair of upright members 226 . Alternatively, one or more upright members may be separately formed and attached to shelf 202 using conventional fastening means. In the alternative, the upright members) may extend behind the paint mixer 10 and be connected to shelf 202 in a generally C-shaped configuration in which the shelf 202 is cantilevered from the upright member behind the mixer. The shelf 202 may rest on top of or in close clearance to the upper surface 204 of mixer 10 . Upright members 226 are preferably attached to a base member 224 .
[0040] This invention is not to be taken as limited to all of the details thereof as modifications and variations thereof may be made without departing from the spirit or scope of the invention. For example and not by way of limitation, it is to be understood that the present invention is useful in lifting non-cylindrical, as well as cylindrical containers, into and out of mixers. By way of another example, and not by way of limitation, the spring member may be connected to the mixer instead of the support structure (even though the support structure is separate from the mixer) while still remaining within the scope of the present invention. | A lifting apparatus for lifting paint containers into and out of paint mixers of the type supported by a generally horizontal surface and including at least one side, the lifting apparatus having a pair of rigidly connected arms, each including a proximal end pivotably connected to a support structure and a distal end extending from the support structure, a mechanical link in the form of a strap and hook connected to a cross member connecting each of the pair of arms for lifting and lowering a paint bucket into and out of the paint mixer and a pair of gas springs connected between the support structure and the lifting arms for urging the lifting attachment upwards. The support structure may be separate from the paint mixer and may include sliding as well as pivoting movement between the arms and the support structure. | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a shaft seal mechanism that is disposed in the vicinity of a rotating shaft of a steam turbine or a gas turbine and reduces a leakage of a fluid from a high pressure side to a low pressure side.
[0002] BACKGROUND ART
[0003] Conventionally, a shaft seal mechanism for reducing a leakage of a fluid from a high pressure side to a low pressure side is disposed in the vicinity of a rotating shaft of a steam turbine or a gas turbine, in order to suppress a loss of driving force. Such a shaft seal mechanism has a ring-shaped seal structure in which thin-plate seal pieces having flat plate shapes with their width dimensions being in the rotating shaft direction are arranged into multiple layers in the circumferential direction of the rotating shaft. Outer-circumferential-side proximal end sections of the thin-plate seal pieces are fixed to a ring-shaped seal housing; on the other hand, inner-circumferential-side distal end sections of the thin-plate seal pieces are in sliding contact with the outer circumferential surface of the rotating shaft at a predetermined preload. In the shaft seal mechanism having this configuration, the surrounding space of the rotating shaft can be divided into a high-pressure-side region and a low-pressure-side region with the boundary formed by a large number of the thin-plate seal pieces arranged into a ring shape outward in the radial direction of the rotating shaft.
[0004] While the rotation of the rotating shaft is stopping, the inner-circumferential-side distal end sections of the thin-plate seal pieces are into contact with the outer circumferential surface of the rotating shaft at the predetermined preload. On the other hand, while the rotating shaft is rotating, the thin-plate seal pieces are bent by pressure difference due to relative positional shift in pressure distribution between the top and bottom surfaces of the thin-plate seal pieces and by dynamic pressure effect of the fluid generated by the rotation of the rotating shaft, and accordingly, the inner-circumferential-side distal end sections of the thin-plate seal pieces are lifted up from the outer circumferential surface of the rotating shaft into a noncontact state. This configuration prevents abrasion of and heat generation in the thin-plate seal pieces and the rotating shaft. The bottom surfaces of the thin-plate seal pieces refer to surfaces facing the rotating shaft, and the top surfaces thereof refer to surfaces opposite to the bottom surfaces.
[0005] Such a conventional shaft seal mechanism is disclosed, for example, in Patent Document 1 listed below.
CITATION LIST
Patent Document
[0006] Patent Document 1: US Unexamined Patent Application Publication No. 2013/0154199A
SUMMARY OF INVENTION
Technical Problem
[0007] In this shaft seal mechanism, gaps of predetermined sizes are provided on both low pressure and high pressure sides of the thin-plate seal pieces. The sizes of the low-pressure-side gap and the high-pressure-side gap are adjusted to generate the pressure difference in the thin-plate seal pieces and thus to provide lifting-up force to the thin-plate seal pieces. That is, control of the sizes of the low-pressure-side gap and the high-pressure-side gap is highly important to lift up the thin-plate seal pieces.
[0008] Unfortunately, the gap sizes are minute and defined by the thin-plate seal pieces and multiple support members disposed in the vicinity thereof. As a result, even if the gap sizes are preset correctly, a machining error, an assembling error, or the like of the thin-plate seal pieces and the support members may cause the actual gap sizes in assembly not to be appropriate to provide stable lifting-up force, in some cases.
[0009] At this time, the actual gap sizes smaller than appropriate gap sizes disturb the pressure distribution and pressure difference and may thus apply pressing force in a direction opposite to the applying direction of the lifting-up force to the thin-plate seal pieces in some cases. If the pressing force pressing the inner-circumferential-side distal end sections is applied to the thin-plate seal pieces, the inner-circumferential-side distal end sections come into contact with the rotating shaft and may have abrasion.
[0010] To solve the above problem, an object of the present invention is to provide a shaft seal mechanism that, even if pressing force is applied to thin-plate seal pieces, can suppress deformation due to the pressing force and prevent abrasion due to contact with a rotating shaft in the thin-plate seal pieces.
Solution to Problem
[0011] A shaft seal mechanism according to a first invention that solves the above problem, is disposed in a ring-shaped space defined between a fixed section and a rotating shaft to divide the ring-shaped space into a high-pressure-side region and a low-pressure-side region and to block a fluid flowing from the high-pressure-side region to the low-pressure-side region in a rotating shaft direction within the ring-shaped space, the shaft seal mechanism including: a ring-shaped seal housing being disposed on an inner circumferential section of the fixed section; multiple thin-plate seal pieces including outer-circumferential-side proximal end sections fixed to the seal housing and inner-circumferential-side distal end sections being free ends forming acute angles with an outer circumferential surface of the rotating shaft, the thin-plate seal pieces having width dimensions in the rotating shaft direction, and the thin-plate seal pieces being layered in a ring shape in a circumferential direction of the rotating shaft; a ring-shaped high-pressure-side plate being disposed adjacent to high-pressure-side side edge sections, facing the high-pressure-side region, of the thin-plate seal pieces so that a high-pressure-side gap is defined between the high-pressure-side plate and the seal housing in the rotating shaft direction; a ring-shaped low-pressure-side plate being held between low-pressure-side side edge sections, facing the low-pressure-side region, of the thin-plate seal pieces and the seal housing so that a low-pressure-side gap is defined between the low-pressure-side side edge sections and the seal housing in the rotating shaft direction; high-pressure-side stepped sections being formed on the high-pressure-side side edge sections; low-pressure-side stepped sections being formed on the low-pressure-side side edge sections; a high-pressure-side locking section being formed on the high-pressure-side plate and locking the high-pressure-side stepped sections from an inside in a radial direction of the rotating shaft; and a low-pressure-side locking section being formed on the low-pressure-side plate and locking the low-pressure-side stepped sections from the inside in the radial direction of the rotating shaft.
[0012] In a shaft seal mechanism according to a second invention that solves the above problem, the high-pressure-side stepped sections each include an inclined end surface engaged with an inclined surface of the high-pressure-side locking section in the radial direction of the rotating shaft; and the low-pressure-side stepped sections each include an inclined end surface engaged with an inclined surface of the low-pressure-side locking section in the radial direction of the rotating shaft.
[0013] A shaft seal mechanism according to a third invention that solves the above problem, is disposed in a ring-shaped space defined between a fixed section and a rotating shaft to divide the ring-shaped space into a high-pressure-side region and a low-pressure-side region and to block a fluid flowing from the high-pressure-side region to the low-pressure-side region in a rotating shaft direction within the ring-shaped space, the shaft seal mechanism including: a ring-shaped seal housing being disposed on an inner circumferential section of the fixed section; multiple thin-plate seal pieces including outer-circumferential-side proximal end sections fixed to the seal housing and inner-circumferential-side distal end sections being free ends forming acute angles with an outer circumferential surface of the rotating shaft, the thin-plate seal pieces having width dimensions in the rotating shaft direction, and the thin-plate seal pieces being layered in a ring shape in a circumferential direction of the rotating shaft so that a low-pressure-side gap is defined between low-pressure-side side edge sections facing the low-pressure-side region and the seal housing in the rotating shaft direction; low-pressure-side stepped sections being formed on the low-pressure-side side edge sections; and a low-pressure-side locking section being formed on the seal housing and locking the low-pressure-side stepped sections from the inside in a radial direction of the rotating shaft.
[0014] In a shaft seal mechanism according to a fourth invention that solves the above problem, the shaft seal mechanism further includes a ring-shaped low-pressure-side plate being held between the low-pressure-side side edge sections and the seal housing so that the low-pressure-side gap is defined between the low-pressure-side side edge sections and the seal housing; and the low-pressure-side locking section locks the low-pressure-side stepped sections inward in the radial direction of the rotating shaft with respect to an inner-circumferential-side distal end section of the low-pressure-side plate.
[0015] In a shaft seal mechanism according to fifth invention that solves the above problem, the low-pressure-side stepped sections each include an inclined end surface engaged with an inclined surface of the low-pressure-side locking section in the radial direction of the rotating shaft.
Advantageous Effects of Invention
[0016] The shaft seal mechanism according to the present invention locks the thin-plate seal pieces from the inside in the radial direction of the rotating shaft and accordingly, even if pressing force is applied to the thin-plate seal pieces, can suppress deformation due to the pressing force and prevent abrasion due to contact with the rotating shaft in the thin-plate seal pieces.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a schematic configuration diagram of a shaft seal mechanism according to the present invention.
[0018] FIG. 2 is an axial cross-sectional view of the shaft seal mechanism according to the present invention.
[0019] FIG. 3 is an exploded view of a support structure of thin-plate seal pieces.
[0020] FIG. 4 is a detailed view of a shaft seal mechanism according to Example 1 and is a front view of a thin-plate seal piece.
[0021] FIG. 5 is a detailed view of a shaft seal mechanism according to Example 2 and is a front view of a thin-plate seal piece.
[0022] FIG. 6 is a detailed view of a shaft seal mechanism according to Example 3 and is a front view of a thin-plate seal piece.
DESCRIPTION OF EMBODIMENTS
[0023] A shaft seal mechanism according to the present invention will be described in detail with reference to the drawings.
EXAMPLES
[0024] With reference to FIG. 1 , a shaft seal mechanism 11 according to the present invention is applied to, for example, a steam turbine or a gas turbine and is disposed in a ring-shaped space 14 defined between a fixed section (stationary section) 12 and a rotating shaft 13 of a casing, a vane, or the like.
[0025] Specifically, with reference to FIGS. 1 and 2 , a seal housing 21 being an outer shell of the shaft seal mechanism 11 is disposed on an inner circumferential section of the fixed section 12 in the circumferential direction of the rotating shaft 13 and has a ring shape. A ring-shaped groove 21 a is formed in an inner circumferential section of the seal housing 21 . In the ring-shaped groove 21 a , a large number of thin-plate seal pieces 22 are arranged in the circumferential direction of the rotating shaft 13 .
[0026] Outer-circumferential-side proximal end sections 22 a of the thin-plate seal pieces 22 are fixed to the ring-shaped groove 21 a ; on the other hand, inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 are in sliding contact with the outer circumferential surface of the rotating shaft 13 at a predetermined preload. Here, the thin-plate seal pieces 22 are arranged in such a manner that the inner-circumferential-side distal end sections 22 b being free ends are inclined in the rotational direction with respect to the outer circumferential surface of the rotating shaft 13 and form acute angles with the outer circumferential surface. Bottom surfaces of the thin-plate seal pieces 22 supported in an inclined manner refer to surfaces facing the rotating shaft 13 , and top surfaces thereof refer to surfaces opposite to the bottom surfaces.
[0027] A fluid G, such as steam and combustion gas, flows from a high pressure side to a low pressure side in the axial direction of the rotating time 13 in the ring-shaped space 14 defined between the fixed section 12 and the rotating shaft 13 . In response to this, the shaft seal mechanism 11 has a ring-shaped seal structure in which the thin-plate seal pieces 22 are arranged into multiple layers in the circumferential direction of the rotating shaft 13 . The ring-shaped space 14 is divided into a high-pressure-side region being an upstream side in the fluid flowing direction and a low-pressure-side region being an downstream side in the fluid flowing direction with the boundary formed by a large number of the thin-plate seal pieces 22 arranged into a ring shape. This configuration reduces a leakage of the fluid G from the high-pressure-side region to the low-pressure-side region.
[0028] With reference to FIGS. 2 and 3 , each of the thin-plate seal pieces 22 is made from a flexible material having flexibility and is formed into a flat plate shape with its width dimension being in the axial direction of the rotating shaft 13 . Specifically, the thin-plate seal piece 22 is formed into a T shape in which the plate width on the proximal end side (the outer-circumferential-side proximal end section 22 a ) is wider than the plate width on the distal end side (the inner-circumferential-side distal end section 22 b ) and is thinned so as to exhibit flexibility. The thin-plate seal pieces 22 are arranged into a ring shape while having minute gaps of a certain size therebetween in the circumferential direction of the rotating shaft 13 .
[0029] The proximal end sides of the thin-plate seal pieces 22 are held between a pair of right and left retainers 23 , 24 for maintaining the ring-shaped arrangement of the thin-plate seal pieces 22 so as to be enclosed from both sides in the plate width direction. The retainers 23 , 24 are fitted into the ring-shaped groove 21 a of the seal housing 21 .
[0030] A high-pressure-side plate 25 and a low-pressure-side plate 26 are disposed respectively on the high pressure side and the low pressure side of the thin-plate seal pieces 22 and function as guide plates for the fluid G.
[0031] Specifically, the high-pressure-side plate 25 having a ring shape is disposed on left side sections (side sections positioned at the left in FIGS. 2 and 3 on paper), facing the high-pressure-side region, of the thin-plate seal pieces 22 . This high-pressure-side plate 25 is disposed adjacent to high-pressure-side side edge sections 22 c , facing the high-pressure-side region, of the thin-plate seal pieces 22 and is held between the high-pressure-side side edge sections 22 c and the retainer 23 .
[0032] Here, an inner-circumferential-side distal end section 25 a of the high-pressure-side plate 25 extends to an opening edge section of the ring-shaped groove 21 a but does not reach the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 . Moreover, a high-pressure-side gap δH of a certain size is defined between a high-pressure-side side surface 21 b , facing the high-pressure-side region, of the ring-shaped groove 21 a and the high-pressure-side plate 25 in the axial direction of the rotating shaft 13 (the fluid flowing direction, the plate width direction of the seal pieces).
[0033] The high-pressure-side plate 25 provided in this way allows the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 to be positioned inward in the radial direction of the rotating shaft 13 with respect to the inner-circumferential-side distal end section 25 a of the high-pressure-side plate 25 . Accordingly the fluid G flows in from the high-pressure-side region through the distal end side of the thin-plate seal pieces 22 .
[0034] On the other hand, the low-pressure-side plate 26 having a ring shape is disposed on right side sections (side sections positioned at the right in FIGS. 2 and 3 on paper), facing the low-pressure-side region, of the thin-plate seal pieces 22 . This low-pressure-side plate 26 is disposed adjacent to low-pressure-side side edge sections 22 d , facing the low-pressure-side region, of the thin-plate seal pieces 22 and is held between the low-pressure-side side edge sections 22 d , and the retainer 24 and a low-pressure-side side surface 21 c , facing the low-pressure-side region, of the ring-shaped groove 21 a.
[0035] IIere, an inner-circumferential-side distal end section 26 a of the low-pressure-side plate 26 does not reach an opening edge section of the ring-shaped groove 21 a and the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 and is positioned outward in the radial direction of the rotating shaft 13 with respect to the inner-circumferential-side distal end section 25 a of the high-pressure-side plate 25 . In other words, the low-pressure-side plate 26 is shorter than the high-pressure-side plate 25 . Moreover, a low-pressure-side gap δL of a certain size is defined between the low-pressure-side side surface 21 c of the ring-shaped groove 21 a and the low-pressure-side side edge sections 22 d in the axial direction of the rotating shaft 13 .
[0036] The low-pressure-side plate 26 provided in this way allows the low-pressure-side gap δL to be defined between the low-pressure-side side surface 21 c and the low-pressure-side side edge sections 22 d . The low-pressure-side gap δL is defined by the thickness of the low-pressure-side plate 26 , and the size of the low-pressure-side gap δL can thus be set by adjusting the thickness of the low-pressure-side plate 26 .
[0037] The pressure distribution of the fluid G generated in the top and bottom surfaces of the thin-plate seal pieces 22 can be set in accordance with the sizes of the high-pressure-side gap δH and the low-pressure-side gap δL. In addition, the magnitude of the pressure difference (lifting-up force) due to relative positional shift in the pressure distribution between the top and bottom surfaces of the thin-plate seal pieces 22 can be set in accordance with the quantitative relationship between the size of the high-pressure-side gap δH and the size of the low-pressure-side gap δL.
[0038] In the shaft seal mechanism 11 according to the present invention, the radial gap size between the inner-circumferential-side distal end section 26 a of the low-pressure-side plate 26 and the outer circumferential surface of the rotating shaft 13 is greater than the radial gap size between the inner-circumferential-side distal end section 25 a of the high-pressure-side plate 25 and the outer circumferential surface of the rotating shaft 13 , in order to yield stable lifting-up force.
[0039] With this configuration, while the rotation of the rotating shaft 13 is stopping, the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 are in contact with the outer circumferential surface of the rotating shaft 13 at the predetermined preload. On the other hand, while the rotating shaft 13 is rotating, lifting-up force is applied to the thin-plate seal pieces 22 by the pressure difference due to relative positional shift in the pressure distribution between the top and bottom surfaces of the thin-plate sheet pieces 22 and by dynamic pressure effect of the fluid G generated by the rotation of the rotating shaft 13 . This force bends the thin-plate seal pieces 22 , and accordingly, the inner-circumferential-side distal end sections 22 b thereof are lifted up from the outer circumferential surface of the rotating shaft 13 into a noncontact state, resulting in prevention of abrasion of and heat generation in the rotating shaft 13 and the thin-plate seal pieces 22 . At the same time, the thin-plate seal pieces 22 in a noncontact state with the rotating shaft 13 reduce a leakage of the fluid G flowing from the high-pressure-side region to the low-pressure-side region.
[0040] With reference to FIG. 4 , a stepped section (high-pressure-side stepped section) 31 and a stepped section (low-pressure-side stepped section) 32 are respectively formed on the high-pressure-side side edge section 22 c and the low-pressure-side side edge section 22 d of each of the thin-plate seal pieces 22 .
[0041] These stepped sections 31 , 32 are disposed in radial intermediate sections (longitudinal intermediate sections) of the side edge sections 22 c , 22 d and are shaped into such steps that a section, inward from the stepped section 31 in the radial direction, of the thin-plate seal piece 22 has a uniform plate width and that the thin-plate seal piece 22 is tapered. The steps of the stepped sections 31 , 32 are formed by inclined end surfaces. These inclined end surfaces face inward in the radial direction of the rotating shaft 13 and are inclined such that an inclined end section outward in the plate width direction of the seal piece is positioned inward in the radial direction of the rotating shaft 13 with respect to an inclined end section inward in the plate width direction of the seal piece.
[0042] In response to this, a locking section (high-pressure-side locking section) 25 b is formed on the inner-circumferential-side distal end section 25 a of the high-pressure-side plate 25 . The locking section 25 b is formed so as to protrude from the high-pressure-side plate 25 toward the high-pressure-side side edge section 22 c in the plate width direction of the thin-plate seal piece 22 , and a ring-shaped inclined surface is formed on the distal end section of the protrusion. This inclined surface faces outward in the radial direction of the rotating shaft 13 and is inclined such that an inclined end section inward in the plate width direction of the seal piece is positioned outward in the radial direction of the rotating shaft 13 with respect to an inclined end section outward in the plate width direction of the seal piece.
[0043] In addition, a locking section (low-pressure-side locking section) 26 b is formed on the inner-circumferential-side distal end section 26 a of the low-pressure-side plate 26 . The locking section 26 b is formed so as to protrude from the low-pressure-side plate 26 toward the low-pressure-side side edge section 22 d in the plate width direction of the thin-plate seal piece 22 , and a ring-shaped inclined surface is formed on the distal end section of the protrusion. This inclined surface faces outward in the radial direction of the rotating shaft 13 and is inclined such that an inclined end section inward in the plate width direction of the seal piece is positioned outward in the radial direction of the rotating shaft 13 with respect to an inclined end section outward in the plate width direction of the seal piece.
[0044] That is, the inclined end surface of the stepped section 31 and the inclined surface of the locking section 25 b can be engaged with each other in the radial direction of the rotating shaft 13 , and the inclined end surface of the stepped section 32 and the inclined surface of the locking section 26 b can be engaged with each other in the radial direction of the rotating shaft 13 . This configuration prevents detachment in the radial direction of the rotating shaft 13 , between the inclined surfaces of the locking sections 25 b , 26 b and the inclined end surfaces of the stepped sections 31 , 32 that are engaged with each other.
[0045] For example, if the pressure of the fluid G flowing from the high-pressure-side region to the low-pressure-side region in turbine operation presses the thin-plate seal pieces 22 toward the low-pressure-side region, or if a mechanism assembling error occurs after assembly of the shaft seal mechanism 11 , the size of the low-pressure-side gap δL becomes smaller than the gap size for yielding stable lifting-up force (for example, δH>δL), resulting in disturbance in the pressure distribution and pressure difference generated in the thin-plate seal pieces 22 . This disturbance applies pressing force in a direction opposite to the applying direction of the lifting-up force to the thin-plate seal pieces 22 . Accordingly, the inner-circumferential-side distal end sections 22 b are deformed to be pressed against the rotating shaft 13 by pressure greater than the preload while the rotation of the rotating shaft 13 is stopping.
[0046] However, in the shaft seal mechanism 11 according to the present invention, the locking sections 25 b , 26 b provided in the high-pressure-side plate 25 and the low-pressure-side plate 26 can be engaged with the stepped sections 31 , 32 of the thin-plate seal pieces 22 from the inside toward the outside in the radial direction of the rotating shaft 13 . This engagement allows the stepped sections 31 , 32 to be hooked on the locking sections 25 b , 26 b even if pressing force greater than the preload is applied to the thin-plate seal pieces 22 and thus suppresses deformation of the thin-plate seal pieces 22 against the rotating shaft 13 . This configuration can maintain the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 in a noncontact state without contact with the rotating shaft 13 , resulting in prevention of abrasion of the thin-plate seal pieces 22 .
[0047] The inclined surfaces of the locking sections 25 b , 26 b and the inclined end surfaces of the stepped sections 31 , 32 can be engaged with each other in the radial direction of the rotating shaft 13 . Consequently, even if the thin-plate seal pieces 22 are assembled while being inclined toward the high pressure side or the low pressure side, the locking sections 25 b , 26 b ensure locking of the stepped sections 31 , 32 .
[0048] Furthermore, in the shaft seal mechanism 11 according to the present invention, only the thin-plate seal pieces 22 , the high-pressure-side plate 25 , and the low-pressure-side plate 26 change in shapes among the components of existing seal mechanisms. A large component, such as the seal housing 21 , is not required to change in shape, so that abrasion of the thin-plate seal pieces 22 due to pressing force can be prevented without a significant design change.
[0049] The thin-plate seal pieces 22 are locked by the high-pressure-side plate 25 and the low-pressure-side plate 26 in the aforementioned embodiment but may be locked by the seal housing 21 as illustrated in FIGS. 5 and 6 .
[0050] With reference to FIG. 5 , a stepped section (low-pressure-side stepped section) 33 is formed on the low-pressure-side side edge section 22 d of each of the thin-plate seal pieces 22 . This stepped section 33 is disposed inward in the radial direction of the rotating shaft 13 with respect to the inner-circumferential-side distal end section 26 a of the low-pressure-side plate 26 and is shaped into a notch formed by cutting out a portion of the low-pressure-side side edge section 22 d . A step of the stepped section 33 is formed by an inclined end surface. This inclined end surface faces inward in the radial direction of the rotating shaft 13 and is inclined such that an inclined end section outward in the plate width direction of the seal piece is positioned inward in the radial direction of the rotating shaft 13 with respect to an inclined end section inward in the plate width direction of the seal piece.
[0051] In response to this, a locking section (low-pressure-side locking section) 21 d is formed on the low-pressure-side side surface 21 c of the seal housing 21 . The locking section 21 d is formed so as to protrude from the low-pressure-side side surface 21 c toward the low-pressure-side side edge section 22 d in the plate width direction of the thin-plate seal piece 22 , and a ring-shaped inclined surface is formed on the distal end section of the protrusion. This inclined surface faces outward in the radial direction of the rotating shaft 13 and is inclined such that an inclined end section inward in the plate width direction of the seal piece is positioned outward in the radial direction of the rotating shaft 13 with respect to an inclined end section outward in the plate width direction of the seal piece.
[0052] That is, the locking section 21 d is positioned inward in the radial direction of the rotating shaft 13 with respect to the inner-circumferential-side distal end section 26 a of the low-pressure-side plate 26 , and the inclined surface of the locking section 21 d and the inclined end surface of the stepped section 33 can be engaged with each other in the radial direction of the rotating shaft 13 . This configuration prevents detachment in the radial direction of the rotating shaft 13 , between the inclined surface of the locking section 21 d and the inclined end surface of the stepped section 33 that are engaged with each other.
[0053] The locking section 21 d provided in the seal housing 21 can be engaged with the stepped sections 33 of the thin-plate seal pieces 22 from the inside toward the outside in the radial direction of the rotating shaft 13 . This engagement allows the stepped sections 33 to be hooked on the locking section 21 d even if pressing force greater than the preload is applied to the thin-plate seal pieces 22 and thus suppresses deformation of the thin-plate seal pieces 22 against the rotating shaft 13 . This configuration can maintain the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 in a noncontact state without contact with the rotating shaft 13 , resulting in prevention of abrasion of the thin-plate seal pieces 22 .
[0054] Moreover, the locking section 21 d is provided in the seal housing 21 being a large component and can thus have enhanced rigidity, resulting in maintaining an engagement state between the locking section 21 d and the stepped sections 33 over a long period.
[0055] With reference to FIG. 6 , a stepped section (low-pressure-side stepped section) 34 is formed on the low-pressure-side side edge section 22 d of each of the thin-plate seal pieces 22 . This stepped section 34 is disposed in a radial intermediate section (longitudinal intermediate section) of the low-pressure-side side edge section 22 d and is shaped into such a step that the thin-plate seal piece 22 is tapered by being recessed toward the center of the thin-plate seal piece 22 in the plate width direction. The step of the stepped section 34 is formed by an inclined end surface. This inclined end surface faces inward in the radial direction of the rotating shaft 13 and is inclined such that an inclined end section outward in the plate width direction of the seal piece is positioned inward in the radial direction of the rotating shaft 13 with respect to an inclined end section inward in the plate width direction of the seal piece.
[0056] In response to this, a locking section (low-pressure-side locking section) 21 e is formed on the low-pressure-side side surface 21 c of the seal housing 21 . The locking section 21 e is formed so as to protrude from the low-pressure-side side surface 21 c toward the low-pressure-side side edge section 22 d in the plate width direction of the thin-plate seal piece 22 , and a ring-shaped inclined surface is formed on the distal end section of the protrusion. This inclined surface faces outward in the radial direction of the rotating shaft 13 and is inclined such that an inclined end section inward in the plate width direction of the seal piece is positioned outward in the radial direction of the rotating shaft 13 with respect to an inclined end section outward in the plate width direction of the seal piece.
[0057] That is, the inclined surface of the locking section 21 e and the inclined end surface of the stepped section 34 can be engaged with each other in the radial direction of the rotating shaft 13 . This configuration prevents detachment in the radial direction of the rotating shaft 13 , between the inclined surface of the locking section 21 e and the inclined end surface of the stepped section 34 that are engaged with each other.
[0058] The locking section 21 e provided in the seal housing 21 can be engaged with the stepped sections 34 of the thin-plate seal pieces 22 from the inside toward the outside in the radial direction of the rotating shaft 13 . This engagement allows the stepped sections 34 to be hooked on the locking section 21 e even if pressing force greater than the preload is applied to the thin-plate seal pieces 22 and thus suppresses deformation of the thin-plate seal pieces 22 against the rotating shaft 13 . This configuration can maintain the inner-circumferential-side distal end sections 22 b of the thin-plate seal pieces 22 in a noncontact state without contact with the rotating shaft 13 , resulting in prevention of abrasion of the thin-plate seal pieces 22 .
[0059] Moreover, the locking section 21 e is provided in the seal housing 21 being a large component and can thus have enhanced rigidity, resulting in maintaining an engagement state between the locking section 21 e and the stepped sections 34 over a long period. In addition, the low-pressure-side plate 26 is not required to be provided, so that the shaft seal mechanism 11 can have a simple configuration and that the manufacturing cost of the shaft seal mechanism 11 can be reduced.
INDUSTRIAL APPLICABILITY
[0060] The shaft seal mechanism according to the present invention can prevent damage of the thin-plate seal pieces due to pressing force and increase the life of the seal pieces, and can thus be applied significantly advantageously in continuous operation of a turbine.
REFERENCE SIGNS LIST
[0000]
11 Shaft seal mechanism
12 Fixed section
13 Rotating shaft
14 Ring-shaped space
21 Seal housing
21 a Ring-shaped groove
21 b High-pressure-side side surface
21 c Low-pressure-side side surface
21 d , 21 e Locking section
22 Thin-plate seal piece
22 a Outer-circumferential-side proximal end section
22 b Inner-circumferential-side proximal end section
22 c High-pressure-side side edge section
22 d Low-pressure-side side edge section
23 , 24 Retainer
25 High-pressure-side plate
25 a Inner-circumferential-side distal end section
25 b Locking section
26 Low-pressure-side plate
26 a Inner-circumferential-side distal end section
26 b Locking section
31 to 34 Stepped section
G Fluid
δH High-pressure-side gap
δL Low-pressure-side gap | A shaft seal mechanism ( 11 ) that blocks a fluid (G) flowing within a ring-shaped space ( 14 ) is equipped with: a ring-shaped seal housing ( 21 ) disposed on a fixed section ( 12 ); a plurality of thin-plate seal pieces ( 22 ) that are secured to the seal housing ( 21 ), are in sliding contact with a rotating shaft ( 13 ), and are layered in a ring shape; a ring-shaped high-pressure-side plate ( 25 ) that forms a high-pressure-side gap (δH) between itself and the seal housing ( 21 ); a ring-shaped low-pressure-side plate ( 26 ) that forms a low-pressure-side gap (δL) between the seal housing ( 21 ) and the thin-plate seal pieces ( 22 ); stepped sections ( 31, 32 ) that are formed on side edge sections ( 22 c, 22 d ) of the thin-plate seal pieces ( 22 ); and locking sections ( 25 b, 26 b ) that lock the stepped sections ( 31, 32 ). | 5 |
CROSS-REFERENCE
This application claims priority of provisional application No. 60/104,375 filed Oct. 15, 1998 and provisional application No. 60/145,460, filed Jul. 23, 1999.
BACKGROUND OF THE INVENTION
The present invention relates to certain compounds of Formula II below, which are useful intermediates in the synthesis of certain β 3 -adrenergic receptor agonists having the general Formula I: ##STR3## where R 3 is as defined below and Y 2 is ##STR4## Examples of such substituents and the resultant β 3 -adrenergic receptor agonists can be found in commonly assigned International Application Publication No. WO 94/35671. The invention also relates to processes for synthesizing the compounds of Formula II, which are useful intermediates in the synthesis of the compounds of Formula I. The invention further relates to processes for synthesizing the compounds of Formula I. The β 3 -adrenergic receptor agonists also possess utility for increasing lean meat deposition and/or improving the lean meat to fat ratio in edible animals.
(4-(2-(2-(6-Aminopyridin-3-yl)-2(R)-hydroxyethylamino)ethoxy)phenyl)acetic acid has the structure of Formula XII: ##STR5##
(4-(2-(2-(6-Aminopyridin-3-yl)-2(R)-hydroxyethylamino)ethoxy)phenyl)acetic acid is disclosed in commonly assigned International Patent Application Publication Number WO 96/35671, the disclosure of which is incorporated herein by reference, as a β-adrenergic agent. Accordingly, (4-(2-(2-(6-aminopyridin-3-yl)-2(R)-hydroxyethylamino)ethoxy)phenyl)acetic acid has utility in the treatment of obesity.
The β-adrenergic receptor agonists further possess utility in the treatment of intestinal motility disorders, depression, prostate disease, dyslipidemia, and airway inflammatory disorders such as asthma and obstructive lung disease.
The β 3 -receptor is also expressed in human prostate. Because stimulation of the β 3 -receptor causes relaxation of smooth muscles that have been shown to express the β 3 -receptor (e.g. intestine), one skilled in the art would predict relaxation of prostate smooth muscle. Therefore, β 3 -agonists will be useful for the treatment or prevention of prostate disease.
SUMMARY OF THE INVENTION
This invention is directed to compounds of Formula II, ##STR6## enantiomers thereof and pharmaceutically acceptable salts thereof, wherein:
R 1 is a leaving group selected from halo, methanesulfonyloxy, benzenesulfonyloxy, p-toluenesulfonyloxy, m-nitrobenzenesulfonyloxy and p-nitrobenzenesulfonyloxy;
R 2 is tetrahydrofuranyl, tetrahydropyranyl or a silyl protecting group; and
R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo.
A preferred group of compounds, designated the A Group, comprises those compounds having the Formula II as shown above, enantiomers thereof and pharmaceutically acceptable salts thereof, wherein R 2 is SiR 5 R 6 R 7 , wherein R 5 , R 6 and R 7 are each independently (C 1 -C 4 )alkyl or aryl.
A preferred group of compounds within the A Group, designated the B Group, comprises those compounds, enantiomers thereof and pharmaceutically acceptable salts thereof wherein R 3 is acetyl, R 1 is toluenesulfonyloxy and said silyl protecting group is selected from t-butyldimethylsilyl, triethylsilyl and triisopropylsilyl.
A preferred group of compounds within the B Group, designated the C Group, comprises those compounds, enantiomers thereof and pharmaceutically acceptable salts thereof, wherein R 2 is t-butyldimethylsilyl.
A preferred compound within the C Group comprises the compound and pharmaceutically acceptable salts thereof having (R) stereochemistry.
A preferred compound of this invention is toluene-4-sulfonic acid 2-(6-acetylamino-pyridin-3-yl)-2(R)-(tert-butyldimethyl-silyloxy)-ethyl ester.
This invention is also directed to compounds of Formula III ##STR7## enantiomers thereof and pharmaceutically acceptable salts thereof, wherein:
R 2 is tetrahydrofuranyl, tetrahydropyranyl or a silyl protecting group;
R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo; and
R 4 is (C 1 -C 8 )alkyl.
A preferred group of compounds, designated the D Group, comprises those compounds of Formula III, enantiomers thereof and pharmaceutically acceptable salts thereof, wherein said hydroxy protecting group is t-butyldimethylsilyl, triethylsilyl, trimethylsilyl, triisopropylsilyl or tetrahydropyranyl.
A preferred group of compounds within the D Group, designated the E Group, comprises those compounds, enantiomers thereof and pharmaceutically acceptable salts thereof, wherein R 3 is acetyl, R 2 is t-butyldimethylsilyl, and R 4 is methyl.
A preferred compound within the E Group comprises the compound and pharmaceutically acceptable salts thereof having (R) stereochemistry.
A preferred compound within this invention is 2-(4-(2-(2-(6-acetylamino-pyridin-3-yl)-2(R)-(t-butyldimethylsilyloxy)-ethylamino)-ethoxy)-phenyl-N-methyl-acetamide.
Another preferred compound within this invention is the monohydrochloride salt of (4-(2-(2-(6-aminopyridin-3-yl)-2(R)-hydroxyethylamino)ethoxy)phenyl)acetic acid.
This invention is also directed to a process, designated Process A, for preparing a compound of Formula II, ##STR8## or enantiomers thereof, wherein R 1 is a leaving group selected from halo, methanesulfonyloxy, p-toluenesulfonyloxy, benzenesulfonyloxy, m-nitrobenzenesulfonyloxy and p-nitrobenzenesulfonyloxy;
R 2 is tetrahydrofuranyl, tetrahydropyranyl or a silyl protecting group; and
R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo, comprising reacting a compound of the Formula IV, ##STR9## or enantiomers thereof, wherein R 1 and R 3 are as defined above with a silylating agent and a suitable base in a reaction inert solvent for about 12 hours to about 18 hours at about 20° C. to about 50° C.
A preferred process within Process A, designated Process B, comprises the process wherein said suitable base is imidazole.
A preferred process within Process B, designated Process C, comprises the process wherein R 1 is p-toluenesulfonyloxy, R 3 is acetyl and said silylating agent is t-butyldimethylchlorosilane.
A preferred process within Process C comprises the process wherein ##STR10## is prepared from ##STR11##
This invention is also directed to a process, designated Process D, for preparing a compound of the Formula III ##STR12## or enantiomers thereof, wherein R 2 is tetrahydrofuranyl, tetrahydropyranyl or a silyl protecting group; R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo; and
R 4 is (C 1 -C 8 )alkyl comprising reacting a compound of the Formula II ##STR13## or enantiomers thereof, wherein R 1 , R 2 and R 3 are as defined above, with a compound of the Formula VII, ##STR14## wherein R 4 is (C 1 -C 8 )alkyl and a suitable base in a reaction inert solvent for a time of about 6 hours to 24 hours at a temperature of about 60° C. to 100° C.
A preferred process within Process D, designated Process E, is wherein said time is about 18 hours and said temperature is about 80° C. and which comprises the process wherein R 2 is t-butyldimethylsilyl, trimethylsilyl, triethylsilyl, triisopropylsilyl or tetrahydropyranyl and said suitable base is N,N-diisopropylethylamine, triethylamine, N-methylmorpholine or 1,4-diazabicyclo[2.2.2]octane.
A preferred process within Process E, designated Process F, comprises the process wherein R 1 is toluenesulfonyloxy, R 2 is t-butyldimethylsilyl; R 3 is acetyl; and R 4 is methyl.
A preferred process within Process F comprises the process wherein the compound of Formula VIII, ##STR15## is prepared from the compound of Formula V, ##STR16##
This invention is also directed to a process, designated Process G, for preparing a compound of Formula IX, ##STR17## or enantiomers thereof, wherein R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo and R 4 is (C 1 -C 8 )alkyl comprising reacting a compound of Formula III ##STR18## or enantiomers thereof, wherein R 2 is tetrahydrofuranyl, tetrahydropyranyl or a silyl protecting group and R 3 and R 4 are as defined above with a fluoride source in a reaction inert solvent for a time of about 6 hours to about 12 hours at a temperature of about 0° C. to about 50° C.
A preferred process within Process G, designated Process H, is wherein said temperature is about room temperature and which comprises the process wherein R 2 is t-butyldimethylsilyl and said fluoride source is tetrabutylammonium fluoride.
A preferred process within Process H, designated Process I, comprises the process wherein R 3 is acetyl and R 4 is methyl.
A preferred process within Process I, designated Process J, comprises the process wherein the compound of Formula X, ##STR19## is prepared from the compound of Formula VIII, ##STR20##
This invention is also directed to a process, designated Process K, for preparing a compound of Formula IX-a, ##STR21## or enantiomers thereof, wherein R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo and R 4 is (C 1 -C 8 )alkyl comprising
(a) reacting a compound of Formula III ##STR22## or an enantiomer thereof, wherein R 2 is tetrahydrofuranyl, tetrahydropyranyl or a silyl protecting group and R 3 and R 4 are as defined above with a fluoride source in a reaction inert solvent for about 6 hours to about 12 hours at a temperature of about 0° C. to about 50° C. to form a compound of Formula IX ##STR23## or an enantiomer thereof, wherein R 3 and R 4 are as defined above and
(b) reacting said compound of Formula IX or an enantiomer thereof, with two equivalents of hydrochloric acid in a reaction inert solvent.
A preferred process within Process K, designated Process L, is wherein said temperature is about room temperature and which comprises the process wherein R 2 is t-butyldimethylsilyl and said fluoride source is tetrabutylammonium fluoride.
A preferred process within Process L, designated Process M, comprises the process wherein R 3 is acetyl and R 4 is methyl.
A preferred process within Process M, designated Process N, comprises the process wherein said compound of Formula IX-a is prepared from the compound of Formula VIII, ##STR24##
This invention is also directed to a process, designated Process O, for preparing a compound of Formula XII, ##STR25## comprising reacting a compound of Formula III-a ##STR26## wherein R 2 is a silyl protecting group; R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo and R 4 is (C 1 -C 8 )alkyl with aqueous base for about six hours to about thirty hours at about 90° C. to about 100° C. It will be appreciated by those skilled in the art that the time and temperatures required to effect this hydrolysis will be dependent upon the protecting groups being removed. Particularly preferred, when R 3 is acetyl and R 4 is methyl, is a time of 24 hours and a temperature of 100° C.
A preferred process within Process O comprises the process wherein the compound of Formula XII ##STR27## is prepared from the compound of Formula VIII, ##STR28##
This invention is also directed to a process, designated Process P, for preparing a compound of Formula XII, ##STR29## comprising: (a) reacting a compound of Formula XIII, ##STR30## wherein R 1 is a leaving group selected from halo, toluenesulfonyloxy and methylsulfonyloxy; and R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo, with a silylating agent and a first suitable base in a reaction inert solvent for a time of about 12 hours to about 18 hours at a temperature of about 20° C. to about 50° C. to form a compound of Formula XIV, ##STR31## wherein R 2 is a silyl protecting group and R 1 and R 3 are as defined above;
(b) reacting said compound of Formula XIV with a compound of Formula VII, ##STR32## wherein R 4 is (C 1 -C 8 )alkyl and a second suitable base in a reaction inert solvent for a time of about six hours to about 24 hours at a temperature of about 60° C. to about 100° C. to form a compound of Formula XV, ##STR33## wherein R 2 , R 3 and R 4 are as defined above; (c) reacting said compound of Formula XV with a fluoride source in a reaction inert solvent for a time of about 6 hours to 12 hours at a temperature of about 0° C. to about 50° C. to form a compound of Formula XVI, ##STR34## wherein R 3 and R 4 are as defined above; and (d) reacting said compound of Formula XVI with aqueous base for a time of about six hours to about thirty hours at a temperature of about 90° C. to about 100° C. to form said compound of Formula XII.
A preferred process within Process P, designated Process Q, comprises the process wherein R 1 is toluenesulfonyloxy; R 2 is t-butyldimethylsilyl; R 3 is acetyl and R 4 is methyl.
A preferred process within Process Q comprises the process wherein in step (a), said silylating agent is t-butyldimethylchlorosilane and said first suitable base is imidazole; in step (b), said temperature is about 80° C., said time is about 18 hours and said second suitable base is dilsopropylethylamine; in step (c), said temperature is about room temperature and said fluoride source is tetrabutylammonium fluoride; and in step (d), said time is about 24 hours, said temperature is about 100° C. and said aqueous base is sodium hydroxide.
This invention is also directed to a process, designated Process R, for preparing a compound of Formula XII, ##STR35## comprising: (a) reacting a compound of Formula XIII, ##STR36## wherein R 1 is a leaving group selected from halo, methanesulfonyloxy, benzenesulfonyloxy, p-toluenesulfonyloxy, m-nitrobenzenesulfonyloxy and p-nitrobenzenesulfonyloxy; and R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo, with a silylating agent and a first suitable base in a reaction inert solvent for a time of about 12 hours to about 18 hours at a temperature of about 20° C. to about 50° C. to form a compound of Formula XIV, ##STR37## wherein R 2 is a silyl protecting group and R 1 and R 3 are as defined above; and
(b) reacting said compound of Formula XIV with a compound of Formula VII ##STR38## wherein R 4 is (C 1 -C 8 )alkyl and a second suitable base in a reaction inert solvent for a time of about 12 to about 18 hours at a temperature of about 60° C. to about 100° C. to form a compound of Formula XV, ##STR39## wherein R 2 , R 3 and R 4 are as defined above; and (c) reacting said compound of Formula XV with aqueous base for a time of about six hours to about 24 hours at a temperature of about 90° C. to about 100° C. to form said compound of Formula XII.
A preferred process within Process R, designated Process S, comprises the process wherein R 1 is toluenesulfonyloxy; R 2 is t-butyldimethylsilyl; R 3 is acetyl and R 4 is methyl.
A preferred process within Process S comprises the process wherein in step (a), said silylating agent is t-butyldimethylchlorosilane and said first suitable base is imidazole; in step (b), said temperature is about 80° C. and said second suitable base is diisopropylethylamine; and in step (c) said time is about 24 hours, said temperature is about 100° C. and said aqueous base is sodium hydroxide.
This invention is also directed to a process, designated Process T, for preparing a compound of Formula XIIa, ##STR40## comprising: (a) reacting a compound of Formula XIII, ##STR41## wherein R 1 is a leaving group selected from halo, methanesulfonyloxy, benzenesulfonyloxy, p-toluenesulfonyloxy, m-nitrobenzenesulfonyloxy and p-nitrobenzenesulfonyloxy; and R 3 is (C 1 -C 5 )alkanoyl or benzoyl optionally substituted independently with up to three (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy or halo, with a silylating agent and a first suitable base in a reaction inert solvent for a time of about 12 hours to about 18 hours at a temperature of about 20° C. to about 50° C. to form a compound of Formula XIV, ##STR42## wherein R 2 is a silyl protecting group and R 1 and R 3 are as defined above;
(b) reacting said compound of Formula XIV with a compound of Formula VII, ##STR43## wherein R 4 is (C 1 -C 8 )alkyl and a second suitable base in a reaction inert solvent for a time of about 12 hours to about 18 hours at a temperature of about 60° C. to about 100° C. to form a compound of Formula XV, ##STR44## wherein R 2 , R 3 and R 4 are as defined above; (c) reacting said compound of Formula XV with aqueous base for a time of about six hours to about 30 hours at a temperature of about 90° C. to about 100° C. to form said compound of Formula XII, ##STR45## (d) reacting said compound of Formula XII with HCl.
A preferred process within Process T, designated Process U, comprises the process wherein R 1 is toluenesulfonyloxy; R 2 is t-butyldimethylsilyl; R 3 is acetyl and R 4 is methyl.
A preferred process within Process U comprises the process wherein in step (a), said silylating agent is t-butyldimethylchlorosilane and said first suitable base is imidazole, in step (b), said temperature is about 80° C. and said second suitable base is diisopropylethylamine; and in step (c), said time is about 24 hours, said temperature is about 100° C. and said aqueous base is sodium hydroxide.
This invention is also directed to a process for purifying the zwitterionic form of the compound of Formula XII, comprising the steps of:
(a) forming a solution of an acid addition salt of said compound;
(b) adjusting the pH of said solution to within a range of between about 7.0 and about 7.5; and
(c) collecting the zwitterionic crystals of said compound of Formula XII which form in said pH range.
It is noted that the capability for isolating compound XII by precipitation as the zwitterion represents a significant advantage in view of the relatively high aqueous solubility of salts (both acid addition and base addition) of compound XII. That is, the high aqueous solubility of such salts makes it difficult to isolate such salts in high yield by recrystallization, and isolation by evaporation is energy intensive. By isolating compound XII as the zwitterion, it is easily obtained in relatively high yields (typically about 90% and higher) without any of the aforementioned process difficulties.
Any pharmaceutically acceptable mineral or organic acid can be used to make an acid addition salt. Such adds include various mineral and organic acids such as hydrochloric, hydrobromic, hydriodic, sulfuric, phosphoric, acetic, trifluoroacetic, lactic, maleic, fumaric, citric, tartaric, succinic, and gluconic. The salt is made conventionally by adding an equivalent amount of the acid to the zwitterionic form, i.e., by
(a) forming an aqueous solution and/or suspension of said compound of Formula XII (i.e., as the zwitterion); and
(b) treating said aqueous solution or suspension with at least one equivalent (and up to two equivalents) of a pharmaceutically acceptable acid, thereby forming a suspension/solution of the resulting pharmaceutical salt. A di-acid salt can be formed, although mono-acid addition salts are also feasible. When making a solution (or suspension since the zwitterion has low aqueous solubility) of the compound of Formula XII, usually much of the zwitterion remains in suspended (undissolved) form until addition of the acid is commenced, due to the fact that the zwitterion has relatively low aqueous solubility. Initially undissolved zwitterion dissolves as acid is added to the solution.
Once the aqueous solution of an add addition salt of the compound of formula XII has been made, the solution is acidic. The solution can then be titrated to within the range of about 7.0 to about 7.5, at which point the compound of formula XII, in crystalline zwitterionic form, precipitates out of solution. The titration is conducted conventionally with a base, typically an aqueous alkali metal hydroxide such as lithium hydroxide, sodium hydroxide, or potassium hydroxide.
If desired, the aqueous solution of an acid addition salt of the compound of formula XII can be titrated directly to within the range of 7.0 to 7.5. Alternatively, the desired pH range of 7.0 to 7.5 can be "overshot", i.e., a pH above the desired range of 7 to 7.5 can be obtained by the titration. Typically a pH of 9 to 12 is obtained, thereby ensuring completeness of the neutralization reaction. Then the solution can be back titrated to a range of between 7.0 and 7.5 where the crystalline zwitterion precipitates and can be harvested. Typically a mineral acid such as HCl is employed for the back titration.
In a preferred embodiment this invention is directed to a process for purifying the zwitterionic form of the compound of Formula XII comprising
(a) treating the zwitterionic form of the compound of Formula XII with one equivalent of hydrochloric acid in water to form a suspension of the hydrochloride salt of the compound of Formula XII;
(b) filtering said suspension of said hydrochloride salt of the compound of Formula XII to isolate said hydrochloride salt;
(c) suspending said hydrochloride salt in water to form a suspension; and
(d) adjusting said suspension to a pH of 9 to 12 by adding base and titrating said solution to pH 7 by adding acid.
In an especially preferred embodiment for purification of the zwitterion, the hydrochloride salt of the compound of Formula XII is made by adding aqueous HCl to the zwitterionic form of compound XII until a pH of about 3 is obtained, thereby forming an HCl addition salt (likely as a mixture of mono-HCl and di-HCl salts). The pH of the solution is then adjusted to about 7.0 to 7.5 by titrating with aqueous sodium hydroxide. At this point, and optionally, the zwitterion crystals which form at pH 7.0 to 7.5 may be treated by the following process: (i) the crystals may be filtered and the filtrate discarded; (ii) additional aqueous base may be added to the filtered crystals from (i) until a solution having pH of about 11-12 is obtained; (iii) the resulting solution from (ii) may be titrated with aqueous acid (e.g., HCl) back to a pH in the range of about 7.0 to about 7.5: and (iv) the resulting solution may be filtered to obtain the zwitterion and the filtrate discarded. One further equivalent of aqueous sodium hydroxide is then added to the zwitterion (crystals or solution), thereby changing the pH to about 11-12. Aqueous HCl is then used to titrate the solution back to a pH of about 7.0 to 7.5, whereby zwitterionic crystals of compound XII are formed and the solution is transformed into a slurry or suspension containing the poorly soluble zwitterion.
A final purification step can then be implemented, wherein an equivalent of HCl is first added to the slurry or suspension to re-form the HCl salt. The salt solution is then titrated with aqueous NaOH up to a pH of about 9-12, and then titrated back down to a pH of about 7.0 to about 7.5 using aqueous HCl. The crystals can be harvested by conventional filtration.
The zwitterionic crystals thereby produced by the processes discussed above are formed in a preferred polymorph of this invention, referred to herein and in the claims as "Form B", and is characterized by the major peaks in the following X-ray diffraction pattern.
__________________________________________________________________________Peak No. 1 2 3 4 5 6 7 8 9 10__________________________________________________________________________2Θ(°) Cu 13.2 18.5 20.1 20.4 21.1 25.0 25.2 25.7 29.6 30.2I rel 24.1 22.0 100 83.0 51.9 28.8 30.2 36.4 19.0 11.4d space (A) 6.7 4.8 4.4 4.3 4.2 3.6 3.5 3.5 3.0 3.0__________________________________________________________________________
wherein relative intensities (I(rel)) are also shown for convenience. In differential scanning calorimetry (DSC), Form B is additionally characterized, relative to Form A discussed below, by a distinct, single melt temperature of 205° C.
Polymorph Form B can be formulated to treat a mammal, including a human, for any of the conditions disclosed in PCT application PCT/IB95/00344, which was published Nov. 14, 1996 as WO 96/35671, and which is herein incorporated by reference. The polymorph can be formulated as a composition in the form of any of the dosage forms disclosed in the aforementioned published application, and can include excipients conventionally employed in the formulation arts. Such dosage forms are compositions comprising an amount of polymorph Form B effective to treat the particular condition, and an a pharmaceutically acceptable carrier or diluent. An effective amount of polymorph form B is an amount as disclosed in the aforementioned WO 96/35671, and will generally be a daily dose in the range of 0.01 to 100 mg/kg of body weight.
A second polymorph of the compound of Formula XII, herein designated as Form A, also exists and results from the synthetic procedures disclosed in commonly assigned application PCT/IB97/01367, published internationally on Nov. 3, 1997 as WO 98/21184. It is characterized by the major peaks in the following X-ray diffraction pattern.
______________________________________Peak No. 1 2 3 4 5 6______________________________________2Θ(°) Cu 20.0 21.1 22.0 25.5 25.8 29.8I (rel) 100 55.9 13.6 34.3 44.6 14.1d space (A) 4.4 4.2 4.4 3.4 3.4 3.0______________________________________
Form A is additionally characterized by a DSC melt lower than that of Form B. The DSC reveals a melt at 170 C followed by a second event at 195 C.
Thus the polymorphic zwitterionic forms of compound XII are easily distinguishable from each other by their x-ray patterns and DSC melts.
DETAILED DESCRIPTION OF THE INVENTION
A process for the manufacture of a compound of Formula XII as defined above is provided as a feature of the invention and is illustrated by the following procedure, set forth in Scheme 1, in which the meanings of generic radicals are as described above unless otherwise specified. ##STR46##
Processes for the manufacture of a compound of Formula XII as defined above are illustrated by the following procedures.
The compounds of Formula XII are synthesized from compounds of Formula XVI by reaction with aqueous alkali hydroxide for a sufficient time to hydrolyze the two amide groups. It will be appreciated by those skilled in the art that the time and temperatures required for this hydrolysis reaction will be dependent upon the protecting groups being removed. This reaction is typically carried out by reacting the hydrochloride salt of the compound of Formula XVI with an excess of sodium hydroxide in water at about 90° C. to about 100° C., or, convenienty, at reflux, for about six hours to about thirty hours. It is particularly preferred, when R 3 is acetyl and R 4 is methyl, to heat the reaction mixture at about 100° C. for about 24 hours. The compound of Formula XII can be isolated as its zwitterion, e.g., ##STR47## or as a mono-hydrochloride salt by proper adjustment of the pH of the aqueous solution. The mono-hydrochloride salt process has the advantage that trace impurities which sometimes co-precipitate with the zwitterion can be separated from the product.
Alternatively, the compound of Formula XII is prepared by heating a compound of Formula XV wherein R 2 is a trialkylsilane moiety in aqueous alkali hydroxide. In this instance, the initial basic aqueous reaction mixture is filtered to remove the bulk of the silicon containing residues which precipitate during the course of the reaction.
The compounds of Formula XVI are prepared by treating a compound of Formula XV wherein R 2 is trialkylsilyl with a fluoride reagent in a reaction inert solvent. This reaction may be carried out at a temperature of from about 0° C. to about 50° C. for about six hours to about twelve hours. Conveniently, the reaction is carried out at room temperature in tetrahydrofuran. The compounds of Formula XVI are isolated from the reaction by the introduction of sufficient hydrochloric acid to precipitate the product as a hydrochloride salt. This provides a convenient method to aid in the purification of compounds of Formula XVI. The preferred fluoride reagent is tetrabutyl ammonium fluoride.
The compounds of formula XV are prepared by treating a compound of Formula XIV with an excess (generally two equivalents) of a primary amine of Formula VII in a reaction inert solvent for about six hours to about 24 hours at a temperature of about 60° C. to about 100° C. Typically, the optimum temperature for this reaction is 80° C. Generally this reaction is carried out in the presence of a suitable tertiary amine base. Suitable bases include but are not limited to triethylamine, N-methylmorpholine, pyridine, 2,6-lutidine, N,N-diisopropyl-ethylamine or excess (e.g., three equivalents) compound of Formula VII. A preferred base is N,N-diisopropylethylamine. With respect to this particular reaction, it is preferred that the solvent is a polar, non-hydroxylic solvent such as dimethylformamide, dimethyl acetamide, N-methyl pyrrolidinone or dimethylsulfoxide. Generally the most preferred solvent is dimethylsulfoxide.
A particular advantage of the compounds of Formula XV of this invention as intermediates is the solubility of those compounds in organic solvents. The high water solubility of the intermediates used in previous processes to prepare the compound of Formula XII required the protection of the secondary nitrogen atom with a lipophilic protecting group to allow extraction of the desired intermediate from the crude reaction mixture. This required protection and deprotection steps, adding two steps to the overall synthesis. The compounds of Formula XV of this invention are easily isolated and therefore require no additional steps to allow easy isolation and further processing. In addition, the previous processes used to prepare the compound of Formula XII utilized epoxide intermediates which have been found to be prone to both racemization of the chiral center and opening at the undesired benzylic carbon atom of the epoxide. These tendencies were particularly noticeable at larger scale. Furthermore, it has been found that the acidic hydrolyses used in previous processes to prepare the compound of Formula XII surprisingly caused some racemization of the chiral alcohol center especially at large scale. Both the reaction of amine of Formula VII at the benzylic carbon center and racemization of the chiral center does not occur in the current invention.
The compounds of Formula XIV are prepared by treating a compound of Formula XIII wherein R 1 is as defined above with a silylating agent in a reaction inert solvent in the presence of a suitable base at about 0° C. to about 50° C. for about 12 hours to about 18 hours. The preferred R 1 group is p-toluenesulfonyloxy. Suitable silylating agents include but are not limited to trialkylchlorosilanes such as triethylchlorosilane, t-butyl-dimethyl-chlorosilane, triisopropylchlorosilane and alkyl-arylchlorosilanes such as diphenylmethyl-chlorosilane. A preferred silylating agent is t-butyl-dimethyl-chlorosilane. Suitable bases include but are not limited to triethylamine, N,N-diisopropylethylamine, imidazole, pyridine, 2,6-lutidine, and N-methyl-morpholine. A preferred base is imidazole. Suitable reaction inert solvents include dimethylacetamide, tetrahydrofuran, dimethylformamide, methylene chloride and chloroform. A preferred solvent is dimethylformamide. Silylation reactions are described in E. J. Corey and J. O. Link [J. Organic Chemistry, 56, 443 (1991)] and P. R. Brodfuehrer et al. [Organic Process Research and Development, 1, 176 (1997)].
Alternatively, a compound of Formula XIV wherein R 2 is tetrahydropyranyl is obtained by reaction of a compound of Formula XIII with dihydropyran in a reaction inert solvent such as methylene chloride in the presence of an acid catalyst such as toluenesulfonic acid. ##STR48##
When the compounds of Formula XIII are organosulfonyloxy derivatives, said compounds may be prepared by reacting an appropriate compound of Formula XVII with an organosulfonyl chloride in the presence of a suitable base. Suitable bases which may be used to effect this transformation include the lower trialkylamines, pyridine and pyridine derivatives. Preferred bases within those groups include but are not limited to triethylamine, diisopropylethylamine, pyridine, 2,4,6-collidine and 2,6-lutidine. Pyridine is the most preferred base. Suitable organosulfonyl chlorides include methanesulfonyl chloride, p-nitrobenzenesulfonyl chloride, m-nitrobenzenesulfonyl chloride, p-toluenesulfonyl chloride and benzenesulfonyl chloride. A generally preferred organosulfonyl chloride derivative is p-toluenesulfonyl chloride. The reaction is conveniently conducted by stirring the desired substrate compound of Formula XVII together with the appropriate organosulfonyl chloride in a reaction inert solvent at a temperature of about 20° C. to about 50° C. It is preferred that the solvent is a polar solvent such as an ether derivative including but not limited to tetrahydrofuran, dioxane and dimethoxyethane; chlorinated hydrocarbons including but not limited to carbon tetrachloride, chloroform and methylene chloride; aromatic hydrocarbons including but not limited to benzene, toluene and xylene;
dimethylformamide; N-methyl-2-pyrrolidinone; dimethylacetamide; pyridine or any mixture of these solvents. Generally the most preferred solvent is pyridine.
To prepare the compounds of Formula XIII wherein R 1 is halo, the 2-organosulfonyloxy derivatives of the compound of Formula XIII or mixtures thereof containing 2-chloro derivatives of the Formula XIII are reacted with a halogenating agent in a reaction inert solvent. The reaction may be conducted conveniently at a temperature of from about 25° C. to the reflux temperature of the solvent utilized. It is generally preferred to conduct the reaction at the reflux temperature. Halogenating agents are compounds which are capable of transferring a halo group to an organic substrate, said substrate having a leaving group which can be displaced by said halide ion. Preferred halogenating agents are lithium halides. A particularly preferred chlorinating agent used to prepare the compounds of formula XVII is lithium chloride. A preferred solvent is ethanol.
The preparation of the compounds of Formula XVII and the compound of Formula VII has been described in International Patent Publication Number WO98/21184. Those compounds may be prepared as set forth in the preparation section below. Specifically, the compound of Formula XVII wherein R 3 is acetyl is prepared as set forth in Preparation Two below. For example, the compound of Formula VII wherein R 4 is methyl is prepared as set forth in Preparation Seven below. Other compounds of Formula VII may be prepared by methods analogous thereto.
It will be appreciated by those skilled in the art that the compound of Formula IX contains two basic nitrogen atoms and that under certain conditions used to precipitate the compound of Formula IX as a salt, e.g., where more than two equivalents of add are used, the compound of Formula IX may form a dihydrochloride salt. Said dihydrochloride salt can be used in subsequent steps in the processes of this invention and is within the scope of the processes of this invention.
It will be appreciated by those skilled in the art that the compounds of Formulas XII, XIII, XIV, XV and XVI contain at least one chiral center. Accordingly, those compounds may exist in, and be isolated in, optically active and racemic forms. Some compounds may exhibit polymorphism. It is to be understood that the present invention encompasses any racemic, optically active, polymorphic or stereoisomeric form, or any, mixture thereof, which form possesses properties useful in the treatment of the diseases or conditions noted herein or useful as intermediates in the preparation of any compounds useful in the treatment of said diseases or conditions, it being well known in the art how to prepare optically active forms (for example, by resolution of the racemic form by recrystallization techniques, by synthesis from optically active starting materials, by chiral synthesis or by chromatographic separation using a chiral stationary phase) and how to determine efficacy for the treatment of said utilities. In general, (R)-stereochemistry is preferred at all chiral centers in the compounds disclosed in this invention.
Conventional methods and techniques of purification and separation known to those skilled in the art may be used to isolate the compounds of this invention. Such techniques include all types of chromatography, including but not limited to high performance liquid chromatography, column chromatography using common adsorbents such as silica gel, thin layer chromatography and the like; recrystallizaton; and differential (i.e., liquid--liquid) extraction techniques.
As used in the specification and appendant claims the following terms have the meanings described. The terms "alkyl", "alkoxy" and "alkanoyl" include both straight and branched chain radicals, but it is to be understood that references to individual radicals such as propyl or propoxy embrace only the straight chain radical unless reference is specifically made to for example isopropyl or isopropoxy, in which case the branched chain isomer is meant.
The term "halo", unless otherwise indicated, includes chloro, fluoro, bromo and iodo.
The term "suitable leaving group" includes a group which may be readily displaced by a nucleophile which has a greater affinity for the positively charged carbon atom to which said leaving group is attached than said leaving group. Preferred leaving groups are chloro and organosulfonyloxy groups. Particularly preferred leaving groups are organosulfonyloxy groups. Particularly preferred organosulfonyloxy groups are methanesulfonyloxy, benzenesulfonyloxy, p-toluenesulfonyloxy, p-nitobenzenesulfonyloxy or m-nitrobenzenesulfonyloxy.
The term "suitable base" includes a base which, when added to the reaction mixture in which said base is to operate, increases the pH of the reaction mixture or operates on the substrate to remove a proton from said substrate or otherwise render said substrate susceptible to electrophilic attack without affecting other potentially reactive functional groups in said substrate.
The term "silyl protecting group" means a silicone moiety which is attached to an oxygen atom of the substrate forming a silyloxy compound, wherein the bond between the silicone and oxygen atoms is easily cleaved under standard deprotecting conditions. Preferred silylating agents are silyl chlorides.
The expressions "reaction inert solvent" and "inert solvent" refer to a solvent which does not interact with starting materials, reagents, intermediates or products in a manner which adversely affects the yield of the desired product. Further, the term reaction inert solvent may refer to a single, dual or multiple solvent system depending upon the nature of the reaction and the solubility of the substrate and/or reagents being disclosed.
The expression "pharmaceutically-acceptable salts" is intended to include but not be limited to such salts as the hydrochloride, hydrobromide, sulfate, hydrogen sulfate, phosphate, hydrogen phosphate, dihydrogenphosphate, acetate, succinate, citrate, methanesulfonate (mesylate) and p-toluenesulfonate (tosylate) salts.
The acid addition salts of the compounds of the present invention are readily prepared by reacting the base forms of the compounds disclosed in this invention with an appropriate acid. When the salt is of a monobasic acid (e.g., the hydrochloride, the hydrobromide, the p-toluenesulfonate, the acetate) the hydrogen form of a dibasic add (e.g., the hydrogen sulfate, the succinate) or the dihydrogen form of a tribasic add (e.g., the dihydrogen phosphate, the citrate), at least one molar equivalent and usually a molar excess of the acid is employed. However, when such salts as the sulfate, the hemisuccinate, the hydrogen phosphate or the phosphate are desired, the appropriate and exact chemical equivalents of acid will generally be used. The free base and the acid are conveniently combined in a co-solvent from which the desired salt precipitates or can otherwise be isolated by concentration and addition of a non-solvent or by simple addition of a non-solvent without concentration or by lyophilization of an aqueous solution of said salt.
If not commercially available, the necessary starting materials for the chemical reactions disclosed herein may be prepared by procedures which may be selected from standard organic chemical techniques found in standard organic chemistry textbook references. The techniques found therein may be applied directly to the synthesis of known starting materials described directly in that reference or may be applied by analogy to compounds having similar functionality to achieve predictable results.
In this specification the following abbreviations and acronyms are used with the following meanings:
Ts, meaning toluenesulfonyl;
TBDMS, meaning t-butyldimethylsilyl;
THF, meaning tetrahydrofuran;
DMF, meaning N,N-dimethylformamide;
NMP, meaning N-methyl-2-pyrrolidinone;
DMAC, meaning N,N-dimethylacetamide;
DMSO, meaning dimethylsulfoxide; and
TFA, meaning trifluoroacefic acid.
The present invention is illustrated by the following Examples. However, it should be understood that the invention is not limited to the specific details of these Examples. ##STR49## Toluene-4-sulfonic Acid 2(R)-(6-acetylamino-pyridin-3-yl)-2-(tert-butyl-dimethyl-silyloxy)-ethyl Ester.
Toluene-4-sulfonic acid 2(R)-(6-acetylamino-pyridin-3-yl)-2-(hydroxy)ethyl ester (the compound of Preparation Three, 1000 g, 2.85 moles) and imidazole (388.5 g, 5.7 moles) were dissolved in dry dimethylformamide (1 L) with cooling in an ice water bath under a nitrogen atmosphere. To the resulting amber solution was added t-butyldimethylchlorosilane (559 g, 3.7 moles) over a 10 minute period. The reaction temperature slowly rose to 35° C. over the next 40 minutes. The mixture was stirred at room temperature for 18 hours. Ethyl acetate (8 L) and water (4 L) were added to the reaction. The layers were separated and the ethyl acetate layer was washed 1× water (4 L). The organic layer was separated and concentrated by distillation under vacuum to less than 2 L volume at which point a slurry had formed. Hexanes (4 L) were added to the warm slurry and mixture was cooled to 5° C. and stirred for 3 hours. The crystalline product was isolated by filtration and washed with cold hexanes. The yield of white solids after vacuum drying was 1059 g, 80%. mp 121-124° C. [a] D -48.9 (c=1.01, MeOH). 1 NMR (400 MHz, DMSO-d 6 ) δ=10.42 (s, 1), 8.16 (s, 1), 7.93 (d, 1, 8.7 Hz), 7.7-7.59 (m, 3), 7.37 (d, 2), 4.93 (t, 1), 4.00 (s, 2), 3.28 (s, 1), 2.35 (s, 3), 2.03 (s, 3), 0.73 (s, 9), -0.04 (s, 3), -0.19 (s, 3). ##STR50## 2-(4-{2-[2-(6-Acetylamino-pyridin-3-yl)-2(R)-(t-butyldimethylsilyloxy)-ethylamino]-ethoxy}phenyl)-N-methyl-acetamide.
Toluene-4-sulfonic acid 2-(6-acetylamino-pyridin-3-yl)-2(R)-(tert-butyl-dimethyl-silyloxy)-ethyl ester (the compound of Example One, 200 g, 0.43 moles) and 4-(2-aminoethoxy)-N-methylbenzene acetamide (179.1 g, 0.86 moles) were combined in dry dimethylsulfoxide (130 ml). To this mixture under nitrogen was added N,N-diisopropylethylamine (55.6 g, 0.43 moles) in one portion. The reaction was heated to 80° C. during which it became an amber solution. The reaction was heated at this temperature for 17 hours. The reaction mixture was cooled to 35° C. and water (784 ml) was added followed by ethyl acetate (874 ml). This was stirred for 10 min, then the layers separated and the organic layer was washed twice more with water (200 ml each). The organic layer was dried over sodium sulfate, filtered and concentrated to give crude 2-(4-{2-[2-(6-acetylamino-pyridin-3-yl)-2(R)-(t-butyldimethylsilyloxy)ethylamino]-ethoxy}phenyl)-N-methyl-acetamide. A purified sample was obtained by column chromatography (silica gel, 5% MeOH/CHCl 3 ). [a] D -52.3 (c=1.04, CHCl 3 ). NMR (300 MHz, CDCl 3 ) δ=8.64 (s, 1), 8.23 (s, 1), 8.17 (d, 1), 7.69 (d, 1), 7.14 (d, 2), 6.86 (d, 2), 5.48 (bs, 1), 4.86 (m, 1), 4.06 (t, 2), 3.50 (s, 2), 3.01 (t, 2), 2.90 (t, 1), 2.74 (m, 4), 2.20 (s, 3), 0.90 (s, 9), 0.1 (s, 3), -0.4 (s, 3). Mass spectrum: m/e: 500 (M + ). ##STR51## 2-(4-{2-[2-(6-Acetylamino-pyridin-3-yl)-2(R)-hydroxy-ethylamino]-ethoxy}-phenyl)-N-methyl-acetamide hydrochloride.
The ethyl acetate solution from Example 2 was concentrated in vacuo without drying to provide the crude oil. This was dissolved in toluene (336 ml) and reconcentrated to remove ethyl acetate and the resulting oil was dissolved in dry tetrahydrofuran (1400 ml). The THF solution was stirred under nitrogen while a solution of 1M tetrabutylammonium fluoride in THF was added over 15 min. The reaction was stirred overnight at room temperature. The mixture was cooled to less than 10° C. and treated with ethanolic hydrochloric acid prepared by careful addition of acetyl chloride (91.75 ml) to ethanol (250 ml) with cooling in a separate reactor. After the hydrochloric acid addition, the slurry was stirred for 1 hr at less than 10° C. The resulting solids were collected by filtration under nitrogen to prevent the uptake of moisture and washed with THF (500 ml), followed by isopropyl ether (2×1 L). The solids were pulled dry and transferred to a clean flask and stirred with acetonitrile (1792 ml) at room temperature overnight. The solids were collected by filtration and washed with acetonitrile (1 L) followed by isopropyl ether (2×500 ml). The white solid was dried in vacuo at 45° C. to 50° C. to provide the title compound as its hydrochloride, 164 g, 83% yield. ##STR52## (4-{2-[2-(6-Amino-pyridin-3-yl)-2(R)-hydroxy-ethylamino]-ethoxy}-phenyl)-acetic Acid.
2-(4-{2-[2-(6-Acetylamino-pyridin-3-yl)-2(R)-hydroxy-ethylamino]-ethoxy}-phenyl)-N-methyl-acetamide hydrochloride (the compound of Example Three, 50 g, 0.11 moles) was dissolved in water (236 ml) and stirred while a solution of sodium hydroxide (21.8 g, 0.545 moles) in water (98 ml) was added over a ten min period. The reaction was heated to 98-100° C. on a steam bath and held at that temperature for 24 hr. Darco® G-60 (5 g) was added to the warm reaction which was stirred for 30 min, then filtered through Celite® to remove the Darco®. The filter cake was washed with hot water (50 ml). The aqueous filtrate was cooled to 10° C. and the pH was adjusted with conc. HCl (about 19 ml) from pH 12.5 to pH 7.0. The resulting slurry was stirred for 3 hr. The solids were collected by filtration and washed well with water followed by THF (100 ml). The crude product was dried in vacuo to provide 26.4 g, a 73% yield. The crude solids were purified by an acid/base process. The material (50 g, 0.15 moles) isolated as described from the basic hydrolysis was slurried in water (200 ml). To the slurry was added conc. HCl (24.9 ml, 0.3 moles) to get a hazy solution. The solution was filtered through Celite® to remove the haze and the cake was washed with water. The pH of the filtrate was adjusted with 10% NaOH to pH 8.0 and stirred overnight. In the morning, the pH had drifted to 6.7. More NaOH solution was added to achieve a stable pH of 7.0. A total of about 135 ml of 10% NaOH was used. The overnight stirring before the final adjusting of the pH was instituted due to the buffering capacity of the compound and in particular the slow conversion of the highly crystalline mono-hydrochloride salt to the zwitterion. The solids were collected by filtration and redissolved in water (250 ml) with NaOH (6 g, 0.15 moles). The resulting hazy solution was filtered through Celite®. The filtrate was adjusted to pH 7.0 with 3N HCl (about 44 ml) to give the purified zwifteron which was filtered off and dried in vacuo at 45° C. The yield for the purification was 71.6%, 35.8 g; mp 207-208° C. (dec.) NMR (300 MHz, D 2 O+DCl) δ=7.93 (d, 1), 7.86 (s, 1), 7.28 (d, 2), 7.05 (d, 1), 7.00 (d, 2), 5.10 (dd, 1), 4.34 (t, 2), 3.69 (s, 2), 3.60 (t, 2), 3.40 (m, 2). ##STR53## (4-{2-[2-(6-Amino-pyridin)-3-yl)-2(R)-hydroxy-ethylamino]-ethoxy}-phenyl)-acetic Acid.
2-(4-{2-[2-(6-Acetylamino-pyridin-3-yl)-2(R)-(t-butyldimethylsilyloxy)-ethylamino]-ethoxy}-phenyl)-N-methyl-acetamide (the compound of Example Two, 19.6 g, 39 mmoles in toluene (60 ml)) was combined with water (196 ml) and evaporated to remove most of the toluene in vacuo. To the slurry of oily silyl ether and water was added sodium hydroxide (8.7 g, 21.8 mmoles). The mixture was heated to reflux and the residual toluene was removed and the volume reduced to about 120 ml. After the reaction was judged complete by thin layer chromatography (silica gel, 10% methanol in chloroform as eluant), Darco® G-60 (4.5 g) was added and the reaction was cooled to room temperature. The slurry was filtered through Celite® to remove the silicon containing by-products which precipitated from the aqueous mixture. The filtrate was acidified with conc. HCl to pH 7.0 to precipitate the crude product. The product was purified by first dissolving in aqueous HCl at pH 1-2 and filtering off insolubles. The product was precipitated by addition of NaOH to pH 7.0. This was followed by the basic dissolution--filtration and crystallization at pH 7.0. Ten grams of crude amino acid from this procedure gave 4.13 g of purified product, 41.3% recovery. If further purification was needed the material was recrystallized from hot water or dimethylformamide. This was identical with that from Example 4. ##STR54## (4-{2-[2-(6-Amino-pyridin-3-yl)-2(R)-hydroxy-ethylamino]-ethoxy}phenyl)-acetic Acid Mono-hydrochloride Salt.
(4-{2-[2-(6-Amino-pyridin-3-yl)-2(R)-hydroxy-ethylamino]-ethoxy}-phenyl)-acetic acid (prepared according to the procedure set forth in Example Five, 1035 g, 3.123 moles) was suspended in water (5.175 L) at room temperature. Conc. hydrochloric acid (36%, 258 ml, 3.123 moles) was added over a 5-10 minute period which caused a slight rise in the temperature. This caused partial dissolution of the zwitterion and precipitation of the mono-hydrochloride salt. After stirring overnight, the solids were collected, washed with tetrahydrofuran and dried to give the title salt, 988 g, 86.1% yield. The hydrochloride salt (983 g, 2.67 moles) was suspended in 9.83 liters of water. The pH was adjusted to about pH 9.1 with 10% sodium hydroxide solution (1 liter) to give a solution. The pH was then adjusted to about 7.0 with conc. HCl. The resulting precipitate of the zwitterion form of the compound was collected by filtraton, washed with water and tetrahydrofuran. After drying in vacuo, the compound weighed 823 g, 78% yield. The spectral properties were identical with those set forth in Example Five.
This procedure is useful for the removal of trace impurities from the crude product which co-precipitate with the zwitterion.
EXAMPLE 7
This example illustrates formulations of a compound of Formula XII.
Film coated tablets containing 25, 100, and 200 mg of Compound XII, as polymorph Form B, were prepared. The composition of the tablets is given in the following table
______________________________________ mg/Tablet mg/Tablet mg/TabletComponent (25 mgA) (100 mgA) (200 mgA)______________________________________1. Formula XII 25 100 2002. Microcrystalline 200 367.5 267.5Cellulose(Avicel ® PH200)3. Microcrystalline 245 -- --Cellulose(Avicel ® PH200)4. Sodium 25 25 25Croscarmellose(Ac-Di-Sol ®)5. Magnesium 2.5 5.0 5.0Stearate6. Magnesium 2.5 2.5 2.5Stearate7. White Opadry ® I 15 15 15(YS-1-18027-A)8. Clear Opadry ® I 1.25 1.25 1.25(YS-1-19025-A)Total Weight (core) 500 mg 500 mg 500 mgTotal Weight (tablet) 516.25 mg 516.25 mg 516.25 mg______________________________________
The tablets were made by screening each of the compound of formula XII, microcrystalline cellulose (item 2), and sodium croscarmellose (item 4) through a 40 mesh sieve, followed by mixing and blending the mixture for 10 minutes in a S/S twin shell V-blender. Any remaining microcrystalline cellulose (item 3) was added at this point and blending was continued for an additional 10 minutes. Magnesium stearate was added and blending continued for 5 minutes. The resulting mixture was then roller compacted using a roller pressure of 40 kg/cm 3 and granulated in a rotary granulator with #20 mesh and an auger speed of 16 rpm. Blending was then continued for 10 minutes. Additional magnesium stearate (item 6) was then added and blending continued for 5 minutes. Tablets were then made on a Killian T-100 tablet press (30,000 tablets/hr) using 0.25"×0.5625" capsular tooling. The tablets were then film coated in a HCT30 coating pan using an aqueous Opadry®I YS-1-18027-A (white) (item 7) spray solution at a concentration of 15%, and employing the following conditions: pan speed: 20 rpm; inlet temperature: 58° C.; Outlet temperature: 40° C.; Spray rate: 5.5-5.8 g/min. An additional clear film coat of Opadry®YS-1-19025-A (item 8) was then applied (5% aqueous concentration) under the following conditions: pan speed: 20 rpm; inlet temperature: 60° C.; Outlet temperature: 40° C.; Spray rate: 5.7-5.9 g/min. ##STR55## N-(5-Vinyl-pyridin-2-yl)-acetamide.
A solution of N-(5-bromo-pyridin-2-yl)-acetamide (4.30 g, 20 mmol) in acetonitrile (15 ml) and triethylamine (5.04 ml) was treated with palladium acetate (45 mg, 0.2 mmol) and triotolylphosphine (203 mg, 0.66 mmol). The mixture was placed in a pressure reactor under 50 psig of ethylene pressure and heated at 85° C. for 66 hours. The reaction mixture was cooled, vented, and partitioned between phosphate buffer (0.1 M, pH 6.6) and ethyl acetate. The aqueous phase was extracted with ethyl acetate twice more. The combined ethyl acetate extracts were washed with additional phosphate buffer, brine and dried over sodium sulfate. The extracts were filtered and evaporated to afford 2.06 g (63%) of the title product as a flaky crystalline residue. Recrystallization from ethyl acetate/cydohexane gave colorless flakes. mp 120-121° C. 1H NMR (CDCl 3 ): δ=8.55 (br, 1 H); 8.24 (d, 1 H); 8.15 (d, 1 H); 7.76 (d of d, 1H); 6.64 (d of d, 1 H); 5.73 (d, 1 H); 5.28 (d, 1 H); 2.19 (s, 3 H). MS (Cl): m/z=163 (M+H + ). ##STR56## (R)-N-(5-(1,2-Dihydroxy-ethyl)-pyridin-2-yl)-acetamide.
A suspension of AD-Mix-B® (56.33 g) in water (200 ml) and t-butanol (200 ml) was cooled to 5° C. and N-(5-vinyl-pyridin-2-yl)-acetamide (prepared according to the procedure set forth in Preparation One, 6.52 g, 40.2 mmol) was added followed by 2-propanol (400 ml). The mixture was stirred at 5° C. for 12 hours and then at 20° C. for 12 hours. The reaction mixture was then treated with sodium sulfite (60.4 g), stirred for 30 minutes and then diluted with 500 ml of 2-propanol and stirred for an additional one hour. The mixture was filtered and the alcoholic phase was separated and evaporated to dryness. The residue was slurried in 500 ml of 2-propanol and evaporated again. The residue was dried to afford 6.35 g (80%) of the title product as colorless crystals. The crystals were recrystallized by dissolving in hot glacial acetic acid, diluting 7-fold with 2-propanol, cooling and seeding to give the title product as crystals. mp 184-185° C. 1 H NMR (dmso-d 6 ): δ=8.22 (d, 1 H); 7.99 (d, 1 H); 7.68 (d of d, 1 H); 4.52 (t, 1 H); 3.44 (m, 2 H); 2.07 (s, 3 H). MS (Cl): m/z=197 (M+H + ). Optical Rotation: -4.52° (c=0.05, acetic acid). Analysis: Calculated for C 9 H 12 N 2 O 3 : C, 55.09%; H,6.17%; N, 14.28%. Found: C, 55.43%; H, 5.97%; N,13.96%. ##STR57## (R)-Toluene-4-sulfonic acid 2-(6-acetylamino-pyridin-3-yl)-2-hydroxy-ethyl Ester.
A slurry of (R)-N-(5-(1,2-dihydroxy-ethyl)-pyridin-2-yl)-acetamide (prepared according to the procedure set forth in Preparation Two, 71.2 g, 362 mmol) in anhydrous pyridine (362 ml) was cooled to 5° C. and treated with p-toluenesulfonyl chloride (69.18 g, 362 mmol) in one portion. The reaction mixture was stirred at 5° C. for 20 minutes, then the cooling bath was removed and the mixture was stirred at ambient temperature for two hours. The mixture was then concentrated, dissolved in 30 ml of methanol, concentrated and dissolved in toluene (300 ml) and concentrated again. The residue was treated again with methanol and toluene, then the residue was dissolved in ethyl acetate and washed sequentially with half-saturated brine with the addition of sodium carbonate, brine and dried over sodium sulfate. The filtrate was evaporated to afford 102.2 g (80%) of the title product as light buff crystals. Recrystallization from ethanol-cyclohexane afforded the title product as colorless crystals. mp 124-126° C. 1 H NMR (dmso-d 6 ): δ=10.5 (br, 1 H); 8.21 (d, 1 H); 7.94 (d, 1 H); 7.68 (d, 2 H); 7.51 (d of d, 1 H); 7.41 (d, 1 H); 5.87 (d, 1 H); 4.76 (d of d, 1 H); 4.05 (d, 2 H); 2.41 (s, 3 H); 2.10 (s, 3 H). MS (Cl): m/z=351 (M+H + ). [a] D -36.2 (c=1.19, acetone). Analysis: Calculated for C 16 H 18 N 2 O 5 S: C, 54.85%; H, 5.18%; N, 7.99%. Found: C, 54.91%; H, 5.34%; N, 8.06%. ##STR58## N-Methyl 4-hydroxyphenylacetamide.
Monomethylamine (22.43 kg, 722.15 mol, 6 eq.) was added over a 7-hour period to a solution of methyl-4-hydroxyphenylacetate (20.0 kg, 120.35 mol, 1.0 eq.) in methanol (120 L) and stirred overnight at room temperature. Methanol was then displaced under vacuum with ethyl acetate. The resulting slurry (about 75.7 L) was stirred at +10° C. for 1 hour, then filtered and dried under vacuum at 45° C. to yield of the title compound (18.68 kg, 94% of theory). mp 124-125° C. NMR (300 MHz, d 6 -DMSO): δ=9.26 (s, 1H), 8.00-7.65 (br s, 1H), 7.21-6.90 (m, 2H), 6.86-6.55 (m, 2H), 3.26 (s, 2H), 2.75-2.45 (m, 3H). ##STR59## N-Benzyloxycarbonyl-2-aminoethanol.
Benzylchloroformate (44.95 kg, 263.5 mol, 1.0 eq.) was added over a 2 hour period at room temperature to a solution of ethanolamine (16.1 kg, 263.5 mol, 1.0 eq.) in water (129 L). After stirring for 30 minutes, this was added to a cold (5-10° C.) solution of NaHCO 3 (33.2 kg, 395.25 mol, 1.5 eq) in H 2 O (330 L) over a 30 min period and then allowed to stir at room temperature overnight. Ethyl acetate (83 L) was added, the layers separated, and the aqueous layer extracted again with 83 L of ethyl acetate. The combined organic extracts were concentrated under vacuum to a volume of 38 L, and the remainder displaced with isopropyl ether. The resulting slurry was stirred and cooled to 10° C. for 2 hours, then filtered. The solids were washed with isopropyl ether and vacuum dried to give the title compound (39.1 kg, 71.1%). mp 61-63° C. NMR (300 MHz, d 6 -DMSO): δ=7.50-7.37 (m, 5H), 7.37-7.16 (m, 1H), 5.05 (s, 2H), 4.70-4.63 (m, 1H), 3.46-3.37 (m, 2H), 3.13-3.03 (m, 2H). ##STR60## Methyl 4-(2-(N-benzyloxycarbonylamino)ethoxy)phenylacetamide.
The title compound of Preparation Four (18.68 kg, 113.14 mol. 1.0 eq.) and the title compound of Preparation Five (33.13 kg, 169.75 mol, 1.5 eq.) were dissolved in THF (151 L). Triphenylphosphine (44.5 kg, 169.75 mol, 1.5 eq.) was added and the mixture cooled to -5° C. Dilsopropyl azodicarboxylate (34.3 kg, 169.75 mol, 1.5 eq.) was added over an 8 hour period, and the reaction allowed to warm to room temperature overnight. Ethyl acetate (75 L) was added to the resulting white slurry, stirring was continued for 6 hours, and the solids filtered off and dried to yield crude title compound. (29.6 kg, 76.5% of theory, mp 131-133° C.). The crude product was slurried in ethyl acetate (148 L) for 3 hours at 10° C., then filtered, washed with 14 gal 10° C. ethyl acetate, and vacuum dried to yield the title compound (26.1 kg, 88.2 % recovery, 67.5% overall). mp 134-136° C. NMR (300 MHz, d 6 -DMSO): δ=7.98-7.82 (m, 1H), 7.58-7.49 (m, 1H), 7.42-7.28 (m, 5H), 7.20-7.10 (d, 2H), 6.90-6.80 (d, 2H), 5.06 (s, 2H), 4.02-3.93 (m, 2H), 3.47-3.29 (m, 4H), 2.62-2.54 (d, 3H). ##STR61## Methyl 4-(2-aminoethoxy)phenylacetamide.
The title compound of Preparation Six (18.4 kg, 53.73 mol) and 1.84 kg 10% palladium on carbon (50% H 2 O wet) were suspended in 276 L of methanol under nitrogen, and the reaction vessel pressurized to 50 psig with hydrogen gas. This H 2 pressure was maintained by additional charges of H 2 until there was no further uptake of H 2 (approx. 20 hours) and the reaction was complete by thin layer chromatography. After purging the vessel with N 2 , the mixture was heated to 45° C. and filtered at this temperature through Celite®. The solvent was displaced with toluene until a final volume of 30 L was achieved. After cooling to 5° C. the resulting solids were filtered off, washed with cold toluene, and vacuum dried to give the title compound (9.95 kg, 88.9% of theory). NMR (300 MHz, d 6 -DMSO): δ=7.99-7.57 (m, 1H), 7.20-7.10 (d, 2H), 6.90-6.80 (d, 2H), 3.93-3.83 (m, 2H), 3.30 (s, 2H), 3.00-2.62 (m, 4H), 2.57 (d, 2H). | The instant invention relates to intermediates of Formula II, ##STR1## wherein R 1 , R 2 and R 3 are as defined in the specification, and to processes for preparing such intermediates. This invention also relates to processes for preparing compounds of Formula III, ##STR2## and enantiomers thereof, wherein R 2 , R 3 and R 4 are as defined in the specification. Compounds of Formula II and Formula III are intermediates in the preparation of a potent β 3 adrenergic receptor agonist. The instant invention also relates to processes for preparing the β 3 adrenergic receptor agonist using the compounds of Formula II and Formula III. | 2 |
The present invention relates to a wear resistant compound body comprising a metallic basic material and a wear resistant zone which contains hard substances and/or hard metal particles in addition to the basic material. The present invention further relates to a method for manufacturing such a wear resistant compound body.
BACKGROUND OF THE INVENTION
Compound bodies of the above-mentioned type include parts subject to wear which are armored by welded-on alloys. The welded-on alloys include hard substance or hard metal particles which are enclosed by a welding electrode jacket. When welded onto a metallic substrate, the electrode jacket forms a metal matrix in which the hard substance and hard metal particles are embedded. The metallic substrate and the electrode jacket may be made of the same alloy. The welded-on material forms the wear resistant zone of the part subject to wear. However, the use of welded-on alloys is limited as only thin layers adhere tightly enough to the metal substrate and such thin layers are destroyed relatively quickly.
U.S. Pat. No. 4,365,997 discloses a wear resistant compound body of the above-mentioned type in which the basic material includes 1 to 4 weight percent carbon, 0.3 to 0.6 weight percent silicon, 0.5 to 1.5 weight percent manganese, 0.8 to 2.8 weight percent vanadium, 0.5 to 1.5 weight percent chromium, 2 to 10 weight percent tungsten, 0.01 weight percent aluminum, the remainder being iron, wherein the initial ratio of hard substances and hard metals, respectively, to the basic material is 1:5, with the hard substance and/or hard metal particles having a grain size of from 0.5 to 5 mm. This compound body is produced by adding hard metal and/or hard substance grains, in a size range of from 0.5 to 5 mm, to a liquid metal alloy which has been melted and poured into a mold, whereby the hard metal and hard substance particles descend in the melt before the alloy solidifies. The compound body of U.S. Pat. No. 4,365,997 has the drawback that its basic material is difficult to machine and that, therefore, it is practically impossible to produce a region free of hard substance and/or hard metal from the basic material. Rather, the compound body known from U.S. Pat. No. 4,365,997 must be soldered or welded onto a metallic substrate if it is to be used in a wear resistant workpiece or machine part. An additional drawback of this procedure has been found, as the alloy of which the basic material of the compound body according to U.S. Pat. No. 4,365,997 is comprised is difficult to weld.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a compound body of the above-mentioned type whose region free of hard metal or hard substances can easily be machined and welded to quickly and reliably connect the compound body with other metal parts.
This means that a basic material must be found which can be machined and welded and which has a sufficiently low melting point to be suitable as a metal matrix for embedding hard substance and/or hard metal particles. It is another object of the present invention to provide a method for producing the compound body.
To achieve these objects and in view of its purpose, the present invention provides an alloy composition suitable for use in a compound body which is easily machined and welded, and which securely embeds hard substance and hard metal particles. Also provided is a method for making the compound body by introducing the hard substance or hard metal particles into the molten alloy while in a mold.
DESCRIPTION OF THE DRAWING
The FIGURE is a cross-sectional view of a compound body according to the invention in the form of a hammer mill beater.
DETAILED DESCRIPTION OF THE INVENTION
We have discovered that the objectives of the invention are achieved using a basic material comprising:
0.001 to 1.5 weight percent carbon,
0.5 to 8 weight percent boron,
1 to 8 weight percent niobium,
0 to 30 weight percent nickel,
0 to 10 weight percent manganese,
0.2 to 6 weight percent chromium,
0 to 6 weight percent vanadium,
0 to 5 weight percent molybdenum,
0 to 5 weight percent silicon, remainder iron;
with hard substance and hard metal particles that have a diameter of from 0.1 to 20 mm, wherein the proportion of hard substance and hard metal particles in the wear resistant zone lies between 25 and 95 volume percent.
We have found that an alloy of the above composition has a low melting point range, below 1400° C., and that this alloy can be machined with surprising ease, is easily welded, and firmly embeds the hard substance and hard metal particles. Therefore, this basic material makes it possible to produce compound bodies having large dimensions which present an easily welded and easily machined metallic region free of hard substances and hard metals and a wear resistant zone containing the hard substances and hard metals, wherein the wear resistant zone is fully integrated.
The compound body according to the present invention has particularly advantageous characteristics and, in particular, is easily welded, if the basic material is composed of:
0.05 to 0.5 weight percent carbon,
0.5 to 2 weight percent boron,
2 to 4 weight percent niobium,
2 to 4 weight percent chromium,
10 to 20 weight percent nickel,
4 to 8 weight percent manganese,
1 to 3 weight percent vanadium,
0 to 2 weight percent molybdenum,
1 to 3 weight percent silicon, the remainder being iron.
According to the present invention, in the preferred embodiment hard substance particles include WC and/or W 2 C and the hard metal particles may be comprised of broken-up hard metal scrap. Hard substances in the sense of the present invention are hard carbides, nitrides, borides, and silicides.
Predominantly are used high density carbides like as WC, W 2 C and Mo 2 C or the above mentioned carbides mixed with other carbides, nitrides, borides and silicides. These hard substances should have a density greater than 7,5 g/cm 3 . The hardness values are in the range from 1000 to 2000 HV 30. Hard metals in the sense of the present invention are alloys comprising one or a plurality of hard substances, particularly carbides, and a binder metal or alloy comprising iron, cobalt and/or nickel. Hard metal scrap is available as a waste product from the manufacture and use of hard metal products and can be recycled to particular advantage when used in the present invention.
Predominantly are used cobalt bound hard metals for example with the following composition: 4-12 weight % Co, 2-31 weight % TiC+TaC+NbC, remainder WC with hardnesses between 1200 and 1750 HV 30. Hard metals scrap is a waste product in hard metal tool industry. This waste product is broken up and milled to the necessary grain sizes.
Particle sizes out of the range form 0,1 mm to 20 mm are selected in dependance upon the field of application the wear resistant parts are used. But in the most cases particle sizes between 0,5 and 2 mm are used.
According to the present invention it is provided that the proportion of the wear resistant zone in the compound body is between 2 and 50 volume percent. In particular in larger parts that are subject to wear it is advantageous to have only a relatively small portion of the compound body as a wear resistant zone, with the remainder being a metallic region which is free of hard substances and hard metals that can be machined and welded with ease.
The object of the present invention is further achieved by the provision of a process for manufacturing the compound body, wherein a metal melt comprising
0.001 to 1.5 weight percent carbon,
0.5 to 8 weight percent boron,
1 to 8 weight percent niobium,
0.2 to 6 weight percent chromium,
0 to 30 weight percent nickel,
0 to 10 weight percent manganese,
0 to 6 weight percent vanadium,
0 to 5 weight percent molybdenum,
0 to 5 weight percent silicon, the remainder being iron,
is poured into a ceramic mold and then hard substance and/or hard metal particles having a diameter of 0.1 to 20 mm are added to the liquid metal melt in such quantities that their percentage in the wear resistant zone lies between 25 and 95 volume percent. This process has the advantage that the metallic region and the wear resistant zone form a single body. Moreover, the hard substance and hard metal particles are firmly embedded in the metal matrix, a process facilitated by the fact that the hard substance particles are completely wet by the melt and the hard metal particles are fused with the melt when they sink into the metal melt and thus are firmly embedded in the metal matrix of the wear resistant zone which forms at the bottom of the mold.
The hard metal particles on their way through the melt to the bottom of the mold are fused on their surface to a depth of approximately 50 micron, so that after the solidification of the casting, in the wear resistant zone there exists a strong compound of the hard metal particles with about 1200 HV 30, the surface layer of the hard metal particles with about 650 HV 30 and the basic material (matrix alloy) between the hard metal particles with about 500 HV 30 hardness.
Hard substance and hard metal particles which have an irregular geometric shape are embedded in the metal matrix with a particularly firm bond. The process according to the present invention can be implemented particularly economically if the mold is comprised of bound mold sand.
According to the present invention, the hard substance and/or hard metal particles may be introduced by being uniformly dispersed on the surface of the metal melt, as above, or the hard substance and/or hard metal particles may be embedded in a plastic carrier that evaporates without residue and introduced into the mold before casting.
As carriers for hard metal particles are used polystyrene beads or polystyrene scrap particles with a diameter between 1 mm and 15 mm. The hard metal particles having a size from 0,1-20 mm and the polystyrene particles are bound with waterglass. The core produced in this way is then dried at about 120° C.
According to both variations of the process, the hard substance and hard metal particles descend to the bottom of the liquid metal melt and there form the wear resistant zone of the compound body. The descent of the hard substance and/or hard metal particles in the metal melt can be influenced in an advantageous manner by vibrating the mold during the introduction of the particles with a suitable commercial device to impart a vibratory movement to the mold.
Finally, the present invention provides that the compound body is used in the production of tools for the mineral, removal and/or comminution of coal, rock, minerals, earth, glass and refuse, since such tools are subjected to particularly extensive wear. Parts made with the present compound body may have different geometric shapes and sizes, and may be attached releasably or firmly to the respective machine tools. For example, the compound body according to the present invention can be processed, according to the present invention, into a weldable dredge tooth, a rock drill, a screw fastened beater for hammer mills or into a baffle plate for an impact pulverizer.
The subject matter of the present invention will now be described in greater detail with the aid of the following embodiment and the accompanying drawing.
EXAMPLE I
In order to produce a beater which is to be installed in a hammer mill and there fastened by means of screws--its dimensions being assumed to be 160×200×500 mm 3 --an alloy comprising
0.2 weight percent carbon,
1.5 weight percent silicon,
5 weight percent manganese,
2 weight percent chromium,
15 weight percent nickel,
3 weight percent niobium,
1 weight percent boron,
1 weight percent vanadium, the remainder being iron,
was poured into a ceramic mold of bound mold sand. Before casting, a core consisting of a mixture of polystyrene particles and hard metal particles, consisting of 12 weight % Co, 2 weight % TiC, remainder WC, having a particle diameter between 0,5 to 2 mm, bound with waterglass and dried at 120° C. was first introduced into the mold. Afterwards the melt was poured at a melting temperature of 1620° C. into the mold.
During the casting process, the plastic carrier evaporated without residue and the hard metal particles descended to the bottom of the 1620° C. metal melt to form a wear resistant zone in the lower portion of the cast compound body. This wear resistant zone occupies about 10 volume percent of the beater and has a hard metal content of about 80 volume percent.
FIG. 1 is a cross-sectional view of the beater comprising the hard metal free, metallic region 1 and the hard metal containing, wear resistant zone 2. After casting, bores 3 and 4 were made in metallic region 1 for fastening the beater to the hammer mill. In its individual regions, the beater has the following hardnesses.
metallic region HV30=240,
wear resistant zone HV30=450 to 550,
hard metal particles in the wear resistant zone HV30=1100.
A beater formed according to the present invention has been found very satisfactory in practice for the comminution of chalky sandstone.
EXAMPLE II
In order to produce a dredge tooth with a weight of 50 kg and a height of 700 mm, where the wear resistant zone in the bottom edge should be filled to a height of 150 mm with hard metal particles, an alloy comprising
0,1 weight percent carbon
1 weight percent silicon
8 weight percent manganese
3 weight percent chromium
10 weight percent nickel
2,5 weight percent niobium
0,5 weight percent boron
1 weight percent molybdenum
1,5 weight percent vanadium the remainder being iron
was poured into a ceramic mold of bound mold sand. Before casting, a core consisting of a mixture of polystyrene particles and hard metal particles, consisting of 11,5 weight % Co, 10 weight % TiC+TaC+NbC, remainder WC and having a particle diamater between 0,8 and 1,6 mm, bound with waterglass and dried at 120° C. was first introduced into the mold.
Afterwards the melt with a temperature of 1650° C. was poured into the mold. After solidification of the casting the dredge tooth has in its individual regions the following hardnesses.
(1) metallic region=280 HV 30
(2) wear resistant zone
(a) hard metal particles=1250 HV 30
(b) surface layer on the hard metal particles=600-800 HV 30
(c) basic material between the hard metal particles=580 HV 30
The metallic (hard metal-free) region is suitable for welding.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A wear resistant compound body is disclosed which is comprised of a metallic basic material and has a wear resistant zone which includes hard substance and/or hard metal particles in addition to the basic material. The basic material is composed of
0.001 to 1.5 weight percent carbon,
0.5 to 8 weight percent boron,
1 to 8 weight percent niobium,
0.2 to 6 weight percent chromium,
0 to 30 weight percent nickel,
0 to 10 weight percent manganese,
0 to 6 weight percent vanadium,
0 to 5 weight percent molybdenum,
0 to 5 weight percent silicon, the remainder being iron.
Also disclosed is a casting process for producing the compound body. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/053,307 entitled, “TELESCOPING SLIP JOINT,” which was filed on Sep. 22, 2014, and is hereby incorporated by reference in its entirety.
BACKGROUND
Hydrocarbon fluids such as oil and natural gas are obtained from a subterranean geologic formation, referred to as a reservoir, by drilling a well that penetrates the hydrocarbon-bearing formation. Once a wellbore is drilled, various forms of well completion components may be installed in order to control and enhance the efficiency of producing the various fluids from the reservoir.
SUMMARY
In an example embodiment, a slip joint assembly that is usable with a well includes first, second and third tubular housing sections; and first and second mandrels. The first tubular housing section is adapted to connect to a first tubing string segment; the second tubular housing section is adapted to connect to a second tubing string segment; the third tubular housing section disposed between the first and second tubular housing sections; the first mandrel forms a slidable connection with the first tubular housing section; and the second mandrel forms a slidable connection with the second tubular housing section.
In another example embodiment, a system that is usable with a well, includes a tubing string and a slip joint assembly, which is disposed in the tubing string to allow longitudinal expansion and contraction of the tubing string along a longitudinal axis of the assembly so that the string may change in length by up to a stroke of the assembly. The slip joint assembly includes a housing, a central portion, a first mandrel and a second mandrel. The first mandrel extends from the central portion into the housing in a first direction along the longitudinal axis to provide part of the stroke; and the second mandrel extends from the central portion into the housing in a second direction along the longitudinal axis to provide the remaining part of the stroke. The second direction is opposed to the first direction.
In yet another example embodiment, a technique that is usable with a well includes running a tubing string in the well and using a telescoping symmetrical slip joint in the tubing string to accommodate thermal expansion or contraction of tubing string material.
Other advantages and features will become apparent from the following drawings, description, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a well-based system according an example implementation.
FIG. 2 is a cross-sectional view of a symmetric telescoping slip joint assembly of the tubing string of FIG. 1 illustrating the assembly in a fully refracted state according to an example implantation.
FIG. 3 is a cross-sectional view of the symmetric telescoping slip joint assembly in a fully extended state according an example implementation.
FIG. 4 is a cross-sectional view of the telescoping slip joint assembly taken along line 4 - 4 of FIG. 2 according to an example implementation.
FIG. 5 is a flow diagram depicting a technique to accommodate thermal expansion and contraction in a tubing string according to an example implementation.
DETAILED DESCRIPTION
In the following description, numerous details are set forth to provide an understanding of the present disclosure. However, it will be understood by those skilled in the art that the embodiments of the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
In the specification and appended claims: the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”, “upper” and “lower”, “upwardly” and downwardly”, “upstream” and “downstream”; “above” and “below”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure.
FIG. 1 generally depicts a well-based system 100 , in accordance with example implementations. Referring to FIG. 1 , a tubing string 140 may be run downhole in a wellbore 120 for purposes for performing various downhole functions. For example, the tubing string 140 may be a test string, which is run downhole inside a wellbore 120 for purposes of performing formation tests, pressure tests, and so forth, downhole inside the well. In accordance with further implementations, the tubing string 140 may be run downhole for purposes other than testing.
For the example implementation that is depicted in FIG. 1 , the wellbore 120 is lined, or supported by, a casing string 130 . However, in accordance with further example implementations, the wellbore 120 may not be cased. Moreover, although FIG. 1 depicts a vertical wellbore 120 , the tubing string 140 may be deployed in a deviated or lateral wellbore.
Due to the well environment (downhole temperatures, downhole well fluids, fluids pumped downhole from the Earth surface, and so forth), the tubing string 140 may be subject to various temperature changes, which may, in turn, result in corresponding contraction and/or thermal expansion of the string 140 . The tubing string 140 may be secured in position at one or more locations along its length. In this manner, as depicted in FIG. 1 , the tubing string 140 may be secured in place at such locations as a downhole packer 144 , at a well head and/or blowout preventer (BOP) 150 , and so forth. Due the tubing string 140 being secured at such points, thermal expansion/contraction of the string 140 may result in tubing/equipment failure downhole.
For purposes of accommodating its expansion/contraction, the tubing string 140 may contain one or multiple slip joint assemblies, such as a symmetrical telescoping slip joint assembly 142 that is depicted in FIG. 1 . For the example implementation depicted in FIG. 1 , the slip joint assembly 142 connects an upper segment 140 - 1 of the tubing string 140 to a lower segment 140 - 2 of the string 142 .
In general, a slip joint assembly, or slip joint, is used in a downhole string for purposes of allowing the string to extend and retract to compensate for thermal expansion and contraction of the string. In this manner, the slip joint has a stroke, which is the difference in length of the slip joint between its fully extended and fully contracted positions. As an example, a given slip joint may have a stroke of five to ten feet. The slip joint may also one or multiple sealing elements, which are constructed to isolate the interior of the slip joint (i.e., the interior passageway of the string) from the annulus outside of the slip joint (and string).
The slip joint may be pressure balanced, which means that the slip joint is constructed to be independent of a pressure differential between the inside and outside (or annulus) of the string. In other words, for a pressure balanced slip joint, the pressure differential between the outer and inner pressures of the string does not cause the slip joint to longitudinally contract or expand during normal operations. To achieve the pressure balance, a conventional slip joint may have a relatively intricate arrangement of parts, with several components of the slip joint serving the purposes of maintaining the pressure balance (or pressure independence) of the slip joint.
In accordance with example implementations that are disclosed herein, the symmetric telescoping slip joint assembly 142 has a construction that reduces its overall length (as compared to conventional slip joints), for a given stroke. In accordance with example implementations, the slip joint assembly 142 may provide the same stroke as a conventional slip joint but have an overall length that is one half of the length of a conventional slip joint. More specifically, as described herein, the slip joint assembly 142 takes advantage of its symmetric design: an upper portion of the assembly 142 provides one half of the stroke; and a lower portion of the assembly 142 provides the other half of the stroke. Moreover, due to the symmetric geometry of the slip joint assembly 142 , the assembly 142 maintains a pressure balance between the interior of the assembly 142 and an annulus 143 of the assembly 142 by maintaining the same effective area (upon which the tubing and annulus pressures act) in opposing directions. Therefore, in accordance with example implementations, a change in the tubing-to-annulus pressure does not cause a change in the length of the slip joint assembly 142 .
FIG. 2 depicts the symmetrical telescoping slip joint assembly 142 , in accordance with example implementations. In particular, FIG. 2 depicts the slip joint assembly 142 in its fully refracted state. In general, the slip joint assembly 142 is symmetric about a plane 212 that longitudinally divides the assembly 142 into two telescoping portions: an upper telescoping portion 200 - 1 (called the “upper portion 200 - 1 ” herein); and a lower telescoping portion 200 - 2 (called the “lower portion 200 - 2 ” herein). In accordance with example implementations, the upper portion 200 - 1 is formed from components that are replicas of the components of the lower portion 200 - 2 . As such, the same reference numeral is used to refer to replica components in both portions 200 - 1 and 200 - 2 , with the suffix “ 1 ” being used to denote an actual component in the upper portion 200 - 1 and the suffix “ 2 ” being used to denote an actual component in the lower portion 200 - 2 . For example, example, the slip joint assembly 142 contains a tubular housing section 210 - 1 that is part of the upper portion 200 - 1 and a housing section 210 - 2 that is a replica of the housing section 210 - 1 and is part of the lower portion 200 - 2 . As depicted in FIG. 2 , the plane 212 bisects a tubular, central housing section 211 of the slip joint assembly 142 . Thus, the upper half of the housing section 211 is part of the upper portion 200 - 1 , and the lower half of the housing section 211 is part of the lower portion 200 - 2 .
The upper housing section 210 - 1 is concentric about a longitudinal axis 201 of the assembly 142 . The upper housing section 210 - 1 is disposed above the central housing section 211 and moves with respect to the central housing section 211 along the longitudinal axis 201 to provide a stroke (called “S 1 ” in FIG. 2 ) that is one half of the overall stroke for the assembly 142 . The upper housing section 210 - 1 is connected at its upper end to the upper segment 140 - 1 (see FIG. 1 ) of the tubing string 140 . In this manner, in accordance with example implementations, the upper end of the upper housing section 210 - 1 is connected to (as shown at reference numeral 240 - 1 ) to a tubular connector 204 (a female connector, for example), which, in turn couples the slip joint assembly 142 to the upper 140 - 1 segment of the tubing string 140 (see FIG. 1 ).
In a similar manner, a lower housing section 210 - 2 of the lower portion 200 - 2 of the slip joint assembly 142 is concentric about the longitudinal axis 201 of the assembly 142 ; is disposed below the central housing section 211 and moves with respect to the central housing section 211 to provide a stroke (called “S 2 ” in FIG. 2 ), which is the other half of the overall stroke for the assembly 142 . The lower housing section 210 - 2 is is connected to (as shown at reference numeral 240 - 2 ) to a tubular connector 208 (a male connector, for example), which, in turn couples the slip joint assembly 142 to the lower 140 - 2 segment of the tubing string 140 (see FIG. 1 ).
The central housing section 211 is a tubular body, which is concentric about the longitudinal axis 201 and is secured to both an upper mandrel 250 - 1 (part of the upper portion 200 - 1 ) and a lower mandrel 250 - 2 (part of the lower portion 200 - 2 ). The upper mandrel 250 - 1 is concentric about the longitudinal axis 201 and extends upwardly from the central housing section 211 into the upper housing section 210 - 1 , which circumscribes at least part of the mandrel 250 - 1 . Likewise, the lower mandrel 250 - 2 is concentric about the longitudinal axis 201 and extends downwardly from the central housing section 211 into the lower housing section 210 - 2 , which circumscribes the mandrel 250 - 2 .
The mandrel 250 - 1 and the upper housing section 210 - 1 form a telescoping slip connection for the upper portion 200 - 1 ; and likewise, the mandrel 250 - 2 and the lower housing section 210 - 2 form a telescoping slip connection for the lower portion 200 - 2 . In this manner, the slip connection that is formed between the mandrel 250 - 1 and the upper housing section 210 - 1 provides the S 1 stroke for the slip joint assembly 142 ; and the slip connection that is formed between the mandrel 250 - 2 and the lower housing section 210 - 2 provides the S 2 stroke for the slip joint assembly 142 . Due to the symmetry of the slip joint assembly 142 , the overall stroke of the slip joint assembly 142 is the sum of the strokes S 1 and S 2 .
The slip joint assembly 142 further contains sealing elements for purposes of forming fluid seals between the mandrels 250 and the corresponding housing sections 210 . In accordance with example implementations, the interior of the upper housing section 210 - 1 contains a channel, or groove, that holds a sealing element 230 - 1 to form a pressure/fluid seal between the upper housing section 210 - 1 and the inner mandrel 250 - 1 ; and correspondingly, an interior channel of the lower housing section 210 - 2 contains a groove that holds a sealing element 230 - 2 to form a pressure/fluid seal between the lower housing section 210 - 2 and the inner mandrel 250 - 2 . The seal 230 may be a chevron seal stack, in accordance with example implementations.
FIG. 2 depicts the slip joint assembly 142 in its fully retracted state, and FIG. 3 depicts the slip joint assembly 142 in its fully extended position. Although FIG. 3 depicts the extension of the slip joint assembly 142 as being divided equally between the upper 200 - 1 and lower 200 - 1 portions, in operation, the upper portion 200 - 1 of the slip joint assembly 142 extends and retracts along the longitudinal axis 201 independently from the lower portion 200 - 2 . Therefore, in operation, the distance between the upper housing 210 - 1 and the central housing 211 may be different than the distance between the lower housing 210 - 2 and the central housing 211 .
As depicted by the cross section of FIG. 4 , in accordance with some implementations, the inner mandrel 250 and outer housing 210 may be connected in a manner that allows a torque force to be transferred between these components. Such a torque force transfer allows a rotational force to be applied through the slip joint assembly 142 for purposes of rotating the tubing string 141 (see FIG. 1 ). In this manner, tubing string 141 may be rotated for purposes of setting the packer 144 , releasing the packer 144 , opening a downhole valve or performing other downhole operation.
In accordance with some implementations, the lower mandrel 250 - 2 (as an example) may have channels 251 - 2 that receive associated splines 400 of the housing section 210 - 2 . For the example implementation of FIG. 4 , four splines 400 and four associated channels 251 - 2 are shown. However, in accordance with further example implementations, the slip joint assembly 142 may contain more than four or fewer than four splines (and corresponding channels).
The engagement of the splines 400 with the channels 251 - 2 allow the transfer f a torque force between the inner mandrel 250 - 2 and the outer housing 210 - 2 , while permitting longitudinal translation of the housing section 210 - 2 with respect to the mandrel 250 - 2 . The upper mandrel 250 - 1 and upper housing section 210 - 1 may have a similar spline-based connection, in accordance with example implementations.
The mandrel 250 and the housing section 210 may be connected to allow a torque force connection using a connection other than a spline-based connection, in accordance with further example implementations.
Referring to FIG. 5 , thus, in accordance with example implementations, a technique 500 includes running (block 504 ) a tubing string in a well and using (block 508 ) a symmetric telescoping slip joint assembly in the tubing string to accommodate thermal expansion or contraction of tubing string material.
In accordance with example implementations, the telescoping symmetric slip joint assembly may have one or more of the following advantages. The reduction of length of the telescoping symmetric slip joint assembly, as compared to conventional slip joints, enhances handling of the slip joint assembly and reduces its overall manufacturing cost. The telescoping symmetric slip joint assembly may have fewer components than the conventional slip joint, thereby translating into lower manufacturing costs. Moreover, due to a lower number of components, the number of potential leak paths (sources of potential tool failure) may be reduced. Other and different advantages are contemplated, which are within the scope of the appended claims.
Other implementations are contemplated, which are within the scope of the appended claims. For example, in accordance with further implementations, a slip joint assembly may have a similar design to the slip joint assembly 142 , except that the slip joint assembly is not symmetric about the plane 212 . In this manner, the upper mandrel 250 - 1 and the upper housing section 210 may be longer than the lower mandrel 250 - 2 and lower housing section 210 - 1 , or vice versa, to impart differences between the S 1 and S 2 strokes. As another variation, in accordance with further implementations, slip joint assembly may have a similar design to the slip joint assembly 142 , except that the housing section sections 210 - 1 and 210 - 2 may be connected to the central housing section 211 (instead of being connected to the tubular connectors 204 and 208 ); and the mandrels 250 - 1 and 250 - 2 may be connected to the tubular connectors 204 and 208 , respectively (instead of being connected to the central housing section 211 ).
While the present techniques have been described with respect to a number of embodiments, it will be appreciated that numerous modifications and variations may be applicable therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the scope of the present techniques. | A slip joint assembly that is usable with a well includes first, second and third tubular housing sections; and first and second mandrels. The first tubular housing section is adapted to connect to a first tubing string segment; the second tubular housing section is adapted to connect to a second tubing string segment; the third tubular housing section disposed between the first and second tubular housing sections; the first mandrel forms a slidable connection with the first tubular housing section; and the second mandrel forms a slidable connection with the second tubular housing section. | 4 |
FIELD OF THE INVENTION
This invention relates to a pile and a method of installing a pile. More especially, but not exclusively the invention relates to piles for moorings for floating structures such as offshore oil installations and vessels.
BACKGROUND OF THE INVENTION
Known anchoring systems include driven piles, suction anchors, drag embedment anchors and vertically loaded anchors and conventional drilled piles. All have disadvantages:
Driven piles must be of heavy construction since they are hammered into the ground or seabed. They are additionally not suitable for all kinds of ground.
Suction anchors are of limited use in hard soils such as coral or compacted clay. They are expensive. After use because they are above the mud-line they must generally, be recovered which adds to the cost.
Drag embedment anchors require high pre-tensioning to ensure correct embedment. In deep water this is hard to achieve without a tenisioning device. Tensioning devices add to the complexity and cost of the operation. Additionally drag embedment anchors accept only small vertical forces.
Vertically loaded anchors are difficult to embed and require a drag force of about 50% of the ultimate load capacity. This can be hard to achieve in deep water.
Conventional drilled piles are expensive since they are time consuming to install
U.S. Pat. No. 3,934,528 (Deep Oil Technology Inc.) describes an offshore tension leg platform. Lengths of drill pipe may be connected together and extend through an annular casing received in a buoyant support member. The lengths of drill pipe can be manipulated by a power swivel and winch. The string of drill pipe can be used to introduce ballast to or remove it from an anchor member on the seabed. Once the anchor is ballasted in position a pile may be installed by conventional drilling and cementing. The drill pipe, swivel and winch can be used for this.
SUMMARY OF THE INVENTION
The invention seeks to overcome or reduce the problems associated with the prior art. According to the invention there is provided a method of drilling a pile in ground comprising the steps of:
i. providing a pile,
ii. providing a drill bit at an end of the pile rotatable relative to the pile;
iii. engaging the ground with the drill bit; and
iv. rotating the the bit relative to the ground and the pile generating a hole into which the pile is received.
According to the invention there is further provided a pile having provided one end thereof with a drill bit rotatable relative to the pile.
The invention can be relatively quick and inexpensive to install since it can be a one trip process; drilling and insertion occur in the same process. At least some embodiments of the invention provide a pile system for example for moorings which may be drilled to its design depth without the need for pre-drilled hole or for retraction and re-insertion of the pile during installation. The pile is drilled by rotating a drilling bit relative to the ground while restraining, generally the pile as a whole from rotation. Rotary motion may be transmitted to the drill bit by rotating an elongate member received in the pile. Bearings may be provided to aid this. The elongate member may be connected to a non-recoverable drilling bit of a diameter greater than the pile for example by a drive spline. The elongate member may be conduit supplying fluid to a downhole motor Some of the components such as the elongate member and motor or turbine may be recovered following deployment. Instead of using a downhole motor the elongate member may be driven from an installation vessel for example by a rotary motor. In some embodiments of the invention the drill bit may drill a hole of greater diameter than the pile. This can be achieved using, bi-centred, jetting bits or under-reamers (or other collapsible bits) which can be retrieved Alternatively a hole of a diameter less that the pile could be drilled, allowing recovery of the bit; embedment being achieved either by relying on fluid erosion to create a diameter large enough to allow the pile to advance or by relying on applied weight to displace soft sediments. This is of particular application where it is desired to grout the pile into the hole. Grouting may be undertaken even if oversize bits are not employed. Grouting can be achieved in conventional way or by using a cement fill-up device to divert slurry into cement hoses which are directed to an annular gap. The mooring line, parts or terminations thereof can be pre-installed prior to deployment of the pile. If desired a linkage point such as a mooring line termination can be mounted on a bearing assembly allowing the linkage to swivel to align itself to applied tension thereby avoiding the need to orient the pile with respect to the anticipated load to maintain its efficiency. If desired the pile can be oriented with respect to the anticipated load. If desired the pile may comprise a nest of concentric members coupled together for example with cement. This can provide a cheap high strength pile especially where the concentric members are made from standard oil field casing. The invention may be installed in the seabed utilising a vessel without using a rigid, tubular conduit. This allows the use of a (low cost) barge rather than an (expensive) floating drilling unit. This may be achieved by suspending the pile from a flexible member such as a crane line and driving the bit by a downhole motor connected by a hose to a fluid supply on the barge. In some embodiments of the invention fins which may be fixed or movable axially are provided on the pile. They resist reaction forces attempting to rotate the pile generated by the motor and allow the pile to be drilled when suspended from a member which is not torsionally rigid such as a crane wire.
Rotation of the bit may be achieved by rotation of the elongate member using rotary transmission means of an installation vessel.
Where a downhole motor is provided means for decoupling and recoupling it in situ may be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will be described by way of non-limiting example by reference to the accompanying figures of which:
FIG. 1 is a side elevation;
FIG. 2 is a cross-section of the embodiment of FIG. 1;
FIG. 3 is a schematic representation of a fluid path during drilling;
FIG. 4 is a side elevation of a further embodiment;
FIG. 5 is a cross section of the embodiment of FIG. 4;
FIG. 6 is a schematic representation of the embodiment of FIG. 1 being deployed;
FIG. 7 is a side elevation of a still further embodiment;
FIG. 8 is a schematic representation of the embodiment of FIGS. 4, 5 and 7 being deployed from a barge;
FIG. 9 is a partially cutaway plan view of a member for use in some embodiments of the invention;
FIG. 10 is a partially cutaway perspective view of the member of FIG. 9;
FIG. 11 is a side elevation of the member of FIG. 9;
FIG. 12 is a cross section of the member of FIG. 9;
FIG. 13 is a side elevation of a yet further embodiment in a first configuration; and
FIG. 14 is a side elevation of the embodiment of FIG. 13 in a second configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2, pile 1 comprises pipe 2 . Received in pipe 2 is elongate member 3 . Elongate member 3 is supported in the illustrated embodiment by bearing 4 . Further bearings could be provided if necessary or desired. Elongate member 3 is provided with a first drive spline 5 . Drive spline 5 is coupled to a second drive spline 6 to which is connected drill bit 7 . Other means of coupling could be used. Drill bit 7 may be a conventional roller bit used in drill holes. This is in fact preferred since many of the engineering problems associated with developing the bits have been solved. Furthermore suitable used bits may be available cheaply as surplus.
Drill bit 7 should be capable of drilling a hole which receives the pipe 1 . The hole may be the same size or larger than the pile. It may also be smaller with the combination of the weight of the pile and the fluid flow to be described hereinafter allowing the pile to penetrate soft ground.
Where the drill bit is larger than the outside diameter of the pipe 2 it will not, generally, be possible to recover the drill bit. Where relatively cheap bits are used this is not a serious problem. In any event the cost of the bit is small relative to the cost savings resulting from not needing to drill a hole recover the bit and drilling assembly and running the pile as separate sequential operations. The savings would generally become much more significant with increases in water depth.
Means for attaching an object to the pile may be provided FIGS. 1 and 2 show a convenient swivel assembly. Ring 8 is retained for rotational movement about the pipe by collars 9 , 10 . Pad eye 11 is provided for mooring chain 12 . Other mooring terminations could be provided.
Means 13 for engaging latch tool 14 may be provided.
Desirably means for resisting forces tending to extract the pile from the hole are provided, while preferably providing minimal resistance whilst installing the pile. In the illustrated embodiment a plurality of barbs are provided.
The barbs as illustrated are broadly rectangular. The edge nearer to the drill bit is joined for example by welding to the pipe. The edge further from the drill bit is spaced away from the pipe. Each barb comprises two generally planar portions 16 , 17 joined together at fold line 18 .
Desirably a sealing ring 19 for example of resilient material is provided toward the end of the pipe nearer the drill bit. As can be seen from FIG. 3 the sealing ring can be used to help divert fluid inside the pile. In FIG. 3, cutting fluid, for example “drilling mud”, passes downwardly through elongate member 3 . It escapes through one or more holes for example in the drill bit into bore cavity 20 . The cutting fluid cools the drill bit, and washes debris away. Cutting fluid with entrained debris is restrained from escaping out of the bore cavity by the sealing ring. Much cutting fluid therefore enters the annular space defined by the pipe and elongate member via a hole or holes (not shown). It ascends the hole and may be discharged to the sea or carried via a conduit to a vessel for reconditioning for re-use for example by filtering off debris to the surface for reconditioning for example by filtering the debris off and refuse. This arrangement prevents excessive washing of the bore hole which could undermine the ultimate strength of the pile and could create problems in grouted embodiments in effectively grouting the pile to the ground formations.
FIGS. 4 and 5 show a pile broadly similar to that of FIGS. 2 and 3. At least some of the common parts are shown with the same reference numbers. There are two principle differences which may be used independently of each other. First to provide even greater reaction to rotational forces exerted on the pile a plurality of reaction splines 21 are provided towards the end of the pipe carrying the drill bit. The splines comprise radial plates. Where the pile is installed suspended from a member which is not torsionally rigid, desirably means for restricting or preventing rotation of the pile in reaction to the forces generated by the drill bit are provided. Preferably the means for preventing rotation provide little resistance to downward movement of the pile. This may comprise a plurality of reaction splines. The splines may be provided toward the bit end of the pile. The splines may comprise radial plates. In the illustrated embodiment a plurality of fins are provided. Fins present a large area restraining rotational movement but a small area resisting axial movement.
Secondly a downhole motor 22 is provided. Means for actuating the downhole motor are provided. Those skilled will have little difficulty in devising suitable means. Examples include fluid such as liquid or gas under pressure or electricity. The down hole motor 22 is provided with a drive shaft 23 . Drive shaft 23 engages a drive box 24 connected to the drill bit. This arrangement is advantageous because downhole motors are reliable, and readily available and relatively cheap to hire but expensive to buy. The arrangement allows the downhole motor to be retrieved following deployment by disengaging the drive shaft from the drive box.
FIG. 6 illustrates the embodiment of FIGS. 1 to 3 being deployed by a drilling rig 25 . Elongate member 26 extends upwardly from the pile via bumper sub 27 , which is used to help provide a steady weight feed to the bit during the installation process. In use the drill bit is rotated as hereinbefore described. As the bore cavity is generated the pile sinks into the ground until it is at the required depth. Elongate member 26 is removed and the pile is ready for use. In some cases it may be desirable to grout the pile to the ground. Those skilled in the art will have no difficulty in devising suitable method for example using fluid divertor subs.
FIG. 7 illustrates an additional, deflection reaction, member for use with any of the piles described herein. It is illustrated in more detail in FIGS. 9 to 12 . The additional member is intended to increase the forces which the pile can withstand. It may be fitted following deployment of the pile or may be fitted to the pile before deployment. Deflection assembly 28 comprises a plurality of nested rings 29 , 30 , 31 . Inner ring 29 engages the pile while intermediate soil reaction ring 30 and outer soil reaction ring 31 are spaced apart from it. In a typical 50 cm (20 in) diameter pile the outer soil reaction ring 31 may have a diameter of about 3 m. The depth of the inner ring 29 is greater than that of the intermediate soil ring which is deeper an the outer soil ring. The rings are joined by axial ribs 32 , 33 , 34 . A grating 35 providing extra strength extends over the top surface of the deflection assembly leaving a central hole. The deflection reaction member may be fitted after drilling of the pile.
FIGS. 13 and 14 illustrate a yet further embodiment. Once again similar numbered parts have similar functions. As illustrated there are two different features which can be used separately or together. Means for resisting rotational forces are provided axially movable relative to the pile. In the illustrated embodiment this comprises both a deflection assembly 28 and fins to be described in greater detail hereinafter. It will be apparent that the deflection assembly or the fins could be omitted or fixed relative to the pile.
Sleeve 36 carries a plurality of quadrilateral fins 39 and a mooring termination. It is also provided with a deflection assembly 28 . One of the sleeve 36 and pipe 2 is provided with a key 40 for engagement with a keyway of the other. In the illustrated embodiment the pipe has the key but the reverse arrangement could be employed. More than one key and key way could be provided. Alternatively other means for transferring rotational drive forces while allowing relative axial movement could be used. The key prevents rotation of the pipe relative to the sleeve but does not prevent axial movement. An initial configuration is shown in FIG. 13 . The tip of the pipe has penetrated the ground G—G with the fins 39 partially engaged. The drill can be actuated. Rotation of the pile is inhibited by the fins. As the drill drills a hole the pipe descends. The sleeve may also descend but it does not descend as far as the pile but moves axially relative to the pile guided by the key way or splines. At some point the sleeve may slide beyond the end of the key way. The pipe may then become movable relative to the sleeve. At the end of its travel the sleeve 36 may engage end stop 41 . Further drilling will allow the sleeve to move in conjunction with the pile. Drilling may continue with this as well as the other embodiments until the end of the pile is flush with or under the surface of the ground. This is desirable since at the end of the useful life it may be possible to simply abandon the pile rather than attempt to recover it. This can be preferred since the pile can be made of relatively low cost components.
If desired the invention can be made de novo by methods apparent to the skilled worker from new materials. However it may be preferred on cost grounds to adopt materials originally intended for or used in other applications. In particular the pipe 2 can be made from drill casing which may be available on the surplus market.
The invention in at least some embodiment allows a pile to be installed by drilling more rapidly than is generally possible with a driven pile or a suction pumped pile.
The invention allows in at least some embodiment a pile to be installed in a wide range of soils which is not easily achievable with a driven or suction pumped pile.
At least some embodiments of the invention provide a high strength pile capable of withstanding high lateral and vertical loads such as those generated by deep water mooring systems.
At least some embodiments of the invention can be used as anchoring points for taut leg mooring systems providing a high vertical load capability using tubular casings of lesser diameter than required for comparable suction anchors in view of the deep embodiment achievable in any soil.
A single pile design can be used in a wide range of soil conditions reducing the need for accurate assessment, for example by site survey of soil conditions.
While the invention has been described by reference to subsea applications the invention is not so restricted and may be used on land. | A method of drilling and installing a pile in ground comprising the steps of
providing a pile,
providing a drill bit at an end of the pile rotatable relative to the pile;
engaging the ground with the drill bit, and
rotating the drill bit relative to the ground and the pile generating a hole into which the pile is received. | 4 |
[0001] The present invention relates to a foldable bicycle with spokeless wheels.
BACKGROUND OF THE INVENTION
[0002] Foldable bicycles have been known for many years, e.g., the bicycle described in GB 2,287,438, in which the frame has a middle articulation joint which allows it to be folded by 180° about a vertical axis, after releasing a locking mechanism, in order to halve the longitudinal size of the bicycle and allow the latter to be eaily carried on a vehicle.
[0003] Other foldable bicycle are known, e.g., from DE 10 2007 013158 A1, wherein the frame consists of various frame parts hinged to one another about transverse axes and are interconnected for simultaneously rotating from an operative configuration to a folded, carrying configuration.
[0004] The above-described foldable bicycles have the drawback that the frame and the wheels are relatively small-sized, because they are designed to obtain a very compact folded configuration, to the detriment of the driving comfort and performance, which, in fact, are very limited, especially on uneven roads.
[0005] Moreover, even in their folded configuration, the above bicycles are heavy-weighted and sizable, so that they are not suitable to be carried by hand.
[0006] In the attempt of improving the driving comfort, WO/2006/131742 describes a foldable bicycle provided with standard-sized wheels. The frame has a front end and a rear end which are foldable about respective vertical axes, to which ends the two wheels are hinged. In particular, both the wheels of the bycicle of the above document are spokeless and are supported by a set of bearings engaged between the wheel and a respective guide attached to the frame. The lack of spokes allows some mechanical parts, such as the pedals, to be stored in the inner area of the wheels when the bicycle is folded, in order to reduce its overall size.
[0007] The above-mentioned bicycle, of course, is handier to be driven than the bicycles with small-sized wheels such as the one described in the above-cited document, GB 2,287,438, and the folding system makes it easier to carry the bicycle on a vehicle. However, the bicycle, even when folded, is yet too cumbersome to be carried by hand.
[0008] Furthermore, the above folding system having a frame provided with two articulation joints may be difficult to handle for the cyclist, who must handle the various parts of the frame while the latter is laying in precarious balance on the two wheels.
[0009] Nevertheless, although the use spokeless wheels is convenient because it reduces the weight of the bicycle, improves the aerodynamic properties, and prevents the risk of undesired locks caused by the intrusion of rigid bodies and/or limbs of the human body between the spokes, however the wheel-supporting system of the above document is liable to jamming in case of dust, sand or stones slipping into the bearings.
[0010] Other systems are known for connecting spokeless wheels to the frame of a bicycle, such as those described in U.S. Pat. No. 5,419,619 and U.S. Pat. No. 5,248,019, which provide for the use of an inner, stationary rim integral with the frame and an outer, rotary rim, with a crown of balls engaged between the rims. In other systems, such as the one described in U.S. Pat. No. 917,967, the wheel is locked by three rollers spaced from one another by two adjustable members.
[0011] With the above-cited systems, the advantages resulting from using spokeless wheels are limited, because the structure that connects the wheel to the frame is heavy and obstructs a considerable fraction of the inner area of the wheel.
SUMMARY OF THE INVENTION
[0012] Therefore, it is a main object of this invention to provide a foldable bicycle which, in its operative configuration, has a standard size likewise a traditional city bicycle, but can be converted to a folded, carrying configuration which is considerably smaller in size than the known foldable bicycles, in order to allow the bicycle to be easily carried by hand or on a shoulder.
[0013] It is another object of the invention to provide a bicycle provided with a handy, practical folding system, which minimizes the number of actions and operations required for converting the bicycle from its operative configuration to its folded configuration, and vice versa.
[0014] In is a further object of the invention to provide a bicycle which, even though provided with spokeless wheels, is not subjected to jamming and has a reliable, lightweight system for connecting the wheels to the frame.
[0015] The above object and other advantages, which will better appear from the following description, are achieved by the foldable bicycle having the features recited in claim 1 , while the dependent claims state other advantageous, though secondary features, of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will be now described in more detail with reference to a preferred, non-exclusive embodiment, shown by way of non limiting example in the attached drawings, wherein:
[0017] FIG. 1 is a view in side elevation of the bicycle according to the invention;
[0018] FIG. 2 is another view in side elevation of the bicycle according to the invention, from the opposite side with respect to FIG. 1 ;
[0019] FIG. 3 is an exploded, perspective view of the bicycle according to the invention;
[0020] FIG. 4 is a view in axial cross-section to an enlarged scale of a detail of FIG. 1 along plane IV-IV;
[0021] FIG. 5 is a view in axial cross-section to an enlarged scale of a detail of FIG. 1 along plane V-V;
[0022] FIG. 6 is a view in axial cross-section to an enlarged scale of a detail of FIG. 1 along plane VI-VI;
[0023] FIG. 7 is a view in axial cross-section to an enlarged scale of a detail of FIG. 1 along plane VII-VII;
[0024] FIGS. 8 to 13 show the bicycle according to the invention in six consecutive steps of convertion from an operative configuration to a folded, carrying configuration;
[0025] FIG. 14 is a view similar to FIG. 9 to an enlarged scale;
[0026] FIG. 15 is a perspective view of the frame of the bicycle in the folded, carrying configuration;
[0027] FIG. 16 shows the bicycle folded in its carrying configuration, while carried in a bag by a generic user.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] With reference to the above Figures, a bicycle 10 is provided with a frame supported on a rear wheel 12 and a front wheel 14 . Each of the wheels comprises an annular frame, usually called spokeless rim 12 a , 14 a , which supports a conventional tubular tire 12 b , 14 b made of a synthetic material. Tubular tire 12 b , 14 b may be both of the type provided with an inner tube and of the tubeless type. The profile of rim 12 a , 14 a will be described in more detail later on.
[0029] The frame comprises a bar 15 splitted in two side-by-side, half-bars 16 , 18 ( FIG. 3 ), which are arranged in mirror-like fashion with respect to the middle plane of bicycle 10 , and have an arched profile with its concavity facing downwards. A lower arm 20 and an upper arm 22 have their front ends 20 a , 22 a hinged to the rear ends 16 a , 18 a of half-bars 16 , 18 about a first transverse axis X 1 parallel to the axis of rear wheel 12 . As shown in the Figures, arms 20 , 22 project from their hinge axis in a scissor-like open fashion. Lower arm 20 and upper arm 22 bear respective rear rollers, i.e., a lower roller 24 and an upper roller 26 respectively, at their rear ends 20 b , 22 b , which engage the inner profile of rim 12 a of rear wheel 12 at diametrally opposite positions.
[0030] As shown in FIGS. 4 , 5 , the inner profile of rear rim 12 a has a cylindrical middle portion 28 engaged by corresponding cylindrical middle sections 24 a , 26 a of lower roller 24 and upper roller 26 respectively, as well as two bevelled, opposite side walls 30 ′, 30 ″ which are laterally restrained between corresponding side edges 24 b ′, 24 b ″, 26 b ′, 26 b ″ of rear rollers 24 , 26 having a complementary profile. Lower arm 20 also bears a stabilizing roller 32 at an intermediate position, which internally engages the rim of the rear wheel at third point in front of the other two rear rollers.
[0031] Lower roller 24 is connected to a gear wheel 34 , which is rotatably coupled with a crown gear 35 of a driving assembly 36 provided with pedals 38 via a chain 40 . Driving assembly 36 is hinged to lower arm 20 about a second transverse axis X 2 ( FIG. 2 ).
[0032] Having now particular reference to FIGS. 1 and 2 , a saddle 42 is supported on the top of a post 44 , the lower end of which is received in a sleeve 46 which is transversely hinged to lower arm 20 about second axis X 2 . The axial position of post 44 in sleeve 46 is locked by a conventional locking mechanism (not shown). A first bush 48 is slidably fitted to post 44 and is connected to lower arm 20 via a connecting rod 50 ( FIG. 2 ). Connecting rod 50 has a lower end 50 a hinged to lower arm 20 behind the hinge point of sleeve 46 , and an opposite, upper end 50 b hinged to bush 48 . As shown in the Figures, the length of connecting rod 50 and the position of the various hinge points are preferably chosen in such a way that post 44 is sligthly inclined rearwards when the bicycle in its operative configuration, for the scopes which will be clarified later on.
[0033] A contoured groove 52 acting as a guide is formed on the inner vertical surface of upper arm 22 . Groove 52 is engaged by a sliding pin 53 , integral with connecting rod 50 , which acts a slide. Groove 52 is shaped in such a way that, when post 44 is rotated towards the front end of the bicycle about hinge axis X 2 of sleeve 46 (i.e., clockwise direction in FIG. 1 , counterclockwise direction in FIG. 2 ), upper arm 22 rotates towards lower arm 20 (i.e., counterclockwise direction in FIG. 1 , clockwise direction in FIG. 2 ) by camming action of sliding pin 53 running through groove 52 .
[0034] Preferably, as shown in detail in FIG. 14 , the rear end of groove 52 extends beyond the point in which both lower roller 24 and upper roller 26 engage rear rim 12 a without deforming it, with an interference portion 52 a which terminates with a notch 52 b . Notch 52 b is shaped in such a way that, once pin 53 has been forced into it, after running through interference portion 52 a (during this step rim 21 a of rear wheel is subjected to a slight elastic deformation), lower roller 24 and upper roller 26 come back to the position of FIG. 2 , in which both of them engage rear rim 12 a without deforming it.
[0035] Upper arm 22 has a first sector gear 54 formed at its front end about its hinging axis X 1 , for the scopes which will be clarified later on.
[0036] The front end of half-bars 16 , 18 are connected, via a second sleeve 57 , to a fork 58 integral with a pole 59 , at the top of which a handlebar 60 is supported. Second sleeve 57 is hinged to the front ends 16 b , 18 b of half-bars 16 , 18 about a third transverse axis X 3 . The lower end 59 a of pole 59 is received within second sleeve 57 . A second bush 64 slidable along pole 59 above second sleeve 57 is connected to the rear ends of half bars 16 , 18 via a lever 66 . Lever 66 has a rear end 66 a hinged between the rear ends 16 a , 18 a of half-bars 16 , 18 , about a third transverse axis X 4 ( FIG. 4 ) located close to, and in front of, the hinge axis X 1 about which half-bars 16 , 18 are hinged to the rear arms. A front end 66 b of lever 66 is hinged to second bush 64 . In particular, rear end 66 a of lever 66 terminates with two projections 66 a ′, 66 a ″, each of which is hinged to the half-bar on the corresponding side. A second sector gear is formed on one of the projections, 66 a ″, about the hinge axis of the latter, which meshes with sector gear 54 of upper arm 22 .
[0037] Fork 58 supports front wheel 14 via a pair of side-by-side, mirror-like jaws 68 , 70 , which are interconnected by bridges 71 a , 71 b ( FIG. 3 ) and support two pairs of counterposed frustoconical rollers 72 a , 72 b and 74 a , 74 b arranged therebetween, which are advantageously spaced at an angle in the range 45° to 90°, preferably 70°, as well as an inner roller 76 . As shown in detail in FIGS. 6 , 7 , front rim 14 a is shaped with a cylindrical middle portion 78 engaged by a corresponding, cylindrical middle section 76 a of roller 76 , as well as two opposite, bevelled side walls 80 ′, 80 ″ which are laterally restrained between corresponding side edges 76 b ′, 76 b ″ of inner roller 76 , which have a complementary profile. Each pair of rollers 72 a , 72 b and 74 a , 74 b externally engages respective opposite bevelled walls 82 ′, 82 ″ of the outer profile of rim 14 a . Roller 76 is hinged to fork 58 about a removable pin 84 which passes through jaws 68 , 70 ( FIG. 6 ). The jaws are also anchored to fork 58 via respective studs 86 , 88 .
[0038] FIG. 1 illustrates bicycle 10 in its operative configuration. When rear arms 20 , 22 are open in a scissor-like fashion, both rear rollers 24 , 26 and stabilizing roller 32 internally engage rim 12 a of rear wheel 12 . In this configuration, sliding pin 53 restrainedly engages notch 52 b ( FIG. 2 ) and, by effect of the inclination of post 44 towards the rear end of the bicycle, the weight of the cyclist (not shown) sitting on saddle 42 contributes in maintaining sliding pin 53 in that position.
[0039] With particular reference to FIGS. 8-13 , in order to convert the bicycle to its folded, carrying configuration, pin 84 ( FIG. 9 ) is removed, whereby roller 76 is unlocked and front wheel 14 is consequently set free. To remove rear wheel 12 , rear arms 20 , 22 are slightly opened (with consequent, slight, elastic deformation of rear rim 12 a ) until pin 53 disengages notch 52 b and engages groove 52 ( FIGS. 9 , 14 ). Now that rear wheel 12 can be removed, post 44 supporting saddle 42 is rotated forwards, i.e., in the direction indicated by arrow A 1 in FIG. 10 , so that upper arm 22 progressively rotates towards lower arm 20 , in the direction indicated by arrow A 2 in FIG. 10 , by engagement of sliding pin 53 along groove 52 .
[0040] The rotation of upper arm 22 causes lever 66 to simultaneously rotate in the opposite direction, i.e., in the direction indicated by arrow A 3 in FIG. 10 , by meshing of first sector gear 54 with second sector gear 66 a ″. The rotation of lever 66 causes fork 58 and bar 15 to rotate in the same direction ( FIGS. 10 , 11 ), by action of second bush 64 sliding along pole 59 , until the frame is completely folded to the compact configuration of FIG. 12 . It should be noted that, when bar 15 is closed, jaws 68 , 79 , which are free to rotate about the respective studs 86 , 88 , are stored in the concave lower area defined by half-bars 16 , 18 . In order to completely compact the frame to the folded configuration of FIGS. 13 , 15 , saddle 42 can be lowered by unlocking the locking mechanism (not shown) and making post 44 slide along sleeve 46 .
[0041] As the person skilled in the art will immediately understand, the bicycle according to the invention has the advantages of both a traditional bicycle and a foldable bicycle, because, in use, it has a standard size, while, in its folded configuration, it is very compact. Using spokeless wheels allows the free area inside the rims to be used as a housing for the folded frame, so that the whole kit can be received in a bag S, which is shaped and sized ad hoc and can be carried either by hand or on a shoulder, as shown in FIG. 16 . Alternatively, the frame and the wheels could be carried by different users.
[0042] The above-described folding system is also practical and handy because, once removed the wheels, the various projecting parts of the frame, particularly rear arms 20 , 22 , post 44 supporting saddle 42 , bar 15 , and fork 58 with pole 59 attached thereto which supports handlebar 60 , are interconnected in such a way that they simultaneously close in a sole movement.
[0043] The possibility of quickly removing the wheels is also advantageous when replacements or repairs are required, e.g., in case of puncture of a tire.
[0044] A preferred embodiment has been described herein, but of course many changes may be made by a person skilled in the art within the scopes of the claims. In particular, although the bicycle according to the preferred embodiment is provided with spokeless wheels, of course, it could also be provided with traditional wheels with spokes, with mere constructional changes which will be obvious to the person skilled in the art. For instance, fork 58 could be extended in order to support the front wheel at the hinge axis thereof, and lower arm 20 could be suitably shaped in such a way that it supports the rear wheel at the hinge axis thereof. In this case, of course, upper arm 22 can be reduced in length because it does not have to support the rear wheel any more. Moreover, it is evident that other safety locking means could be provided by the skilled person in order to prevent accidental closing of the frame. Of course, mere constructional changes obvious to the skilled person should be included within the scope of the claims. For instance, jaws 68 , 70 could be made from a single piece, rather than being two different elements. Furthermore, the sector gears could be replaced by engagement angular sectors of a different type, such as friction sectors forming a friction gearing, and the like. | A foldable bicycle provided with a frame, the frame comprising a first arm having a rear end to which a rear wheel is linked, a fork with handlebar to which a front wheel is linked, a bar connecting a front end of the first arm to the fork and hinged to the first arm and a post supporting a saddle and hinged to the first arm. The first arm, the bar and the post are interconnected by transmission elements for simultaneously rotating about the axes between an operative configuration and a carrying configuration. The transmission elements comprise a first engagement angular sector rotatably coupled with said post via first linkages, and a second engagement angular sector in rotary engagement with the first engagement angular sector and rotatably coupled with the bar via second linkages. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to safety starters, and more particularly to a fluorescent lamp starter protection circuit.
BACKGROUND OF THE INVENTION
[0002] A fluorescent lamp starter circuit is essentially a time delay switch that allows a preheating circuit to warm the filaments at each end of a fluorescent lamp before the lamp is ignited. The most common automatic starter is a “glow tube starter” circuit that typically includes a glow-switch that is normally open. When current is applied to the glow tube starter circuit, the resulting glow discharge heats a bimetal contact which causes the contacts of the glow-switch to close a short time (1-2 seconds) thereby providing current to a preheating circuit and extinguishing the glow discharge. While the filaments are warming, the bimetal ultimately cools such that the contacts open thereby interrupting the current through the preheating circuit and producing an inductive “kick” through the ballast that should cause the lamp to ignite. However, the magnitude of the inductive kick is dependent upon the current supplied to the glow tube starter circuit and may at times be insufficient to ignite the lamp, thus requiring several successive attempts. Furthermore, the glow tube starter can cycle indefinitely if the lamp driven by the ballast is defective.
[0003] It is known to incorporate a pulse starter circuit in an attempt to improve the reliability of the glow tube starter circuit. A pulse starter circuit is designed to reduce the number of failed ignition attempts by electronically detecting the appropriate time to disengage the preheating circuit so as to optimize the inductive kick produced by the ballast. To increase the safety of the glow tube starter circuit, it is known to incorporate a thermal switch to disengage the glow tube starter circuit if an excessive number of ignition attempts is made, thereby eliminating the persistent blinking that occurs when a lamp cannot be started. Once disengaged, such existing “safety starter” circuits must be reset by means of a manual reset button in the luminaire, which is typically mounted on the ceiling. If a lamp has actually failed, this reset procedure can be accomplished while replacing the lamp. However, the occasional non-defective lamp is difficult to start simply because it is cold, so replacing the lamp is unnecessary. In such a situation, gaining access to the ceiling-mounted luminaire for the sole purpose of performing the manual reset procedure is extremely inconvenient and therefore disadvantageous.
[0004] Despite the improvements afforded by the pulse starter circuit and the safety starter circuit, existing glow tube starter configurations have additional disadvantages. The operation time (i.e., the elapsed time between the first and last attempt to ignite the lamp) is dependent upon the current level in the preheating circuit. Therefore, existing safety starters can only be implemented in lamp circuits that can maintain current levels that are high enough to produce temperatures that will trigger the thermal switch after the maximum allowable number of attempts to start the lamp has been made. Furthermore, the safety starter circuit is commonly configured such that the thermal switch is exposed to ambient environmental conditions (e.g., temperature and humidity), which at times results in sticking contacts that can cause dangerous failures due to overheating.
[0005] In spite of the recognized need, a continuing failure in the art has been an inability to provide an automatic starter that is reliable, safe, versatile, and easy to operate.
SUMMARY OF THE INVENTION
[0006] The circuit of the present invention fulfills the needs described above by implementing an automatic starter that includes a safety starter circuit, comprising a timer switch and a timer such as an electronic timer coupled to the timer switch and prevents the glow-switch from continually striking a lamp that has failed. The safety starter circuit can be configured to automatically reset whenever glow-switch cycling has ended either because the lamp has ignited, or because the safety starter circuit has ended the glow-switch cycling. Alternatively the timer can be reset when the supply voltage is switched on or off. The performance of the safety starter circuit is not affected by the ambient environment or the preheat current.
[0007] An exemplary embodiment of the present invention is a safety starter that controls the ignition of a fluorescent lamp. During operation a supply voltage provides power to a series arrangement comprising a ballast, lamp filaments and the safety starter. The safety starter comprises a series arrangement of a glow-switch and the timer switch. A control electrode of the timer switch is coupled to a timer such as a solid state timer. When both the glow-switch and the timer switch are conductive a preheat current flows through the filaments of the fluorescent lamp so that the lamp electrodes are preheated before a striking voltage is generated to ignite the lamp. The glow-switch allows current to flow through the lamp filaments long enough for the electrodes to be sufficiently heated. The contacts of the glow-switch subsequently open, thereby inducing a striking pulse intended to ignite the lamp. If the lamp is not ignited, the glow-switch cycles again. The timer and the timer switch limit the duration of the cycling of the glow-switch so that cycling does not occur beyond a predetermined maximum operation interval, such as the IEC maximum of five minutes. The solid state timer increments only while current flows through the glow-switch, a sensing resistor (that may be integral to the solid state timer) detecting the current flowing through the glow-switch. A capacitor that suppresses radio frequency (RF) interference is integrated in the safety starter. In this exemplary embodiment, the capacitor is connected in parallel with the glow switch.
[0008] In an alternative embodiment, the capacitor is connected in parallel with the fluorescent lamp. In this alternative embodiment the timer increments continuously, and the capacitor is not protected by the timer switch.
[0009] Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become more apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The accompanying drawings, which are incorporated in and form part of the specification, illustrate the present invention when viewed with reference to the description, wherein:
[0011] [0011]FIG. 1 is a circuit diagram of an exemplary safety starter circuit according to an embodiment of the present invention with a lamp and a ballast connected to it; and
[0012] [0012]FIG. 2 is a circuit diagram of an alternative exemplary safety starter circuit according to an embodiment of the present invention with a lamp and a ballast connected to it.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0013] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
[0014] [0014]FIG. 1 is a circuit diagram of an exemplary safety starter circuit according to an embodiment of the present invention. Referring to FIG. 1, the safety starter circuit includes a timer with an integrated timer switch, a switch S, a capacitor Ca, and a sense resistor Rs. The timer is a solid state device that has no mechanical contacts that are exposed to the environment. The switch S is a glow switch that has the advantage of being relatively inexpensive and compact. In this example, additional capacitors C t1 and C t2 act as voltage buffers and assist in timing, although alternative means can be implemented.
[0015] Referring again to FIG. 1, in the first embodiment of the present invention, the capacitor Ca is connected in parallel with the switch S. The capacitor Ca serves to remove radio frequency interference. The switch S and the capacitor Ca are connected from the timer to the electrode at the first end of the lamp L. The timer is connected from the electrode at the second end of the lamp L to the switch S and the capacitor Ca. Capacitors C t1 and C t2 are connected in parallel with a sensing resistor Rs from the timer to the electrode at the second end of the lamp L. The electrode at the first end of the lamp L is also connected to a ballast for limiting the current through the lamp L. The power supply P main is connected across the ballast and lamp L. A power resistor Rp is connected to the timer and the switch S.
[0016] When the power supply is turned on, the preheating circuit is activated through the switch S. In this exemplary embodiment, the switch S is a glow-switch that contains two contacts, one of which is formed by a bimetallic strip, sealed in a small glass bulb containing an inert gas mixture. The bulb is mounted in a small cylindrical container of aluminum or polycarbonate. A glow discharge between the contacts of the glow switch makes the bimetallic strip heat up and bend until both contacts of the glow switch make contact. While the contacts are in contact with each other the glow switch is conductive and a preheat current flows through the lamp electrodes. While the preheat current flows the contacts of the glow switch cool down and subsequently open, thereby inducing a striking pulse sufficient to ignite the lamp. However, if the ignition attempt fails, the glow-switch continues to cycle through ignition attempts as long as permitted by the protection circuit. The protection circuit includes the timer the timer switch and the sensing resistor Rs. The timer increments while current flows through the glow-switch S (and the sensing resistor Rs) and until a maximum interval has elapsed.
[0017] When the lamp ignites, both the lamp and the lamp ballast carry a current. As a result the voltage across the lamp decreases and therefore also the voltage over the glow switch decreases. Because of this decrease in the voltage over the glow switch no glow discharge develops between the contacts so that the glow switch remains non-conductive. When the lamp ignites before the maximum time interval has elapsed, the timer does not increment further so that the timer switch remains conductive. Therefor the capacitor Ca is part of a conducting series arrangement (consisting of the capacitor Ca, the timer switch and resistor Rs) in parallel with the lamp and suppresses RFI during stationary operation. The timer resets automatically when a user switches the supply voltage off or when the supply voltage is switched on. In case the lamp has not ignited when the timer has timed the maximum time interval, the timer switch is rendered non-conductive so that there are no further attempts to ignite the lamp.
[0018] [0018]FIG. 2 is a circuit diagram of an alternative exemplary safety starter circuit according to an embodiment of the present invention. In this alternative embodiment, the capacitor Ca is connected in parallel with the lamp L and suppresses RFI irrespective of the conductive state of the timer switch. In this configuration the timer increments during a predetermined maximum operation interval and renders the timer switch non-conducting at the end of the predetermined time interval. The predetermined maximum operation interval is chosen such that it encompasses a number of glow switch cycles that is high enough for a lamp that is not defective to ignite. In case of a defective lamp the glow-switch S can continue cycling during the predetermined maximum operation interval. When the lamp ignites before the timer has timed the predetermined maximum operation interval the glow switch stops cycling because of the decrease in the voltage across the lamp. In case the lamp does not ignite, the cycling of the glow switch is stopped and no further attempts are made to ignite the lamp because the timer renders the timer switch non-conductive. Also in this embodiment the timer resets when the supply voltage is switched off or alternatively when the supply voltage is switched on.
[0019] In view of the foregoing, it will be appreciated that the present invention provides a system for accurate, efficient, and cost-effective electrode heating and lamp ignition that limits the number of ignition attempts. Still, it should be understood that the foregoing relates only to the exemplary embodiments of the present invention, and that numerous changes may be made thereto without departing from the spirit and scope of the invention as defined by the following claims. | A fluorescent lamp starter circuit that incorporates the series arrangement of a glow-switch and a semiconductor switch. The semiconductor switch is coupled to a solid state timer. The solid state timer renders the semiconductor switch non-conductive after it has timed a predetermined maximum operation interval. The duration of lamp ignition attempts is thereby limited. | 8 |
This application is based on and claims priority from U.S. Provisional Patent Application No. 61/340,518, filed 17 Mar. 2010,the disclosure of which is fully incorporated herein.
TECHNICAL FIELD
The present invention relates generally to motor structures that can be mounted integrally within a wheel structure and, specifically, to an electric motor designed to be mounted within an aircraft wheel to drive the aircraft wheel.
BACKGROUND OF THE INVENTION
As air travel has increased over the past decades, airport facilities have become more crowded and congested. Minimizing the time between the arrival of an aircraft and its departure to maintain an airline's flight schedule, and also to make a gate or parking location available without delay to an incoming aircraft, has become an airline priority. The safe and efficient ground movement of a large number of aircraft simultaneously into and out of the ramp and gates areas has become increasingly important. As airline fuel costs and safety concerns and regulations have increased, use of the aircraft main engines is no longer the best option for achieving the desired safe and efficient ground movement.
Various alternatives to the use of an aircraft's main engines to move an aircraft on the ground have been tried. The use of a tug or tow vehicle to move an aircraft into and out of a gate or parking location can eliminate the need to use the aircraft main engines. This option, however, is not without its own challenges and costs. More ground vehicles requiring more fuel and more ground personnel to operate them, add to an already congested environment in the gate area. Restricted use of the aircraft engines on low power during arrival at or departure from a gate is an additional option. This option is also problematic. Not only does engine use consume fuel, it is also noisy, and the associated safety hazards of jet blast and engine ingestion in a congested area are significant concerns that cannot be overlooked.
The use of a motor structure integrally mounted with a wheel to rotate the wheel and drive a vehicle, including an aircraft, has been proposed. The use of such a structure, ideally, could move an aircraft with minimal or no use of an aircraft's main engines. In U.S. Pat. No. 2,430,163, for example, Dever describes a motor that may be incorporated in an aircraft landing gear wheel in which the stator is mounted on a stationary part of a wheel assembly and the rotor is connected to the revolving part of the wheel to produce a high rotating torque near the periphery of the wheel. The structure described by Dever, while likely to have been suitable for World War II era aircraft, is not likely to be as effective in the gear wheels of contemporary aircraft. Other patent art, such as U.S. Pat. No. 3,977,631 to Jenny, also describe drive motors associated with aircraft gear wheels intended to drive an aircraft on the ground. The motor assembly disclosed by Jenny is selectively coupled to an aircraft wheel through a rotatably mounted brake apparatus in which the normally non-rotating stator is rotatably mounted and driven. In U.S. Pat. No. 7,445,178, McCoskey et al describe a powered nose aircraft wheel system with a multifunctional wheel motor coupled to the wheel axle and the wheel. A dual cone clutch structure is required to be actuated to allow the wheel motor to spin the wheel freely prior to landing and to change the direction of wheel rotation from forward to reverse. U.S. Pat. No. 7,226,018 to Sullivan also describes a wheel motor useful in an aircraft landing gear wheel. This wheel hub motor/generator disks stack includes within the stack alternating rotor and stator disks and is designed to provide motive force to an aircraft wheel when electric power is applied. The arrangement is stated to function as a unique aircraft braking system that also converts kinetic energy into electrical energy. None of the foregoing patents suggests a compact motor assembly capable of powering an aircraft drive wheel that could be easily installed in the limited landing gear space available on an existing aircraft without substantial modification. This art, moreover, does not contemplate an integral configuration of the motor components that sheds heat during operation and that provides easy access to the motor components for maintenance and repair when the motor is not in operation.
Published U.S. patent applications, including U.S. Patent Application Publication Nos. US2006/0273686 to Edelson, US2007/0282491 to Cox et al, US2009/0152055 to Cox, US2009/0261197 to Cox, International Patent Application Publication No. WO 2008/027458 to Cox et al, and British Patent No. 2457144, owned in common with the present invention, describe aircraft drive systems that use electric drive motors to power aircraft wheels and move an aircraft on the ground. These disclosures focus on specific aspects of the drive systems and motor assemblies, including drive system data, motor design, tire profile, and motor cooling, rather than on integrally configuring motor components with landing gear wheel components to maximize the available space without changes to the aircraft landing gear.
A need exists, therefore, for an electric motor assembly for an aircraft gear wheel designed to fit integrally within the aircraft wheel and efficiently with other existing components into the limited space available for the aircraft landing gear without changes to the existing components.
SUMMARY OF THE INVENTION
It is a primary object of the present invention, therefore, to provide an electric motor assembly for an aircraft gear wheel designed to fit integrally within the aircraft wheel and efficiently with other existing components into the limited space available for the aircraft landing gear without changes to the existing components.
It is another object of the present invention to provide an electric motor integrated with an aircraft gear wheel that does not require replacement of the aircraft's existing axle, wheel, tires, piston, or other landing gear components.
It is an additional object of the present invention to provide an electric motor integrated with an aircraft gear wheel that does not require change or re-certification for the aircraft's wheel rim width, tire bead, or bead seat.
It is a further object of the present invention to provide an electric motor integrated with an aircraft gear wheel assembly that minimizes spin-up weight and maximizes the space available within the landing gear for installation of the motor.
It is yet another object of the present invention to provide an electric motor integrated with an aircraft gear wheel that provides a solid thermal connection between the motor and the wheel axle and landing gear piston to facilitate heat dissipation from the motor and wheel assembly.
It is yet a further object of the present invention to provide an electric motor and aircraft gear wheel assembly that provides easy access to motor components for maintenance or repair after installation of the assembly.
In accordance with the aforesaid objects, an electric motor is integrally incorporated into an aircraft gear wheel to enable the aircraft gear wheel to be driven on the ground independently of the aircraft main engines. The electric motor is designed and sized to fit in the space available in an existing aircraft landing gear without changing the existing landing gear components so that the motor powers not only the wheel within which it is installed to drive the aircraft, but also provides the wheel support. Alternate electric motor configurations in combination with different bearing arrangements may be employed to provide structural support and drive power for the wheel. A mechanical connection from the motor to a non-rotating landing gear component is preferably included to provide for a torque reaction. Maintenance, such as tire changes, and service of the motor is much simplified by the configuration of the electric motor and gear wheel assembly of the present invention.
Other objects and advantages will be apparent from the following description, drawings, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration of one possible arrangement of an electric motor within an aircraft gear wheel according to the present invention; and
FIG. 2 illustrates schematically another possible arrangement of an electric motor within an aircraft gear wheel according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The many advantages of being able to drive an aircraft on the ground independently without using the aircraft main engines, as discussed above, have been acknowledged. Integrating a motor with an aircraft gear wheel as the aircraft is being constructed does not present problems because the space available for landing gear components, including motors for driving gear wheels, can be adjusted, as required. Retrofitting existing aircraft presents challenges, however. The integral electric motor and gear wheel assembly of the present invention overcomes these challenges and provides a motor and gear wheel assembly that can be fitted into the limited space available for aircraft landing gear components without modifying any of the other landing gear components. As a result, an aircraft's existing gear wheel, the wheel well, tire, axle, piston, and other landing gear components can be used with the present integrated motor and wheel assembly. The motor and gear wheel assembly of the present invention makes it possible to retrofit existing aircraft simply and effectively so that these older aircraft can achieve the fuel and cost savings and other advantages of aircraft ground movement that is independent of the aircraft engines and external ground vehicles.
Since landing gears on existing aircraft are already completely designed to function without additional components like electric drive motors, there is not much space available for a motor, a clutch, if required, electrical connections, or other structures. Modifications that require changes to the axle or piston, which have been suggested, would be expensive and time consuming, in large part because any changes from existing structure would require re-certification by regulatory authorities such as the United States Federal Aviation Administration (FAA) and equivalent international regulatory authorities.
Referring to the drawings, FIG. 1 illustrates, diagrammatically, one possible arrangement of components in an integral electric motor and gear wheel assembly 10 according to the present invention that can be retrofitted in an existing aircraft landing gear. The arrow A indicates the orientation of the motor and wheel assembly with respect to the aircraft body, which would be in the direction of arrow A. In this arrangement, a section 14 of the wheel 12 along the axle 16 that extends toward an axle cap 18 retains the configuration of a conventional wheel. Piston 20 is associated with the landing gear extension and retraction apparatus (not shown). A second section 22 of the wheel 12 , opposite wheel section 14 , is supported by the motor 24 .
An upper section 26 of the wheel 12 is supported by a bearing 28 that rests on a stationary part of the motor 24 , such as the motor stator 30 , a motor housing (not shown), or an equivalent stationary component capable of supporting the wheel. A stator support bearing 31 may be located between the motor 24 and the axle 16 . A gear wheel tire (not shown) will be mounted on a tire flange 32 . The motor 24 includes a mechanical connection through a torque arm 36 to a non-rotating landing gear component, such as a tow bar or tow jack fitting (not shown), to provide for a torque reaction.
The motor 24 preferably includes a stator 30 and a rotor 38 . Optionally gears, such as gears 40 , and a clutch, such as the clutch 42 , can be provided. Gears and clutch assemblies intended to function in electric motors are known. Appropriate gear and clutch structures can be selected to provide operative connections between the wheel and rotating parts of the motor.
The motor and wheel assembly 10 is shown only on one side of the aircraft axle 16 . The structures on the opposite side of the axle 16 will mirror those shown and described. In addition, a portion of only one wheel is shown. Most commercial aircraft main gear and nose gear assemblies include pairs of wheels. The motor and gear wheel assembly of the present invention can be effectively installed on a single gear wheel or on multiple gear wheels.
FIG. 2 is a schematic illustration of a second possible arrangement of an integrated electric motor and aircraft gear wheel according to the present invention. In this arrangement, the motor 50 provides the structural support for the entire wheel 52 , which is located between the landing gear axle 54 and the tire flange 56 . A pair of bearings 58 , 60 is positioned near the tire bead 62 between the wheel 52 and the motor 50 . Bearing 58 , the inner bearing, supports the section of wheel 52 closest to the landing gear piston 64 , and bearing 60 , the outer bearing, supports the section of the wheel 52 farthest away from the piston 64 . A conduit 66 is provided near the inner bearing 60 in the tire bead 62 and is sized to accommodate a tire valve stem (not shown), which facilitates access to the tire valve for checking tire inflation and air pressure and adding air when needed. The valve stem can be accessed from outside the wheel without interfering with the motor components.
In the FIG. 2 embodiment, the motor 50 forms the wheel support, and both bearings 58 and 60 are located away from the axle 54 , in contrast to the embodiment shown in FIG. 1 , in which only one bearing 28 is required. In FIG. 2 , the motor rotor 68 is preferably located between two stator pieces 70 , 72 that form the mechanical supports for the wheel 52 . The rotor 68 is preferably sandwiched between the stator pieces 70 , 72 at or near the centerline of the tire rim width, and a clutch 76 forms an interface with the remaining section of the wheel 52 .
The wheel 52 is preferably bolted at one or more locations (not shown) on one or both of the stator pieces 70 , 72 . A bearing 74 that also functions as a stator support is positioned between the rotor 68 and the axle 54 . As in the FIG. 1 arrangement, the motor 50 includes a mechanical connection to a torque arm 78 that is preferably attached to a non-rotating landing gear component, such as a tow bar or tow jack fitting (not shown), to provide for a torque reaction. As in FIG. 1 , the motor and wheel assembly is shown on only one side of the aircraft axle 54 . The structures on the opposite side of the axle 54 will mirror those shown and described.
An electric motor preferred for use with the integral motor and gear wheel assembly of the present invention could be any of a number of designs, for example an inside-out motor attached to a wheel hub in which the rotor can be internal to or external to the stator, such as that shown and described in U.S. Patent Application Publication No. 2006/0273686, the disclosure of which is incorporated herein by reference. A toroidally-wound motor, an axial flux motor, or any other electric motor geometry known in the art is also contemplated to be suitable for use in the present invention.
The electric motor selected should be able to move an aircraft gear wheel at a desired speed and torque. One kind of electric drive motor preferred for this purpose is a high phase order electric motor of the kind described in, for example, U.S. Pat. Nos. 6,657,334; 6,838,791; 7,116,019; and 7,469,858, all of which are owned in common with the present invention. A geared motor, such as that shown and described in U.S. Pat. No. 7,469,858, is designed to produce the torque required to move a commercial sized aircraft at an optimum speed for ground movement. The disclosures of the aforementioned patents are incorporated herein by reference. Any form of electric motor capable of driving a gear wheel to move an aircraft on the ground, including but not limited to electric induction motors, permanent magnet brushless DC motors, and switched reluctance motors may also be used. Other motor designs capable of high torque operation across the desired speed range that can be integrated into an aircraft wheel to function as described herein may also be suitable for use in the present invention.
The integral motor and aircraft wheel assembly described above presents significant advantages over known motor and aircraft wheel assemblies. The motor selected for use with this assembly will preferably be sufficiently compact to fit in the available space in an aircraft landing gear assembly and will have a mass that is as low as functionally possible. As a result, spin up loads for the wheel are minimized by removing considerable motor mass. In addition, the present invention allows the motor to spin up and match wheel speed before a clutch is engaged. The effect of this is to permit the electric drive motor to connect or disconnect as required, eliminating the need to bring the aircraft to a stop before the assembly is engaged or disengaged.
Not only is the motor and wheel assembly of the present invention designed to be easily installed in existing aircraft, but service and maintenance tasks are made easier by this design. Existing landing gear aircraft tires, axles, and pistons can be reused, which means that the tire rim width, tire bead, and bead seat do not have to be changed or re-certificated by the FAA, a potentially time consuming and costly process. Additionally, the incorporation of the motor within the aircraft wheel greatly simplifies routine maintenance and service. Access to motor components, such as the rotor and bearings ( 34 and 28 , respectively in FIGS. 1 and 68 and 58 , 60 , respectively in FIG. 2 ), is gained by removing the wheel. Servicing of the assembly, moreover, does not require disconnection of the electrical connections (not shown) between the motor ( 24 in FIGS. 1 and 50 in FIG. 2 ) and a wire harness (not shown) that leads into the aircraft fuselage. Changing an aircraft tire is easier with the present motor and wheel assembly than with available aircraft motor and wheel assemblies because the motor does not have to be removed from the aircraft. The use of a low profile tire in the integral motor and wheel assembly of the present invention, such as that disclosed in International Patent Application No. WO 2008/027458, the disclosure of which is incorporated herein by reference, can provide additional space inside the wheel for the motor.
The amount of wheel mass required to be removed from the aircraft is reduced considerably because the bulk of the inside wheel well would be motor mass that can stay connected to the aircraft. Finally, the present motor assembly can be more easily sealed from environmental contaminants such as water, ice, snow, and corrosive chemicals commonly used at airports, including de-icing fluids, hydraulic fluids, and the like, thereby increasing the useful life of the motor and related components.
It can be seen in FIGS. 1 and 2 that a solid thermal connection between the motor ( 24 , 50 ) and the axle ( 16 , 54 ) and piston ( 20 , 64 ) and associated hardware (not shown) is provided. This connection enables heat to be shed or dissipated through these large metallic components without requiring additional structures or methods. Other arrangements for dissipating heat in a motor-driven aircraft gear wheel could also be used to enhance the heat dissipation by the thermal connection. An example of a system that can be employed effectively to cool wheel motors is described in U.S. Patent Application Publication No. US2009/0152055, which is incorporated herein by reference. This system includes providing a rotor with fan-shaped projections or, alternatively, holes or tunnels, in connection with a fan, to conduct warm air from inside the motor and wheel assembly to the outside.
The motor and gear wheel assembly of the present invention has been described in connection with a single aircraft gear wheel. This assembly can also be used simultaneously on more than one aircraft wheel, including one or more of the nose wheel or the other aircraft wheels.
While the present invention has been described with respect to preferred embodiments, this is not intended to be limiting, and other arrangements and structures that perform the required functions are contemplated to be within the scope of the present invention.
Industrial Applicability
The present invention will find its primary applicability in retrofitting existing aircraft landing gear and gear wheels with the integral electric drive motor and wheel assembly of the present invention when it is desired to obtain the advantages of the capability for moving an aircraft on the ground independently of the aircraft main engines or external tow vehicles. | An integral motor and wheel assembly for aircraft landing gear is provided that includes an electric motor packaged within at least one gear wheel and configured to fit completely within the space provided in an existing aircraft for the landing gear components. The motor is positioned within the wheel to minimize the spin-up weight and to maximize the space within a given volume allocated for the motor. Installation of this motor and gear wheel assembly in an existing aircraft landing gear is designed to permit the continued use of existing landing gear components, including tires, axles, and pistons, so that the assembly can be easily retrofitted into existing aircraft. | 8 |
CLAIM OF PRIORITY
[0001] This is a Continuation-In-Part application of U.S. patent application Ser. No. 10/473,913, filed on Oct. 5, 2003, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The following disclosure relates to building structures. In particular, the disclosure relates to building structures employing modular frameless load bearing structural panels and also to an improved construction system for assembling such modular panels to form a load bearing structure.
BACKGROUND
[0003] The prior art is replete with modular building structures and associated construction methods, many of which suffer from a variety of problems. Amongst such problems are included the complexity and labour intensity of assembling elaborate framing systems to which modular panels are attached, the inconvenience attendant the use of plural individual fasteners to fix structural panels to one another, and the inferior load bearing capacity of many modular structures.
[0004] An example of a prior art modular construction arrangement which employs a plurality of fasteners is U.S. Pat. No. 4,858,398 which discloses a structure using proportionally sized panels secured together by turn-lock fasteners inserted through aligned openings in adjacent sides of panels.
[0005] A further exemplary prior art construction arrangement is that disclosed in French Patent Document Number 2 389 724. This document discloses a modular building using panels having adjacent vertical sides of complementary shapes. The panels are joined together by screws and are reinforced with metal plates at the location of the joints.
[0006] Generally speaking, modular wall construction systems incorporating interfitting or interlocking panel systems may be classified as load bearing or non-load bearing.
[0007] Examples of non-load bearing modular wall constructions are disclosed in U.S. Pat. Nos. 3,511,000; 3,512,819; 4,031,675; 5,094,053 and 6,679,021 which are limited either to internal partitioning or dividing walls or otherwise require a load bearing framework to support a roof structure or the like thereon.
[0008] U.S. Pat. Nos. 5,007,222 and 5,640,824 describe load bearing modular wall structures. In U.S. Pat. No. 5,007,222, there is described an energy efficient load bearing wall construction comprising foamed plastic panels having load bearing studs located between or formed integrally with upright joints between adjacent panels. U.S. Pat. No. 5,640,824 discloses a fire resistant modular wall panel having corrugated or ribbed metal sheets separated by a plurality of bridge girt assemblies in the form of elongate brace members with non-combustible, thermally insulating spacers connecting the webs of the brace members to effect a compound metal/ceramic structure wherein structural loads are borne substantially by the exterior metal rib skin. The outer skins are secured to the brace members by rows of self-drilling/self-tapping screws and the interior cavity may be an air space or it may include a mineral wool-type insulating medium.
[0009] Australian Patent 118357 discloses a modular building construction utilizing cored precast concrete wall panels with an upper channel to receive a horizontally tensionable member over the length of the wall. A truss-like frieze frame sits atop the wall panels.
[0010] Australian Patent Application No 71777/74 describes a lightweight modular panel system comprising a foamed plastics core between decorative sheet styrene skins. These panels include spaced vertical cavities within the core and recessed channel-like apertures on all edges to receive steel reinforcing rods and poured concrete to form a load bearing panel with a steel reinforced concrete framing there within.
[0011] U.S. Pat. No. 6,754,999 discloses a modular system comprising a plurality of metal framed load bearing walls fabricated from C-shaped studs and roof trusses connected by welding or self-tapping screws. Inner and outer walls may be finished with gypsum wallboard and weather resistant plywood respectively.
[0012] Another building system for constructing lightweight preformed wall and roof panels for small dwellings and mobile homes is disclosed in U.S. Pat. No. 3,898,779. This system incorporates interlocking panels having a high density polyurethane core between decorative skins such as styrene sheets with decorative finishes. Although the wall panels are secured under compression by tensioned tie bolts extending through spaced cast-in tubes between a contoured upper tie bar and a base structure, the load bearing capacity of the panels is contributed by the provision of flat load bearing surfaces in the upper and lower edges of the panel members.
[0013] U.S. Pat. No. 5,687,956 describes a reinforced fence and building wall construction with lightweight sandwich panels supported at their ends between spaced upright tubular posts.
[0014] A method and apparatus for manufacturing foamed plastics laminated panels for modular building applications is disclosed in the applicant's Australian Patent No. 620338, the disclosure of which is incorporated herein by reference. Panels manufactured in the manner described therein are an example of those suitable for use with the present disclosure. One particular advantage of the applicant's previously disclosed method is that the panels may be conveniently fabricated at the building site.
SUMMARY
[0015] Techniques related to a building structure and modular construction method are disclosed.
[0016] In one aspect, a load bearing wall structure for a building includes frameless modular wall panels, with each frameless wall panel having spaced skins of fiber reinforced cement sheet separated by a core of expanded in situ high density polyurethane foam bonded to inner faces of said spaced skins. In addition, each frameless wall panel also has formed in upright edges thereof a recessed channel forming, together with a recessed channel of an edge-abutting wall panel, a hollow aperture extending between top and bottom surfaces of said abutting frameless wall panels. The load bearing wall structure also includes a lower panel edge locating channel member securable to a building support base. Further, the load bearing wall structure includes an upper panel edge locating channel member and a tensionable element extending via each hollow aperture between an anchor member secured to said base and said upper panel edge locating channel member whereby, in use, vertical loads applied to said wall structure are distributed substantially evenly through said spaced skins of said frameless modular wall panels.
[0017] Implementations can optionally include one or more of the following features. The upper panel edge locating channel member can include a load transfer member. Also, the load transfer member can also include the upper panel edge locating channel member and a compression member, in use, acting in unison. In addition, one or more of the frameless wall panels can each include an elongate hollow aperture extending between upper and lower edges of said one or more frameless panels intermediate side edges thereof. Further, the elongate hollow aperture can extend adjacent a normally upright edge of the one or more frameless wall panels to accommodate a tensionable element. Also, the load bearing wall structure can further include a ribbed edge locating member securable to a face of a frameless wall panel to engage a recessed channel of a further frameless wall panel to form a 90° junction between the frameless wall panel and the further frameless wall panel. The ribbed edge locating member can include a channel-like recess behind a projecting rib extending longitudinally of the ribbed edge locating member, the channel-like recess, in use, being adapted to accommodate a tensionable element therein. Also, the ribbed edge locating member can include a mounting flange extending longitudinally thereof. Further, in use, a roof structure can be secured directly to the upper panel edge locating channel member to form an integrally coupled building structure.
[0018] According to another aspect of the invention there is provided a building structure incorporating the load bearing wall structure as hereinbefore described, the building structure having a roof structure mechanically coupled to said base via said tensionable elements.
[0019] The subject matter described in this specification provides many advantages. For example, a building structure employing load bearing frameless modular panels which overcomes or ameliorates at least some of the problems associated with the prior art are provided.
[0020] Other features, objects, and advantages will be evident from the following description, drawings and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is a front elevation view of an exemplary building structure;
[0022] FIG. 1B is an end elevation view of the building structure of FIG. 1A ;
[0023] FIG. 1C is a schematic plan view of the building structure of FIGS. 1A and 1B showing the arrangement of frameless modular panels comprising the walls;
[0024] FIG. 2A is an enlarged partial sectional view of a base structure showing the junction of the floor structure with an outer wall;
[0025] FIG. 2B is an enlarged sectional view of the portion of FIG. 2A in the circle;
[0026] FIG. 3A is an exploded isometric view illustrating the erection of frameless, modular panels to form a wall, wherein the top load transfer member is an upper panel edge locating member;
[0027] FIG. 3B is an exploded isometric view illustrating the erection of frameless modular panels to form a wall, wherein the top load transfer member comprises an upper panel edge locating member and a compression member;
[0028] FIG. 3C is an enlarged detail view of an optional arrangement for locating the bottom edges of the frameless modular panels;
[0029] FIGS. 4A and 4B are enlarged sectional plan views of the aligned panels showing the configuration of the positive positioning profiles on the frameless modular panels;
[0030] FIG. 5 is an enlarged partial sectional view of the roof area showing an arrangement of the fascia;
[0031] FIG. 6A is an end elevation of a modular roof panel;
[0032] FIG. 6B is an enlarged detailed view of the showing the positioning profiles on the roof panels; and
[0033] FIG. 7 is an exploded isometric view showing the arrangement of corner junctions and tee-junctions of the walls.
[0034] Like reference symbols and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0035] In general, FIG. 1 shows a building structure 1 in the nature of a small dwelling which may be constructed. The structure includes a base 2 , a number of walls 3 and a roof 4 . The walls, whether external or entirely internal, are composed of modular panels 5 . The modular panels are fabricated to a typical module size of 900 mm wide by 3.0 m high. In some situations larger panels may be used, particularly to accommodate the pitch of a roof. The modular panels are secured to the base by tensionable tie rods (described later) which are disposed along the walls at 900 mm centres 6 . Additional tie rods are disposed at the sides of openings in the walls 7 and at the corners 8 of the building structure.
[0036] The wall panels may be erected on a concrete slab or timber floor structure or, as illustrated in FIG. 2A , on a floor structure comprising a panel support frame supported by screw-in foundations. In the latter arrangement, the walls 3 are supported in locating channels 12 by an inverted T-shaped frame member 10 mounted on screw-in foundations 11 .
[0037] Floor panels 9 are also mounted on the inverted T-shaped member 10 and the floor panels 9 are generally attached via screws 17 A extending into a transverse support flange of member 10 .
[0038] FIG. 2B is an enlarged view of the region of wall support encircled in FIG. 2A and shows a lower panel edge locating channel 12 , in the form of a C section member, mounted on the outer support flange of the inverted T-shaped member 10 with the modular wall panels 5 located therein. Threaded studs 13 , for securing respective tie rods 14 , are fastened to the horizontal face of the outer flange of the inverted T-shaped member 10 by welding, screwing or the like and protrude via apertures 17 through the wall locating channel 12 into an upright hollow aperture 16 formed at the abutting edge junctions of adjacent panels 5 for engagement with a nut 15 fastened to the end of each tensionable tie rod 14 .
[0039] The overall arrangement of the load bearing wall structure may be better understood by reference to the exploded views shown in FIGS. 3A and 3B . Individual wall panels 5 are erected and aligned such that abutting recessed panel edge channels 16 a together define hollow apertures 16 which align with studs 13 and co-operating apertures 17 in the wall locating channel 12 .
[0040] Each tie rod 14 with attached joining nut 15 is inserted into a respective longitudinal aperture 16 and engaged with a respective stud 13 anchored in base 2 . A top member in the form of an inverted channel 19 locates the upper portions of panels 5 in edge to edge alignment and also functions as a load transfer member for vertically applied loads. Apertures 22 in the top member 19 , are sized to accommodate the shaft of the tie rods 14 and are spaced so as to correspond to the spacing of studs 13 whereby the upper ends of the rods 14 protrude through apertures 22 in the top member 19 when it is positioned over the modular wall panels. The upper end of the tie rods 14 is screw-threaded and engageable with a nut 23 to facilitate the tensioning thereof. The nuts 23 are engaged with the rods and tightened against the top member 19 to place the wall structure into compression to a desired degree.
[0041] FIG. 3B illustrates the partial completion of a wall, similar to that of FIG. 3A , but wherein the top member comprises, in combination, an upper panel edge locating channel 20 and a compression member 21 . The compression member 21 is located over channel member 20 . Apertures 22 and 22 A in both the channel member 20 and compression member 21 respectively, are sized to accommodate the shaft of the tie rods 14 and are spaced so as to correspond to the studs 13 .
[0042] As with the embodiment of FIG. 3A , nuts 23 are engaged with the rods and tightened against the compression member 21 whereby the channel member 20 and the compression member 21 act in unison to impart a predetermined degree of compression into the wall structure.
[0043] FIG. 3C is an enlarged view of the manner in which panel edge channel 16 a is aligned with aperture 17 in the lower panel edge locating channel 12 to allow the tie rods 14 to be anchored to the base 2 via studs 13 (not shown). In an alternative embodiment (not illustrated), the tie rods are externally screw threaded at both lower and upper ends thereof. The lower end engages with an internally screw threaded stud adapted, for example, for friction fitting in holes drilled into a concrete slab floor.
[0044] For ease of description, the subsequent embodiments will describe the top member comprising an upper panel edge locating member and a compression member although it should be understood that the top channel-shaped member 19 will function alone as a load bearing member.
[0045] The use of tie rods, preferably of high tensile strength, can overcome problems with fasteners, such as screws or the like, being pulled out of the modular panels in high wind load conditions.
[0046] The capacity of wall structures arises by the ability of the wall panels to distribute vertical loads substantially evenly throughout the panel skins spaced by the foam polyurethane core. While cementitious products such as fibre reinforced cement sheeting show superior strength in compression, they exhibit poor tensile and flexural load capacity. When a relatively thin sheet of fibre reinforced cement of about 4 mm to 6 mm in thickness is subjected to a compressive load via opposed edges, it rapidly fractures due to a buckling mode of failure whereby as it buckles, one face of the sheet resists a compressive load but the other face is unable to resist a tensile load. By forming the core within a closed mould containing the spaced sheet skins, the liquid polyurethane is able to partially penetrate the porous sheet material as it undergoes foaming under pressure whereby the bond between the core material and the skins is maximized. The panel structure is thus analogous to an I-beam in that the fully supported but otherwise fragile outer skins are separated by a “web” of foam material which resists buckling of the outer skins when vertical compression loads are applied and also resists lateral deformation under load.
[0047] Vertical static loads tests conducted on a 75 mm thick×900 mm wide panel with outer skins of 6 mm thick fibre reinforced cement sheeting and a cast in mould core of high density polyurethane having a density of 50 kg per metre 3 showed the panels easily supporting a load of 10 tonnes distributed over the width of the panel. Compression failures were noted at about 15 tonnes or greater. For 100 mm thick panels having 6 mm thick outer skins, a safe compressive load of 25 tonnes was achieved with about a 50% safety margin.
[0048] Compared with low density foamed plastics panels wherein the outer skins are secured to the foam core by adhesives, the panels utilized have a load capacity of 4-5 times that of the laminated low density panels having a core density typically of about 15 kg metre 3 .
[0049] The load bearing wall structures are thus readily able to resist both vertical and lateral wind loads due to the combination of the panel structure and the manner in which the wall structures are anchored to the base under compression via the upper load transfer members which act together in a unitary structure.
[0050] FIG. 4A shows in plan, a schematic view of one form of the upright edge abutment of frameless wall panels 5 having recessed channels 16 a formed in the upright edge faces of panels 5 . The core 25 is typically 65-85 mm thick whilst the skins are between 4.5 mm and 6 mm in thickness. At the butt join between adjacent panels 5 , a hollow aperture 16 is formed from the two recessed channels 16 a in the facing edges of the panels.
[0051] When the panels are abutted, see FIG. 4B , an upright hollow aperture 16 is formed to accommodate tensionable tie rod 14 . If required, additional hollow apertures or recesses (not shown) may be provided immediately under the panel skins for accommodating building services such as electrical wiring.
[0052] As shown in FIG. 4B , the upright joint between adjacent panels 5 may be enhanced by the location within hollow aperture 16 of a thin rectangular section steel or plastics tube 18 which not only assists in maintaining edge to edge alignment of wall panels from top to bottom but also provides additional reinforcement against lateral wind loads. Typically, the abutting ends of wall panels 5 will be coated with a gap filling flexible polymeric adhesive to maximise the insulating properties of the wall structure and otherwise to accommodate any minor movement due to thermal expansion and contraction of the panels. Where the rectangular tube 18 is located in the hollow aperture 16 between adjoining panels, it too may be secured with adhesive but it need not extend completely between the upper and lower channels 12 , 20 as it is not needed as a structural load bearing member, rather a key to maintain channels 16 a in alignment. It readily will be apparent to a skilled addressee that the panel edge joints, whether reinforced with tube 18 or not are thermally efficient as there is no conductivity path from one side of a wall structure to the other.
[0053] A first embodiment of a roof for the building structure is illustrated in FIG. 5 . In this embodiment the roof 4 has a minimum pitch, typically of from 3 to 10 degrees, and is supported directly by the external load bearing walls 30 and by the internal load bearing walls 31 . The roof may also be comprised of modular panels as discussed in more detail below in relation to FIG. 6A .
[0054] The roof panels 33 are secured at one end to the external walls 30 by screws 34 which pass through the roof panels 33 , compression member 21 and upper panel edge locating channel member 20 before terminating inside the core of modular wall panel 5 . In this manner, the roof panels are mechanically coupled via the engagement between screws 34 and the combination load transfer member 20 , 21 and thence via the rods 14 to base 2 to form a unitary structure.
[0055] At the other end of the roof panel, near the ridge, the screws 34 securing the roof panels engage with the load transfer members atop internal walls 31 in the same manner as with the external walls 30 . The peak portion of the roof panels is covered by ridge capping 36 which extends over the roof panel securing screws 34 , which capping is secured to the roof panels by further screws 36 A.
[0056] As shown in FIG. 6A , the modular roof panels 33 in this embodiment include a 0.42 mm ribbed steel outer skin 37 and an injected polyurethane foam core 38 which has a 0.42 mm ribbed steel inner skin 39 , the panel is typically 100 mm thick, The underside of the roof panel is lined ( 39 A). The roof lining ( 39 A) may be 4.5 mm fibre-cement board, 10 mm plasterboard, random grooved ply or a timber ceiling screwed directly onto the ribbed steel inner skin. Suitably the roofing panel is hi-tensile sheet ribbed roofing profile. Wooden support blocks 40 are embedded in the core at spaced locations along one end and one side of the roof panel to provide mounting points for the fascia panel 41 , shown in FIG. 5 .
[0057] The floor panels described in FIG. 2 may also be made of a similar panel construction as the roof panels described above and in reference with FIG. 6 . The floor panels are also formed from hi-tensile ribbed steel decking and may be lined with either composite flooring, waterproof ply or a timber floor applied directly onto the sheeting by screws or gluing.
[0058] The use of hi-tensile ribbed steel decking for roof and floor panels has the advantage of having high strength, light weight, and being able to span up to 7 metres, thereby providing ease of construction whilst reinforcing the building strength without the need for roof trusses, bearer and joist floor constructions or the like.
[0059] The enlarged detail view of the roof panel joint in FIG. 6B shows the arrangement of a projection 42 and cooperating recess 43 formed in the sides of the foam core 38 of a roof panel 33 . The enlargement shows a ridge 37 A of the outer roof skin extending laterally past the core such that, when two cooperating roof panels are engaged, the extended ridge 37 A clips over the ridge nearest the side of an abutting roof panel. The core may also be undercut in the vicinity of the projection so as to produce a longitudinal cavity 44 when the roof panels are clipped together. This cavity may accommodate building services in the same manner as the subsidiary cavities provided in the wall panels.
[0060] Returning to FIG. 5 , the outer roof skin is turned-up 45 at the peak end edge thereof to minimise any leakage. The roof skin also extends past the foam core 38 and coplanar embedded wooden blocks 40 , so as to overhang the guttering 46 at the fascia end 47 . The wood or metal fascia panel 41 is suspended under the valleys of the overhung roof skin by screws 48 and attached to the embedded support blocks 40 by a further series of screws 49 . The screws which are sunk into the fascia support blocks also pass through gutter brackets 50 which brackets in turn support the guttering 46 .
[0061] FIG. 5 is also generally illustrative of one way of forming a multi-story building structure. Instead of securing roof panels 33 over the tops of wall panels 30 as shown, floor panels 9 ( FIG. 2 ) as described above may be secured over the tops of wall panels 30 with threaded ends of tie bolts 14 protruding there through. Additional base locating channels 12 are then aligned on the upper face of the floor panels 9 over tie bolts 14 and further wall panels may then be erected thereon as if the floor panels 9 together form a base 2 equivalent to that shown in FIG. 1A . Upper edge locating channels are then secured over the upper edges of the upper wall structure and tensionable tie bolts 14 are inserted into the apertures 16 formed between adjacent wall panels 30 to tie the top and bottom walls to the base 2 via the tie bolts 14 . Typically, a ground floor wall panel will be 100 mm thick while an upper floor panel is 75 mm thick. Additional rigidity is given to the building structure by the lateral bracing by the floor panels mounted between the upper and lower wall panels as well as a roof structure secured to upper load bearing channels secured over the upper edges of the upper wall panels.
[0062] FIG. 7 shows the arrangement of the corners and tee-junctions of walls, in particular, the alternative arrangements of the upper edge locating channels and compression members at these junctions. A completed outer wall 30 is shown in place upon the base 2 , with an upper channel member 20 and compression member 21 on the top side thereof engaged by tie rod nuts 22 . The wall junctions commonly include positioning profile members 51 which are attached upright to the completed wall 30 at selected positions by screws 52 . Lower panel edge locating channels 12 are fixed upon the floor surface or base 2 to locate the modular panels making up the walls.
[0063] An outer wall panel 53 is shown ready to be positioned at the corner of the structure, whereby the recess 53 A in the upright side of the outer wall panel cooperates with the rib 51 A of the positioning profile member. At a corner the upper edge locating channel 20 will have about 75 mm removed from the inner flange of the C channelling. The remaining web and outer flange of the C channelling member then run to the outer edge of the corner. The upper edge locating channel 20 on the joining wall simply adjoins or overlaps the other upper edge locating channel with a flange partially removed. The compression members 21 at the corner joint are machined to half thickness for the length of the corner joint, thus forming half thickness tongues. These half thickness tongues are arranged so that the compression members interlace or overlap, resulting in an even thickness of the compression members at the corner. One of the frameless modular panels forming the corner join has an additional longitudinal hollow aperture, capable of receiving a tie rod 14 . This additional longitudinal cavity is located so as to be at the centre of the corner join. Apertures 55 and 55 A are provided on the upper edge locating channels 20 and compression members 21 to facilitate fixing the members together and corresponding to the additional longitudinal cavity of the modular panel, thereby contributing to the structural integrity of the building.
[0064] FIG. 7 also shows the tee-junction arrangement of an internal wall where a tie rod in an intersecting wall is not in immediate proximity, but is provided at the intersecting end of the internal wall. The internal wall panel 57 (shown in fragmentary form) engages with the respective positioning profile member 51 thereby defining a longitudinal hollow aperture behind rib 51 A. The upper edge locating channel 58 and compression member 59 include apertures 60 & 60 A at their extremities. The upper edge locating channel 58 and compression member 59 are then disposed on the top side of the internal wall comprised of like panels 57 . The tie rod 14 , provided for the end of the internal wall, may then be inserted through the apertures 60 and 60 A and down into the cavity for securing the internal wall 57 .
[0065] Throughout this specification and claims which follow, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers. | Among other things, a load bearing wall structure for a building is disclosed. The load bearing wall structure includes frameless modular wall panels with each frameless wall panel having spaced skins of fiber reinforced cement sheet separated by a core of expanded in situ high density polyurethane foam bonded to inner faces of the spaced skins. Each frameless wall panel also has formed in upright edges a recessed channel forming, together with a recessed channel of an edge-abutting wall panel, a hollow aperture extending between top and bottom surfaces of the abutting frameless wall panels. A lower panel edge locating channel member securable to a building support base is also included. Further included is an upper panel edge locating channel member and a tensionable element extending via each hollow aperture between an anchor member secured to the base and the upper panel edge locating channel member. | 4 |
BACKGROUND
1. Field of Invention
The invention is directed to a downhole clean-up tool or junk basket for use in oil and gas wells, and in particular, to downhole clean-up tools that are capable of creating a hydraulic barrier within the wellbore annulus above the collection member to facilitate capture of debris flowing within the wellbore annulus.
2. Description of Art
Downhole tools for clean-up of debris in a wellbore are generally known and are referred to as “junk baskets.” In general, the junk baskets have a screen or other structure that catches debris as debris-laden fluid flows through the screen of the tool. Generally, this occurs because at a point in the flow path, the speed of the fluid carrying the debris decreases such that the junk or debris falls out of the flow path and into a basket or screen.
SUMMARY OF INVENTION
Broadly, downhole tools for clean-up of debris within a well comprise a mandrel and a collection member for capturing debris within the wellbore. A fluid flow member for creating a hydraulic barrier above an opening of the collection member is operatively associated with the mandrel. Creation of the hydraulic barrier facilitates movement of the debris laden fluid within the wellbore into the collection member by restricting upward movement of the debris laden fluid. In one particular embodiment, the fluid flow member includes one or more ports disposed above the opening of the collection member, at least one of the ports being oriented to expel a fluid flowing down the bore of the mandrel into the wellbore annulus to create the hydraulic barrier.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a partial cross-sectional view of a specific embodiment of a downhole tool disclosed herein.
FIG. 2 is a partial cross-sectional view of the downhole tool shown in FIG. 1 disposed in a tool string and disposed in a wellbore.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
Referring now to FIGS. 1-2 , in one particular embodiment, downhole tool 30 comprises mandrel or body 31 having upper end 32 , lower end 33 , and bore 34 defined by inner wall surface 35 . Both upper and lower ends 32 , 33 include threads 39 for releasably connecting downhole tool 30 within a tool or work string (not shown in FIG. 1 ). Bore 34 runs the entire longitudinal length of body 31 . Bore 34 permits a fluid flowing down the tool string to pass through downhole tool 30 where it can ultimately be expelled from the tool string into the wellbore to facilitate a downhole operation such as milling. Upon being expelled into the wellbore, the fluid travels up the wellbore annulus carrying debris so that it can be captured by downhole tool 30 .
Downhole tool 30 captures the debris within collection member 40 . As shown in the embodiment of FIGS. 1-2 , collection member 40 included upper end 41 and lower end 42 . Upper end 41 includes one or more openings 43 for receiving debris laden fluid. Lower end 42 is closed so that debris is captured within cavity 44 . One or more ports 46 are disposed around collection member 40 to permit fluid and small debris to flow out of cavity 44 . Thus, port(s) 46 facilitate circulation of debris laden fluid into and out of cavity 44 so that debris that is too large to pass through port(s) 46 is captured within cavity 44 .
To facilitate capturing debris within cavity 44 , downhole tool 30 includes one or more fluid flow members to create a hydraulic barrier within the wellbore annulus above opening(s) 43 . Creation of the hydraulic barrier restricts the upward movement of the debris laden fluid within the wellbore annulus. As a result, more debris laden fluid is directed into opening(s) 43 so that debris can be captured within cavity 44 . In the embodiment of FIGS. 1-2 , the fluid flow member that creates the hydraulic barrier is one or more ports 37 . Port(s) 37 are in fluid communication with bore 34 so that a portion of the fluid flowing through bore 34 is directed out of port(s) 37 into the wellbore annulus.
Although each port 37 can be shaped and sized as desired or necessary to create the hydraulic barrier, in certain embodiments, one or more of ports 37 include a jet nozzle to facilitate creation of the hydraulic barrier. In addition, one or more of ports 37 can be disposed at an angle that is perpendicular to a longitudinal axis of downhole tool 30 . Alternatively, one or more ports 37 can be disposed at an acute angle, oriented in a downward direction such as shown in FIGS. 1-2 .
Referring now to FIG. 2 , in operation, downhole tool 30 is placed in tool string 14 and lowered to the desired location within casing 12 of wellbore 10 . A fluid is flowed or pumped down tool string bore 16 into mandrel bore 34 . A portion of the fluid flowing through mandrel bore 34 is directed through ports 37 into wellbore annulus portion 18 as indicated by arrows 17 . Additional fluid continues down bore 34 , and thus tool string 14 until it is ultimately expelled from tool string 14 into the wellbore. Upon being expelled into the wellbore, the fluid travels up wellbore annulus portion 19 carrying debris as indicated by arrows 21 . Upon encountering the hydraulic barrier created by fluid flowing out of ports 37 (arrows 17 ), the debris laden fluid flowing up through wellbore annulus portion 19 is restricted from flow further up wellbore annulus portion 18 , or above wellbore annulus portion 18 . As a result, the debris laden fluid is directed toward opening 43 of collection member 40 as indicated by arrow 23 .
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the port(s) 37 can be disposed perpendicular to an axis of the downhole tool or they can be disposed at any other angle desired or necessary to create the hydraulic barrier within the wellbore annulus. Further, it is to be understood that the term “wellbore” as used herein includes open-hole, cased, or any other type of wellbores. In addition, the use of the term “well” is to be understood to have the same meaning as “wellbore.” Moreover, in all of the embodiments discussed herein, upward, toward the surface of the well (not shown), is toward the top of Figures, and downward or downhole (the direction going away from the surface of the well) is toward the bottom of the Figures. However, it is to be understood that the tools may have their positions rotated in either direction any number of degrees. Accordingly, the tools can be used in any number of orientations easily determinable and adaptable to persons of ordinary skill in the art. Accordingly, the invention is therefore to be limited only by the scope of the appended claims. | A downhole tool for removing debris from a wellbore comprises a body having a bore, a collection member, and a means for creating a hydraulic barrier within a wellbore annulus. The hydraulic barrier within the wellbore annulus restricts upward movement of a debris laden fluid within the wellbore annulus causing the debris laden fluid to be directed toward the collection member. Thus, the hydraulic barrier facilitates removal of debris from the wellbore. | 4 |
BACKGROUND
The present disclosure pertains to energy and particularly to energy consumption. More particularly, the disclosure pertains to measurement of energy consumption.
SUMMARY
The disclosure reveals a system for disaggregating an indication of total energy consumption for a collection of components into indications of individual energy consumption for each of the components, respectively. The collection of components may be situated in a facility. A sensor may obtain electrical signals from one or more power input lines which convey power to the facility for the components. The signals may indicate the total energy consumption by the collection of components. There may be approaches and/or mechanisms which are used to disaggregate the indication of total energy consumption into indications of individual energy consumption by the components without the need for separately determining the individual energy consumption with additional measurements or instrumentation. Also, approaches and/or mechanisms may be used for integrating a known load activity with whole facility energy consumption for enhancing the component disaggregation. Indications of individual energy consumption may permit evaluation of components from efficiency, conservation and/or other perspectives, in a reasonable manner.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a diagram showing major components of a load disaggregation system for such places as a home or building;
FIG. 2 is a diagram of hardware architecture for a load disaggregation system which is similar to the system in FIG. 1 , except that the system shown in FIG. 2 has a thermostat state feedback and an output which may also be an input for some components of a facility;
FIG. 3 is a diagram of hardware architecture for a load disaggregation system similar to the system of FIG. 2 but with a smart appliance state feedback;
FIG. 4 is a diagram a processor and functionalities for achieving load disaggregation;
FIG. 5 a is a flow diagram of a load disaggregation process;
FIG. 5 b is a diagram of another load disaggregation process;
FIG. 5 c is a diagram of still another load disaggregation process;
FIG. 6 is a diagram of architecture for a base load analysis in a residential scenario;
FIG. 7 is a diagram of architecture for base load analysis in an industrial scenario;
FIG. 8 is a diagram of a processor and functionalities for achieving base load analysis;
FIG. 9 shows a lower portion of a graph of rated loads of two appliances separately at two different levels, combined rated loads of the appliances at another level, and no loads of appliances at still another level, and an upper portion of a graph indicating whether there is a load or not, with shading, symbols or color to indicate a magnitude of the load if there is one;
FIG. 10 is a graph of a correspondence between scales and frequencies relative to wavelet analysis;
FIG. 11 is a diagram of a wavelet scalogram;
FIG. 12 is a graph of power (P) data and normalized power difference (dP/dt) energy data taken to demonstrate the usefulness of derivative power data in change detection;
FIG. 13 is a diagram of power (P) versus time in a graph at an upper portion of the diagram and a corresponding graph at a lower portion of scale versus time showing wavelet transform coefficients; and
FIG. 14 is a diagram having an upper portion with a graph of dP/dT versus time with a corresponding graph of scale versus time showing wavelet coefficients at virtually all scales in an upper portion of the diagram.
DESCRIPTION
A system and approach for load disaggregation (e.g., separation into components) may be noted. An ever increasing interest in energy-efficient buildings may be driving research and development in the field of building design, energy conservation, energy harvesting, renewables, and so on. Energy conservation may be one of the important areas for which, focusing on the electricity consumption from the individual appliances is very useful. This may motivate and guide a user in conservation effort, and also act as a verification tool. Seeing electricity usage in near real time, throughout the day, may make it easier to reduce the consumption and save money. Moreover, automated systems for energy management may use the near real-time energy consumption readings and their changes with respect to an adopted control action to confirm the efficacy and/or further refine the automatic control action for energy management.
Energy awareness concepts among residential and commercial users may be an approach to provide information on the energy usage and thus providing value by preventing the energy wastage. Disaggregation by end-use may be very useful in understanding the scenario and aid both consumers and producers to identify targets for conservation. While hardware-based sub-metering appears costly and labor-intensive, non-intrusive load monitoring (NILM) may be capable of gathering detailed energy-use data with minimal equipment cost and installation time. Installation of energy measurement equipment for each appliance appears to incur extra costs. Besides, additional functionalities like communication may be added to ensure that the energy measurement values are communicated to a central module where the energy awareness can be calculated and displayed. This all may indicate additional cost. Assuming a cost of $50 (US) for each piece of energy measurement equipment, it may easily work out to be an extra $250 in case, for instance, five appliances have to be measured.
The granular energy consumption details for equipment may be critical for demand side management. This approach may provide a way to infer appliance level energy usage without the need for granular energy measurement which would require additional energy measurement devices. However, variations in measurements between metering devices may complicate the process of compiling the necessary appliance profiles. Granular energy details for individual equipments may be useful in developing intelligent algorithms to manage energy consumption. The present approach may estimate the energy consumed by individual appliances, based on a gross energy meter reading.
The present approach does not necessarily involve adding any energy measurement module per piece of equipment. A single digital meter may be installed at the incoming line within the residence/commercial facility. The meter may be fixed after a tariff meter or be the tariff meter itself. This meter may store readings of the total energy consumed at a required level of granularity. The user may provide appliance details and usage hours on a typical day including weekends and holidays. The appliance details may include the rating of the load and type of the load like, for example, a washing machine, hot water circuit, AC, and so on. The system may also learn the actual consumption by monitoring the energy usage on a continuous basis. The system may infer the individual appliance usage with the help of energy measurement and the appliance specifications.
The components of the system may incorporate: 1) An energy measurement device for gross energy measurement; 2) A central node which performs granular measurement; and 3) The energy measurement device which transmits gross energy data to the central node on a periodic basis. The central node may run an algorithm required to break up the gross measurement into individual measurements of load consumption of appliances.
Hardware-based sub-metering appears costly and labor-intensive. Non-intrusive load monitoring (NILM) may be capable of gathering detailed energy-use data with minimal equipment cost and installation time. The granular energy consumption details for equipment may be critical for demand side management. This approach may provide a way to infer appliance level energy usage without the need for granular energy measurement which would require additional energy measurement devices. However, variations in measurements between metering devices may complicate the process of compiling the necessary appliance profiles. Granular energy details for individual pieces of equipment may be useful in developing intelligent algorithms to manage energy consumption
The accuracy of the energy inference may be questionable in such kind of a system. Thus, one may provide a new architecture and algorithm for the load disaggregation.
The salient features of the system may incorporate: 1) Load switching event detection based on instantaneous voltage and current signatures and derived parameters such as instantaneous harmonics, peak current, voltage dip, current and voltage symmetrical component analysis considering whole house energy and residual load energy parameters; 2) Load disaggregation based on time domain, frequency domain and time-frequency domain analysis; 3) An intelligent decision support system; and 4) A hardware platform which can acquire data from a heating, ventilation and air conditioning (HVAC) system and smart appliances for disaggregation purposes.
A system and approach for load disaggregation may be noted. A diagram of FIG. 1 may represent the major components of the load disaggregation system for a facility, such as a home or building. The electrical supply may be a two-phase three-wire system with a 60 Hz frequency and a phase voltage of 120 V. In another approach, the supply may be a three-phase, four-wire system with a 50 Hz electric distribution system with a phase voltage of 230V. In still another approach, the electric power supply system may be single-phase 60 Hz system with a phase voltage of 120V. In yet another approach, the power supply may be a single-phase, 50 Hz and 230V power supply. Other electrical services may be utilized.
FIG. 1 is a diagram of hardware architecture for a load disaggregation system 120 . Power may be provided by lines 112 and 113 to system 120 . A current sensor 100 and voltage sensor 101 may provide current and voltage indications to a filter bank 102 of system 120 . Outputs from filter bank 102 may go to a data acquisition system (DAC) 103 . Information from data acquisition system 103 may go to a micro controller unit (MCU) 104 and/or digital signal processor (DSP) 104 via a serial communication, serial peripheral and communication interfaces. The micro controller may incorporate the digital signal processor. A zero crossing detector 105 may provide voltage and current zero crossing information to MCU and/or DSP 104 . Information may be provided by a data input module 107 to system 120 . A cloud/web server 110 may be connected to system 120 via an internet connection 109 . A hand-held personal digital assistant (PDA) 108 may be connected to system 120 via a wireless connection to an antenna 116 connected to MCU and/or DSP 104 , which may be capable of WiFi, ZigBee, GPRS, and the like. A remote display 106 may have a wireless connection to system 120 . An output 117 may provide disaggregated information from measurements of power lines 112 and 113 about a facility 111 . The information on output 117 may indicate power-using components such as a dryer, dishwasher, refrigerator, HVAC, and so forth, at facility 111 . Also, information may provide information about an associated thermostat 118 , such as settings for an HVAC 119 at facility 111 .
A sensing unit 100 and 101 may provide the required input range to a data acquisition system 103 . Current sensor coils 100 (or current transformer) may be installed in each supply line, which step down the total current drawn (or total load) into a range suitable for measurement using a data acquisition system 103 . The current and voltage sensor network 100 and 101 , respectively, may typically be located at the main electric service panel at a home or building (i.e., facility 111 ) and the wiring may be provided for various appliances and equipment thereafter through regular or miniature circuit breakers (MCBs). The present approach may be adapted for using other power sensing devices such as energy meters, smart AMI (advance metering infrastructure) meters, and so forth.
DAC 103 may be designed to sample the analog voltage and current signals received from the voltage and current sensor network 100 and 101 at a desired sampling frequency. The sampling frequency may be adjusted to optimize the processing capability of the computing units downstream. In one approach, the DAC system 103 may acquire the voltage (V) and current (I) samples at a pre-decided frequency, and the pre-processing system 201 ( FIG. 4 ) may process the raw data and modify the sampling rate as required by the main processing unit 104 . In one approach, the DAC system 103 may acquire an instantaneous voltage and instantaneous current at a desired sampling rate. The approach may be adapted to work with other versions of data acquisition.
FIG. 2 is a diagram of hardware architecture for load disaggregation system 120 , which is similar to the system in FIG. 1 , except that the system of FIG. 2 has a thermostat state feedback 121 . Also, output 117 in FIG. 1 is also an input from thermostat 118 , HVAC 119 and appliances of facility 111 in FIG. 2 . In the configuration of FIG. 2 , system 120 may take inputs from HVAC set points, relay signals and power consumption for improving the accuracy of load disaggregation.
FIG. 3 is a diagram of hardware architecture for a load disaggregation system similar to the system of FIG. 1 but with thermostat setpoint and relay feedback signal 121 , an input 117 from thermostat 118 , HVAC 119 and appliances of facility 111 , and a smart appliance state and energy consumption feedback signal 122 . The system of FIG. 3 may receive inputs from one or more smart appliances, in addition to HVAC setpoints, relay signals, and power consumption for aid in disaggregation of the power used or being used.
The preprocessing block 201 ( FIG. 4 ) may transform the digital voltage and current samples into a form as desired by the algorithms which process the transformed data. In one of the approaches, the preprocessing block 201 may down sample the acquired current and voltage data and provide a data at a rate as requested by the main processing unit 104 ( FIGS. 1-2 ).
In another approach, a power parameter calculation module of a preprocessing block 201 ( FIG. 4 ) may deduce the secondary power/energy parameters, such as, active power, reactive power, apparent power, electrical energy (KWh), line frequency, harmonic content, peak power, instantaneous power, symmetric components, instantaneous harmonics and so forth. The approach may be adapted for other versions of pre-processing, deducing other parameters.
FIG. 4 is a diagram of a processor 200 and various functionalities for achieving load disaggregation. In one approach, the main processor block 104 , 200 ( FIGS. 1-4 ) may consist of a virtual sub-metering (VSM) engine 300 and a decision support system (DSS) 301 for the VSM engine. Also, in another approach, the load disaggregation may be segregated into several steps, namely, load switching detection, a VSM engine analysis 300 , and decision support system 301 . The one or more approaches may be adapted to many other versions for performing the load disaggregation task.
Specifically, processor 200 may have a preprocessing unit 201 with a phase-locked loop (PLL) engine 202 for line frequency calculation and a power/energy parameter calculation mechanism 203 . Another portion of processor 200 may incorporate a VSM engine 300 and a DSS 301 for the VSM. Also a part of processor may incorporate a communication engine 400 and a display/user interface controller 401 .
In one or more approaches, the instantaneous phase current, instantaneous current harmonics, current symmetrical components and phase voltage may be analyzed to detect an appliance/equipment switching event. A detailed analysis of the load signature may be carried out in case of detection of a switching event. Many different detection approaches may be available for this purpose. In one approach, a hypothesis testing technique in combination with maximum likelihood detection may be carried out. Other parallel techniques in the field of data analysis may be incorporated in the one or more present approaches.
After detecting the switching event, the VSM engine may compare the state of HVAC and smart appliances and deduct the power drawn by HVAC and smart appliances from whole house appliances. This may reduce the uncertainty of load disaggregation. The remaining energy information also known as residual load may be analyzed further for load disaggregation.
The VSM engine may carry out the time-frequency analysis of the load signature or the residual load signature to assign the state of individual home appliance/equipment. In one approach, a wavelet based signal transformation approach may be used, wherein the data in time-domain are transformed to a time frequency domain. A continuous or a discrete wavelet transform may be contemplated based on the processing capability of the main processor 104 . In one of the approaches, the system may derive the instantaneous harmonics as discrimination features for detecting the type of load. Many other parallel time domain, frequency domain or time-frequency domain techniques may be contemplated in the present approaches.
A series of transformation coefficients (also known as features) may be extracted from the transformed variables. In one approach, a set of wavelet coefficients across the scales may be selected based on thresholding techniques. Hard or soft thresholding may be used for this purpose and various techniques for fixing the threshold under various levels may be contemplated. A signature analysis on the selected coefficients may be performed to reveal further details on the activities at a home. In another approach, the system may use un-decimated wavelet transforms (UDWT) to detect and classify the load status.
The system may be sufficiently intelligent to estimate the type of loads connected to the house and their power ratings. For this purpose, the system may acquire a set of historical data and analyze the load switching patterns to deduce the different loads connected to the house. In one approach, the system may consider the current difference (or change in current) and active power difference (or change in active power), and then perform the data clustering techniques to understand different loads connected to the system. Then the detected loads may be pruned using load occurrence probability and load magnitude variation. This intelligence in the system may make it versatile for use in any home or building with minimal load information. The outcome of an analysis may be displayed in the energy manager for user review. These load parameters may then be taken ahead as configuration parameters for load disaggregation.
A decision support system may perform a second level of the check on power parameters to minimize false alarms. In one of the approaches, a fuzzy decision support system may be employed. In the field of data analysis, many other parallel decision support systems may be contemplated for the present purpose.
FIG. 5 a is a flow diagram of a load disaggregation process. The process may begin at symbol 131 and go to symbol 132 where samples of V and I are obtained and noise is filtered using filter banks. Filtered samples of V and I may be preprocessed at symbol 133 . Parameters of interest, such as active power, reactive power, apparent power, peak current, instantaneous harmonics, and so forth, may be calculated at symbol 134 . At symbol 135 , the voltage and current samples may be analyzed for event detection. A question whether an event is detected may be asked at symbol 136 . If the answer is no, the process may end at symbol 139 . If the answer is yes, then event classification may be performed at symbol 137 . The results of the classification at symbol 137 may go to a decision support system for down selecting loads at symbol 138 . From symbol 138 , the process may end at symbol 139 .
FIG. 5 b is another diagram of a load disaggregation process. The process may begin at symbol 141 and go to symbol 142 where noisy current and voltage waveforms are filtered. At symbol 143 , feature extraction may be performed and feature vectors may be stored. The features may be sent for detection at symbol 144 . A question is asked at symbol 145 whether an event is detected. If the answer is yes, then event confirmation may be performed at symbol 146 . Event confirmation is required to avoid spurious event detection due to sensing noise or noise introduced from the power line. A question is asked at symbol 147 whether the event is confirmed. If yes, then at symbol 148 load analysis is performed and the possible loads are narrowed down. Signature analysis may be performed at symbol 149 . A question at symbol 151 is whether the load is inductive. If yes, then the prior load inductive information is combined at symbol 152 . At symbol 153 , inductive load disaggregation may be performed. If the answer to the question is no at symbol 151 , then a question at symbol 154 whether the load is an SMPS (switched-mode power supply) may be asked. If yes, then the prior SMPS load information may be combined at symbol 155 . At symbol 156 , SMPS load disaggregation may be performed. If the answer to the question is no at symbol 154 , then a question at 157 whether the load is resistive may be asked. If yes, then the prior resistive load information may be combined. At symbol 159 , resistive load disaggregation may be performed. If the answer to the question is no at symbol 157 , then an overall likely load analysis may be performed at symbol 160 .
FIG. 5 c is still another diagram of a load disaggregation process. The process may begin at symbol 161 and go to symbol 162 where voltage and current signals are decomposed using a wavelet transform. At symbol 163 , the appropriate wavelet coefficients may be retained at the required scales for load disaggregation application. Discontinuities in the individual scales may be detected and load switchings may be detected at symbol 164 . At symbol 165 , the question whether an event is detected might be asked in the same manner as at symbol 145 in FIG. 5 b . Also, the remaining portion of the process is similar to that in FIG. 5 b . It may be particularly noted that signature analysis may be performed using current and voltage signals as indicated at symbol 149 .
One may note that box or symbol 146 of FIGS. 5 b and 5 c may state “Perform Event Confirmation”. A box or symbol 137 in FIG. 5 a may state “Perform Event Classification”. Symbols 146 and 137 appear different. One may note that FIG. 5 a is a generic block diagram and FIG. 5 b shows a step for time domain analysis. The event confirmation in symbol 146 FIG. 5 b may be exclusively meant for a time domain analysis step, where spurious noise in energy signals may trigger events. However, event confirmation steps may make sure that the event trigger was not due to spurious noise but due to actual load switching.
FIGS. 5 b and 5 c show several different approaches relative to load disaggregation. FIG. 5 b reveals time domain analysis where energy signature (voltage and current) may be analyzed for event detection. This may be shown particularly in symbols 141 to 145 . On the other hand, FIG. 5 c reveals time-frequency based approach which may be known as wavelet transform techniques used to detect the event and load disaggregation. This approach may be described in symbols 161 to 165 . Once an event is detected, the rest of disaggregation process may remain the same. Thus, there may be similar symbols in both Figures after an initial event detection mechanism.
There may be process steps between, for example, blocks or symbols 152 and 153 , and steps for load disaggregation in symbol 153 . A process step may be a combining the current load signature/wavelet feature information and prior information. There may be several ways of combing, namely, a fuzzy logic based approach, Bayesian approach or Dempsher-Shepherd information fusion approach. However, one may keep the approach generic.
One may note where the “prior SMPS load info”, for instance, comes from in symbol 155 . The prior information on each type may be obtained after mining historical data. For example, in a particular house, the water heater may likely be switched on in the mornings. Other information may be that a pool pump operates only during noon, when the electricity price is low. One may deduce this information from the historical load data of the house, which can be called “prior info”. In the present particular approach, one may first classify the loads based on their electrical characteristics (resistive, inductive, SMPS, and so forth) and then combine (or make use of “prior info”) to disaggregate the load. In short, the prior SMPS load info may come from an analysis of historical data.
One may note the process and/or end result of the “overall likely load analysis” in symbol 160 . When signature analysis is performed, there may be a situation where the analysis engine fails to recognize the load. These may be regarded as “miscellaneous loads”. One may take this as miscellaneous loads and stop the analysis. Or, one may further analyze the miscellaneous load and provide additional information regarding the likely load (with an associated confidence number). This may be covered in “Overall Likely Load Analysis” 160 . One might replace “overall load” with “miscellaneous load”.
A system and approach for residential, commercial and industrial base load analyses may be noted. A base load may be a range of minimum electrical loads over a given period of time present in a home, industry or a commercial building. A high base load may indicate a potential energy inefficiency of a building. An analysis of the base load may provide ways to improve the energy performance of a building such as a house. In particular, base load analysis may identify persistent loads which may result in ways to reduce elements of consumption, such as continuously operating fans, low level HVAC loads, or various plug loads.
Because of the continuous nature of a base load, a total energy consumption of a residence/building/industrial complex may be significantly reduced by decreasing the base load. This may help in reducing the energy footprint of the building and improving savings in electricity bills.
In an approach, a main processor block may host a suite of base load analysis algorithms. The analysis may be segregated into two steps, namely, anomaly detection and base load analysis. An anomaly detection module may analyze the total active and reactive power drawn by a load. This load may be compared with a reference value which is adaptively obtained from a pre-calculated list/table/function as per standards. This reference value may be a function of many attributes, such as location, time of day, ambient conditions, number of occupants, and so on. The comparison may provide the performance of the home with the values as stipulated in the standards. In another approach, the system may perform a time-based load analysis using acquired data and compare the results with historical data. In this way, the system may provide a chronological comparison of the base load, which could help in detecting an anomaly.
In one approach, instantaneous phase current and phase voltage may be analyzed to detect an appliance/equipment switching event. A detailed analysis of the load signature may be carried out in case of detection of a switching event. Many different detection techniques may be available for this purpose. In one approach, a hypothesis testing technique in combination with maximum likelihood detection may be carried out. After detecting the event, the type of load may be inferred from the available list of loads present in the facility. This load may then be analyzed and further action may be contemplated to reduce the base load consumption.
In another approach, a set of parameters such as peak current, RMS current, rate of change of current, frequency change may be estimated and compared with reference thresholds. Under an anomaly, the event may be analyzed for determining whether the event is of interest or not. In one approach, the algorithm may compare the parameters of interest to stored parameters in the memory. The system may estimate the signature and understand whether a 24×7 appliance/equipment is switched ON or an occupant turned on the system. In case of detection of an event of interest, the base load analysis system may further process the data and investigate the anomaly. In one approach, the system may estimate a spectrum of the instantaneous current signal and analyze the frequency components. In still yet another approach, the base load system may use a short-time-Fourier transform-based spectrum estimation and a non-parametric technique in the other one. In yet another approach, the signal processor may use an adaptive filtering algorithm to estimate the base load. In another approach, the signal processor may use a Kalman filter for the purpose. In yet another approach, the signal processor may use a wavelet-based time-frequency estimation technique.
An overall idea in the present analysis may be to obtain a state of the appliances/equipment and other loads and then to perform a base load analysis. The detailed analysis may bring out the reasons for higher base load and provide a way to control the loads. An active feedback on energy performance and recommended actions may be provided to the user. Another kind of technique in this regard may be adapted.
A system and approach for residential, commercial and industrial base load analyses may be noted. A base load may be a minimum electrical load over a given period of time present in a home, industry or a commercial building. A high base load may indicate an energy inefficiency of a building. An analysis of the base load may reveal various loopholes in the thermal design of a house or building, unnecessary loads, and provide ways to improve the energy performance of the house or building.
FIG. 6 and FIG. 7 are diagrams of major components of the system. The electrical supply may be a two-phase three-wire system with a 60 Hz frequency and a phase voltage of 120V. In another approach, the electrical supply may be a three-phase, four-wire, 50 Hz electric distribution system with a phase voltage of 230V. In another approach, the electric power supply system may be a single-phase 60 Hz system with a phase voltage of 120V. In yet another approach, the power supply may be a single-phase, 50 Hz, 230V supply. The approach may be adapted for other kinds of electrical services.
FIG. 6 is a diagram of hardware architecture for base load analysis in a residential scenario. The diagram is of hardware architecture for a load disaggregation system 120 . Power may be provided by lines 112 and 113 to system 120 . A current detector 100 and voltage sensor 101 may provide current and voltage indications to a filter bank 102 of system 120 . Outputs from filter bank 102 may go to a DAC 103 . Information from DAC 103 may go to an MCU and/or DSP 104 via a serial and other communication, serial peripheral and communication interfaces. A zero crossing detector 105 may provide zero crossing information about the power from lines 112 and 113 to MCU and/or DSP 104 to calculate line frequency and phase information. Information may be provided by a data input module 107 to system 120 . A hand-held PDA 108 may be connected to system 120 via a wireless connection to an antenna 116 connected to MCU and/or DSP 104 , which may be capable of WiFi, ZigBee, GPRS, and the like. A remote display 106 may have a wireless connection to system 120 . An outside sensor 108 may provide information in a form of wireless signals to system 120 via antenna 116 .
FIG. 7 is a diagram of hardware architecture for base load analysis in an industrial scenario. This diagram is similar to the diagram of system 120 in FIG. 6 , except for power lines 127 , 128 and 129 in lieu of power line 113 . Current sensors 100 and voltage sensors 101 may be situated on lines 112 , 127 , 128 and 129 . Outputs from sensors 100 and 101 may go filter bank 102 . Connections from lines 127 , 128 and 129 may go to a mechanism 125 that provides PLL input signals to MCU and/or DSP 104 . Mechanism 125 may be in lieu of the zero crossing detector of system 120 in the diagram of FIG. 6 . A cloud/web server 110 may be connected to system 120 via an internet connection 109 .
Voltage sensing units 101 may provide a needed input range to a data acquisition system 103 . Current sensor coils 100 (or current transformer) may be installed in each supply line, which step down the total current drawn (or total load) into a range suitable for measurement using the data acquisition system 103 . The current and voltage sensor network 100 and 101 may be typically located at the main electric service panel at the home or building, and wiring may be provided for various appliances and equipment thereafter through circuit breakers (or MCBs). The approach may be adapted for using other power sensing devices such as energy meters, smart AMI meters, and so forth.
The DAC 103 may be designed to sample the analog voltage and current signals received from voltage and current sensor network at a desired frequency. The sampling frequency may be adjusted to optimize the processing capability of computing units downstream. In one approach, the DAC may acquire the V and I samples at a pre-decided frequency and the preprocessing unit 201 ( FIG. 8 ) may process the raw data and modify the sampling rate as needed by the main processing unit 104 . The approach may be adapted for other versions of data acquisition.
The preprocessing unit 201 may transform the digital voltage and current samples into a form for the algorithms which process the transformed data. In one approach, the preprocessing unit 201 may down sample the acquired current and voltage data and provide the data rate as demanded by the main processing (MCU and/or DSP) unit 104 . In another approach, a power parameter calculation unit 203 may deduce the secondary energy parameters, active power, reactive power, apparent power, electrical energy (or KWh), line frequency, harmonic content, peak power, instantaneous power, and so forth. The approach may be adapted for utilizing other versions of pre-processing, deducing other parameters, and so on.
FIG. 8 is a diagram of a processor 250 and functionalities. In FIGS. 4 and 8 , one may note whether there might be connection lines between the boxes or symbols, labels for all of the higher level symbols, and a more definitive correspondence of any of the symbols to the components in FIGS. 1-3 and 6 - 7 . It may be seen that FIGS. 4 and 8 show algorithm modules running in the system, that is, FIG. 4 for load disaggregation and FIG. 8 for baseload analysis. Each Figure may have three themes (shown vertically): 1) Data acquisition and pre-processing; 2) Signature analysis and decision support; and 3) Advisory and user interface. Thus, no connection line is necessarily needed.
Specifically in FIG. 8 , processor 250 may have a preprocessing unit 201 with a PLL engine 202 for line frequency calculation and a power parameter calculation mechanism 203 . Another portion of processor 250 may incorporate an anomaly detection mechanism 305 and a base load analyzer 306 . Also a part of processor may incorporate a communication engine 400 and a display/user interface controller 401 .
In one approach, a main processor block 104 ( FIG. 8 ) may host a suite of base load analysis algorithms. The analysis may be segregated into steps, namely, anomaly detection mechanism 305 and base load analyzer 306 . The approach may be adapted for utilizing many other versions for performing the base load analysis task.
The anomaly detection module may analyze the total active and reactive power drawn by the load. This load may be compared with a reference value which may be adaptively obtained from a pre-prepared list/table as per standards. The reference value may be function of many attributes, such as location, time of day, ambient conditions, number of occupants, and so forth. This comparison may provide performance of the home with the values as stipulated in the standards. In another approach, the system may perform time-based base load analysis based on the acquired data and compare the results with historical data. In this way, the system may provide a chronological comparison of the base load.
In one approach, the instantaneous phase current and phase voltage may be analyzed to detect an appliance/equipment switching event. A detailed analysis of the load signature may be carried out in case of detection of a switching event. Many different detection techniques may be contemplated for this purpose. In one approach, a hypothesis testing technique in combination with maximum likelihood detection may be carried out. After detecting the event, the type of load may be inferred from the available list of loads present in the facility. This load may then be analyzed and further action to reduce the base load consumption might be suggested. Other parallel techniques may be contemplated.
In another approach, a set of parameters such as peak current, RMS current, rate of change of current, frequency change may be estimated and compared with the reference. Under an anomaly, the event may be analyzed and it may be decided whether the event is of interest or not. In one approach, the algorithm may compare the parameters of interest to stored parameters in the memory. The system may estimate the signature and understand whether a 24×7 appliance/equipment is switched ON or an occupant switched ON the system. In case of detection of event of interest, the base load analysis system may further process the data and investigate the anomaly. In one approach, the system may estimate a spectrum of the instantaneous current signal and analyze the frequency components. In one approach, the base load analysis may use short-time Fourier transform-based spectrum estimation and a non-parametric technique in the other one. In yet another approach, the signal processor may use an adaptive filtering algorithm to estimate the base load. In another approach, the signal processor may use a Kalman filter for the purpose. In yet another approach, the signal processor may use a wavelet-based time-frequency estimation technique. An overall idea in this analysis may be to obtain a state of the appliances/equipment and other loads, and then to perform the base load analysis. The detailed analysis may bring out the reasons for a higher base load and provide a way to control it. An active feedback on the energy performance and recommended actions may be provided to the user. Other techniques may be contemplated and adapted in the present approach.
In one approach, as noted herein, the main processor block may consist of a VSM engine and a DSS. The load disaggregation may be segregated into several steps, namely, load switching detection, virtual sub-metering analysis, and decision support. In one approach, the instantaneous phase current and phase voltage may be analyzed to detect an appliance/equipment switching event. A detailed analysis of the load signature may be carried out in case of detection of a switching event. Many different detection techniques may be available for this purpose. A hypothesis testing technique in combination with maximum likelihood detection may be carried out.
After detecting the switching event, the virtual sub-metering engine may carry out the time-frequency analysis of the load signature to assign the state of individual home appliance/equipment. A wavelet based signal transformation approach may be used, where the data in a time-domain is transformed to a time frequency domain. A continuous or a discrete wavelet transform may be attempted based on the processing capability of the main processor.
A series of transformation coefficients (also known as features) may be extracted from the transformed variables. A selected set of wavelet coefficients across the scales may be selected based on the thresholding techniques. A hard or a soft thresholding may be used for this purpose and various techniques for fixing the threshold under various levels may be explored. A signature analysis on the selected coefficients may be performed to reveal further details on the activities at home.
A decision support system may perform a second level of check on power parameters to minimize false alarms. A fuzzy decision support system may be employed. Other parallel decision support systems may be contemplated for this purpose.
The wavelet based virtual submetering may be considered. The high frequency energy data may be useful in virtual submetering issues. A wavelet based time-frequency analysis algorithm may be noted for this purpose. Any discontinuity (or spike) in energy data due to appliance/equipment switching may introduce characteristic frequencies. This spectrum may be characterized using wavelet coefficients and the type of switching (appliance type, ON/OFF, operation mode) may be deduced by analyzing the time-frequency spectrum of high frequency data from line-neutral (hot-neutral), neutral-ground currents/voltage (or active power). In this analysis, one may use RMS values for energy parameters. One may consider active power as the input and undertake wavelet analysis. To start with, the analysis may be performed using synthetic data with two loads. For example, a data summary may indicate a number of appliances as 2, the rated load of the appliances as 500 W and 1000 W, respectively, a sampling frequency as 10000 Hz, and a signal time length as 1 sec (for 10000 samples). One portion of FIG. 9 is a graph 20 of rated load of the one at levels 11 and 12 , two at level 13 , or no appliances versus samples. Another portion of FIG. 9 is a graph 30 shows whether there is a load and uses a color red at bars 14 if the load is about 1000 W or greater and a color blue at bars 15 if the load is about 500 W, with the load being indicated as 1 under those conditions. Other colors may be used in the graph. Shading or symbols may instead be used in this graph and other similar graphs mentioned herein.
Wavelet analysis may be noted. A 32-level decomposition of an original signal may be performed using multiple wavelet bases such as gauss, db, morlett, symlet and Naar wavelets. The ability of the system may be analyzed to detect appliance and equipment operation. Symlet and morlett may be identified as wavelet bases for virtual sub-metering applications.
A correspondence between scales and frequencies may be shown in a graph of FIG. 10 . Frequency versus scale is plotted as a curve 16 in the graph. The graph may depend on the selected wavelet, a total number of scales and a sampling frequency. The Nyquist sampling criterion and the maximum frequency component in the signal may be assumed to be half of the sampling frequency.
If there is knowledge regarding the frequency component of the switching/operation of the appliances, then one may estimate the wavelet scales which contain those frequencies and accordingly classify the switching actions.
A wavelet scalogram may be noted in FIG. 11 . A continuous wavelet analysis may be attempted to compute the scalogram of wavelet coefficients. One may experiment with many wavelet bases and infer suitability in virtual sub-metering applications. Symlet and morlet bases may be selected for virtual sub-metering applications.
The location of frequency information in the scalogram may depend on the wavelet used for the analysis. There may be a time and frequency uncertainty in time-frequency analysis applications. Some wavelets may be able to detect the frequency location very well; however, this may depend on what is known as the “support” that the basis function has under each scale.
Wavelet analysis of spa data may be noted. The signal 18 in a diagram of magnitude versus samples in FIG. 11 may be analyzed. Another diagram of scale versus time (or space) such as samples, may show a percentage of energy for each wavelet coefficient in the Figure. A home which was considered may have a spa with an electric heater. Large spikes 19 as seen in the diagram may be from the electric heater. A base load approximately of 1 KW may be observed at virtually all of the time. Intermittently, refrigerator and HVAC activity may also be seen. Wavelet analysis may be performed to understand distinct features which can be obtained for virtual sub-metering applications.
In a graph 21 of FIG. 12 , a wavelet transform of power (P) data and normalized “power difference (dP/dt)” energy data may be taken to demonstrate the efficiency of wavelet transforms in change detection and spectrum estimation. The data may be normalized between zero and one before a transforming the data into a wavelet domain.
FIG. 13 is a diagram of a power (P) versus time in a graph portion 22 with a corresponding graph portion 23 of scale versus time showing wavelet transform coefficients.
As shown in graph portion 24 of dP/dT versus time in FIG. 14 , a sharp discontinuity in power (and dP/dt) signal may give rise to high energy wavelet coefficients at virtually all scales, as shown in graph portion 25 of scale versus time. This may imply that a broad set of frequencies (from DC to sampling frequency (Fs)/2) are present in the data. This may be due to the fact that the power signal is sampled at one second intervals. Thus, virtually all transients (switch ON/switch Off and operation) may have died out and the data may contain steady state switching information. As the sampling rate is too small, switching operation may behave as a pulse with a sharp discontinuity. However, if there are high frequency data (e.g., 100 kHz), the corresponding frequency band, which is active during particular appliance switching, may be captured which could have a distinct signature (both in frequency and energy), that may be used for virtual sub-metering applications.
A U.S. patent application Ser. No. 13/192,096, filed on Jul. 27, 2011, entitled “System and Method for Detection of Home Occupancy”, having the same assignee as that of the present application, is hereby incorporated by reference.
A U.S. patent application Ser. No. 13/192,141, filed on Jul. 27, 2011, entitled “System and Method for Evaluation of Programmable Thermostat Usage Efficiency and Control of HVAC System”, having the same assignee as that of the present application, is hereby incorporated by reference.
Although the present system and/or approach has been described with respect to at least one illustrative example, many variations and modifications will become apparent to those skilled in the art upon reading the specification. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the related art to include all such variations and modifications. | A system for disaggregating a gross energy measurement into individual component energy consumption. A collection of components may be situated in a facility. A sensor may obtain electrical signals from one or more power input lines which convey power to the facility for the components. The signals may indicate the total energy consumption by the collection of components. Approaches and/or mechanisms may be used to disaggregate the indication of total energy consumption into indications of individual energy consumption by the components without the need for separately determining the individual energy consumption with additional measurements or instrumentation. Also, approaches and/or mechanisms may be used for integrating a known load activity with whole facility energy consumption for enhancing the component disaggregation. Indications of individual energy consumption permit a reasonable evaluation of components from efficiency, conservation and/or other perspectives. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
The present disclosure relates to subject matter contained in priority Korean Application No. 10-2011-0076151, filed on Jul. 29, 2011, which is herein expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This specification relates to superparamagnetic nanoparticles, and a method for producing the same. Particularly, the superparamagnetic nanoparticles have osmotic-drawing characteristics, have high dispersibility in water and is recyclable. These nanoparticles can be applied as solutes for water treatment system or for desalinating seawater.
2. Background of the Invention
In order to prepare for the lack or exhaustion of water resources, researches into desalinating seawater or treating wastewater through an osmosis membrane filtration process have currently been conducted. Such water treatment employs a reverse osmosis membrane filtration or a forward osmosis membrane filtration. The reverse osmosis membrane filtration process employs a pressurizing type, which causes high energy consumption. So, in recent time, the forward osmosis membrane filtration process is preferred.
However, the forward osmosis membrane filtration has also primary problems to be solved. One of the problems is found in a method for recovering a solute from an osmotic draw solution after execution of the forward osmosis membrane filtration. Studies of using ammonium carbonate as the solute of the draw solution are actively in progress. This material has an advantage of being recyclable, after used, by being decomposed into gas and then collected. However, this method also has drawbacks of causing considerable energy consumption and generating ammonia gas which is harmful to environments and toxic.
To overcome such drawbacks, a study, in which superparamagnetic nanoparticles dispersible in water are used as solutes to draw a forward osmosis, and a magnetic field is used to collect the superparamagnetic nanoparticles from a draw solution for recycling, has been first reported by Ming M. L. et. al in University for Singapore (Ing. Eng. Chem. Res., 2010, 49, 5869-5876). In regard of this document, a mixture of Fe(acac) 3 precursor with 2-pyrrolidine, triethylene glycol, or triethylene glycol/polyacrylic acid was refluxed at high temperature over 245° C. so as to produce iron oxide superparamagnetic nanoparticles which are dispersible in water. Here, the superparamagnetic iron oxide nanoparticles, which were produced from the mixture of Fe(acac) 3 precursor and triethylene glycol/polyacrylic acid and had surfaces coordinated with polyacrylic acid, showed the most excellent dispersibility and osmosis. This exhibited 7.5 LMH (L·m −2 ·hr −1 ) permeation flux in a primary desalination experiment using salt water. However, several limitations to the recyclability were observed in this document as well. That is, aggregation of the superparamagnetic nanoparticles was caused to thereby increase the size of the nanoparticles recovered under the magnetic field from 21 nm prior to recovery to 50.8 nm after recovery, and accordingly the permeation flux was decreased down to 2 LMH in a secondary desalination experiment. Also, the synthesis of Ming' study is performed using high-priced Fe(acac) 3 precursor at the high temperature of 245° C., so it is not economical.
The osmosis increases in proportion to osmolality of a solute which is dissolved or dispersed in water. Hence, materials, which are dissolved or dispersed in water to provide more solutes and easier to be recovered and recycled, exhibit advantages in economical and eco-friendly aspects. Nanoparticles have many number of organic molecules bonded on surfaces thereof, so water-dispersibility of the nanoparticles and osmolality are in a directly proportional relationship up to a critical concentration. The water-dispersibility of the superparamagnetic nanoparticles is determined by a hydrodynamic size in water, and it is preferable for the nanoparticles to have a size smaller than 20 nm and exhibit a monodispersed distribution.
In general, when the size of a magnetic nanocrystal exceeds 20 nm, the nanocrystal has ferromagnetism or ferrimagnetisms, which makes it impossible to control the aggregation of the magnetic nanoparticles. Iron oxide nanoparticles synthesized by the traditional coprecipitation method may have a size less than 20 nm, but be aggregated due to high surface energy with less surface charge. Thus, it has been known that the hydrodynamic size distribution of the magnetic nanoparticles is wide away.
In the meantime, hydrophobic superparamagnetic nanoparticles synthesized in nonpolar organic solution, as recently reported, exhibit a monodispersed distribution in size and are well dispersed in a nonpolar organic solvent, but not dispersed in water. In order for the hydrophobic superparamagnetic nanoparticles to have the water-dispersibility, they must go through a surface modification process, but the surface modification is complicated and non-economical. Also, even after the surface modification, it is difficult to have hydrodynamic monodispersibility. In addition, economic performance and practicability should have priorities in processes, such as desalination of seawater, requiring for a large quantity of materials made with low costs.
SUMMARY OF THE INVENTION
Therefore, to address such drawbacks of the related art, an aspect of the detailed description is to provide superparamagnetic nanoparticles having a high surface charge, a uniform particle size and excellent water-dispersibility, namely, exhibiting a small hydrodynamic size less than 20 nm and a monodispersed distribution, and a method for producing the same.
Another aspect of the detailed description is to provide superparamagnetic nanoparticles exhibiting high osmosis-drawing characteristics and recyclability by virtue of excellent dispersibility being maintained upon re-dispersion even though being recovered under a magnetic field.
Another aspect of the detailed description is to provide superparamagnetic nanoparticles with the best dispersibility by reaction at room temperature using lowest-priced precursors.
Another aspect of the detailed description is to provide superparamagnetic nanoparticles capable of being economically and practically used as solutes for water treatment such as seawater desalination.
To achieve these and other advantages and in accordance with the purpose of this specification, as embodied and broadly described herein, there is provided a nanoparticle comprising of superparamagnetic nanocrystals less than 20 nm in size, and molecules containing 3 to 5 carboxyl groups, wherein the molecules bond to surfaces of the superparamagnetic nanocrystals.
The superparamagnetic nanocrystals may be at least one type selected from a group consisting of γ-Fe 2 O 3 , MnFe 2 O 3 , Fe 3 O 4 , CoFe 2 O 3 , and NiFe 2 O 3 .
The molecules containing the 3 to 5 carboxyl groups may be at least one type selected from sodium citrate, ethylenediaminetetraacetic acid (EDTA), and ethylenetriaminepentaacetate (ETPA).
According to a method for producing nanoparticles according to this specification, a solution, in which molecules containing 3 to 5 carboxyl groups, a divalent transition metal and ferric precursors are mixed, is added into an alkaline solution with pH 10 to 14, thereby synthesizing nanoparticles consisting of the superparamagnetic nanocrystals and the molecules containing the 3 to 5 carboxyl groups, wherein the superparamagnetic nanocrystals have the molecules bonded to the surfaces thereof.
A method for producing nanoparticles according to this specification may include preparing an alkaline solution with pH 10 to 14, producing a mixture in which molecules containing 3 to 5 carboxyl groups and ferric precursors are dissolved, and adding the mixture into the alkaline solution.
The divalent transition metal may be at least one type selected from a group consisting of Mn 2+ , Fe 2+ , Co 2+ , and Ni 2+ .
The molecules which are containing the 3 to 5 carboxyl groups may be at least one type selected from sodium citrate, ethylenediaminetetraacetic acid (EDTA), and ethylenetriaminepentaacetate (ETPA).
Further scope of applicability of the present application will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from the detailed description.
Effect of the Invention
According to this specification, an iron precursor solution, which contains a ligand material having at least 3 carboxyl groups, is added into an alkaline solution so as to synthesize superparamagnetic nanoparticles, which are economical, practical and highly dispersible in water, namely, have a small hydrodynamic size less than 20 nm. The superparamagnetic nanoparticles can be used for water treatment, such as seawater desalination, by virtue of their excellent osmosis-drawing characteristics and recyclability, and also be utilized as nanofluids for heat-exchangers and MR contrast agents which require for the excellent dispersibility.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is Transmission Electron microscopic (TEM) image of iron oxide nanoparticles synthesized in Example 1;
FIG. 2 is X-Ray Diffraction (XRD) pattern showing that the nanoparticle synthesized in Example 1 is Fe 3 O 4 (magnetite) phase;
FIG. 3 is a hysteresis curve showing superparamagnetic property of the iron oxide nanoparticles synthesized in Example 1;
FIG. 4 shows analysis results of hydrodynamic diameters of the iron oxide nanoparticles synthesized in Example 1, which are collected using a magnet and then dispersed in water; and
FIG. 5 shows analysis results of hydrodynamic diameters of nanoparticles, which are stirred in salt water (seawater) for 1 hour, collected using a magnet and dispersed in water.
DETAILED DESCRIPTION OF THE INVENTION
The present inventors who have long-term expertise for superparamagnetic iron oxide nanoparticles have recognized the following two facts, namely, the first fact that a ligand which is the most stably coordinated to the superparamagnetic iron oxide nanoparticles is a carboxyl group, and the second fact that a ligand material having at least 3 carboxyl groups is required to increase water-dispersibility of the superparamagnetic iron oxide nanoparticles by electrostatic repulsion.
However, the present inventors have determined that if the organic polymer is used as shown in the document such as Ming M. L., some freely dangling polyacrylic acid chains get agglomerated together and many number of carboxyl groups existing on one polymer molecule are coordinated to different nanoparticles, thereby causing the aggregation of the nanoparticles. In other words, according to our analysis, as organic ligands used by them consist of polymers called polyacrylic acid, some parts of polymer chains, which are freely dangling, get twisted while the nanoparticles are recovered by the magnetic field, and one polymer molecule has too many number of carboxylic acid (—COOH) functional groups, whereby those carboxyl (—COO − ) groups are coordinated to different nanoparticles, respectively, to instead cause the aggregation of the nanoparticles.
Hence, superparamagnetic iron oxide nanoparticles having excellent dispersibility in water, osmosis-drawing characteristics and recyclability have been produced according to the configuration of the present disclosure of selecting simple organic molecules having 3 to 5 carboxyl groups as ligands and using low-priced iron precursors at room temperature.
The superparamagnetic iron oxide nanoparticles have a small hydrodynamic size less than 20 nm and exhibit a monodisperse distribution. Although it is not especially necessary to limit the lowest limit of the size of the nanoparticle, the nanoparticle exhibits superparamagnetism and oxidation stability as high as being practically useful when it is at least 2˜3 nm in size, so it is preferable to limit the lowest limit to 2 nm.
Meanwhile, according to traditional coprecipitation of the related art described in the background of the invention, it has been known that γ-Fe 2 O 3 , MnFe 2 O 3 , CoFe 2 O 3 , and NiFe 2 O 3 nanoparticles are synthesized when Fe 2+ is omitted or a different type of divalent transition metal instead of Fe 2+ is used under the same traditional method and conditions as creating Fe 3 O 4 nanoparticles, although nanoparticles are disadvantageously aggregated. Consequently, the method for producing superparamagnetic Fe 3 O 4 nanoparticles of the present disclosure, which exhibit excellent dispersibility in water, osmosis-drawing characteristics and recyclability, can be applied directly to production of γ-Fe 2 O 3 , MnFe 2 O 3 , CoFe 2 O 3 , and NiFe 2 O 3 nanoparticles.
Hereinafter, description will be given in detail of illustrative examples of the present disclosure. The illustrative examples are intended to help clearer and easier understanding of the present disclosure, and should not be construed to limit the scope of the present disclosure.
Example 1
Production of Superparamagnetic Iron Oxide Nanoparticles Having Size Less than 20 nm in Water and Monodispersed Distribution
9.54 g of FeCl 2 .4H 2 O, 25.9 g of FeCl 3 .6H 2 O and 7.2 g of sodium citrate were added and dissolved into 75 mL of distilled water in a sequential manner, thereby preparing a solution (Solution 1). Meanwhile, a mechanical stirrer was installed on a three-prong flask with a capacity of 2 L, and 750 mL of 1 M NaOH solution was prepared (Solution 2). While stirring the solution 2, the solution 1 was slowly added into the solution 2. After stirring the mixture for 5 hours more, iron oxide nanoparticles having a size of about 7 nm were produced. After reaction completed, the solution was centrifuged to obtain the nanoparticles. The obtained nanoparticles were washed using ethanol more than two times, and then dispersed in 250 mL of ethanol. From 10 mL of this solution were collected solids by use of a magnet. The collected solids were completely dried. A weight of the solids was measured as 1.3 g, and thus a yield of the whole reaction was determined as 32.5 g.
A TEM image, an XRD pattern, a magnetic hysteresis curve, a hydrodynamic diameter and the like of the nanoparticles were analyzed, and the results were shown in FIGS. 1 to 4 . The TEM image showed uniform nanoparticles having a size of about 7 nm. The XRD analysis results showed formation of Fe 3 O 4 phase, and a saturation magnetization was 62 emu/g, from which superior superparamagnetism was exhibited. The hydrodynamic diameter was 7.06±1.51 nm, in spite of the magnetic field being already applied, resulting in a monodispersed distribution. Hence, it was confirmed that the nanoparticles had excellent dispersibility without aggregation.
Example 2
Seawater Desalination Experiment
A seawater desalination experiment using forward osmosis was carried out by using 0.0065 M nanoparticle solution, which was prepared in Example 1, as a draw solution. 3.5% salt water was prepared to be used as seawater. A celluloid triacetate (CTA) membrane produced by Hydration Technology Innovations (HTI) was used as a membrane. Water flux when using the nanoparticles according to the present disclosure was measured, under conditions that the draw solution and a capacity of reservoir were 500 mL, respectively, a flow rate was 8.5 m/sec, and 10-hour operation was performed. The measurement result was 8 LMH, which was an excellent performance. It was confirmed that the superparamagnetic nanoparticles were easily recoverable from the draw solution using a magnet after operation, and recyclable by virtue of re-dispersibility thereof.
Example 3
Dispersibility in Salt Water of Superparamagnetic Iron Oxide Nanoparticles Having Size of 7.06 Nm in Water and Monodispersed Distribution
To estimate dispersibility of the nanoparticles under rigorous conditions using the nanoparticles produced in Example 1, the following experiment was carried out. Salt water with the same saline concentration (3.5%) as seawater was prepared. The nanoparticles produced in Example 1 were added to the salt water such that the concentration became 0.0065 M. This solution was stirred for 1 hour, and the nanoparticles were recovered by use of a magnet, followed by two-time washing, and then dispersed in water. Hydrodynamic diameters of the nanoparticles dispersed in water were analyzed, and the results were 8.1±1.2 nm. Accordingly, it was confirmed that no aggregation was caused before and after use of the nanoparticles. The results are shown in FIG. 5 .
The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatuses. This description is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. The features, structures, methods, and other characteristics of the exemplary embodiments described herein may be combined in various ways to obtain additional and/or alternative exemplary embodiments.
As the present features may be embodied in several forms without departing from the characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the appended claims. | A superparamagnetic nanoparticle is comprised of superparamagnetic nanocrystals less than 20 nm in size, and molecules having containing 3 to 5 carboxyl groups, wherein the molecules bond to surfaces of the superparamagnetic nanocrystals. A method for producing superparamagnetic nanoparticles includes preparing an alkaline solution with pH 10 to 14, producing a mixture in which molecules containing 3 to 5 carboxyl groups, a divalent transition metal and ferric precursors are dissolved, and adding the mixture into the alkaline solution. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention is related to the following GE dockets: ______, filed on ______, respectively.
[0002] The present invention relates to airfoils for a rotor blade of a gas turbine. In particular, the invention relates to compressor airfoil profiles for various stages of the compressor. In particular, the invention relates to compressor airfoil profiles for either inlet guide vanes, rotors, or stators at various stages of the compressor.
[0003] In a gas turbine, many system requirements should be met at each stage of a gas turbine's flow path section to meet design goals. These design goals include, but are not limited to, overall improved efficiency and airfoil loading capability. For example, and in no way limiting of the invention, a blade of a compressor stator should achieve thermal and mechanical operating requirements for that particular stage. Further, for example, and in no way limiting of the invention, a blade of a compressor rotor should achieve thermal and mechanical operating requirements for that particular stage.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In accordance with one exemplary aspect of the instant invention, an article of manufacture having a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1. Wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
[0005] In accordance with another exemplary aspect of the instant invention, a compressor comprises a compressor wheel. The compressor wheel has a plurality of articles of manufacture. Each of the articles of manufacture includes an airfoil having an airfoil shape. The airfoil comprises a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1, wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
[0006] In accordance with yet exemplary another aspect of the instant invention, a compressor comprises a compressor wheel having a plurality of articles of manufacture. Each of the articles of manufacture includes an airfoil having an uncoated nominal airfoil profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1, wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic exemplary representation of a compressor flow path through multiple stages of a gas turbine and illustrates an exemplary airfoil according to an embodiment of the invention;
[0008] FIGS. 2 and 3 are respective perspective exemplary views of a rotor blade according to an embodiment of the invention with the rotor blade airfoil illustrated in conjunction with its platform and its substantially or near axial entry dovetail connection;
[0009] FIGS. 4 and 5 are side elevational views of the rotor blade of FIG. 2 and associated platform and dovetail connection as viewed in a generally circumferential direction from the pressure and suction sides of the airfoil, respectively;
[0010] FIG. 6 is a cross-sectional view of the rotor blade airfoil taken generally about on line 6 - 6 in FIG. 5 ;
[0011] FIG. 7 is a perspective views of a rotor blade according to an exemplary embodiment of the invention with coordinate system superimposed thereon; and
[0012] FIG. 8 is a perspective view of a stator blade according to an exemplary embodiment of the invention with coordinate system superimposed thereon.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Referring now to the drawings, FIG. 1 illustrates an axial compressor flow path 1 of a gas turbine compressor 2 that includes a plurality of compressor stages. The compressor stages are sequentially numbered in the Figure. The compressor flow path comprises any number of rotor stages and stator stages, such as eighteen. However, the exact number of rotor and stator stages is a choice of engineering design. Any number of rotor and stator stages can be provided in the combustor, as embodied by the invention. The seventeen rotor stages are merely exemplary of one turbine design. The eighteen rotor stages are not intended to limit the invention in any manner.
[0014] The compressor rotor blades impart kinetic energy to the airflow and therefore bring about a desired pressure rise across the compressor. Directly following the rotor airfoils is a stage of stator airfoils. Both the rotor and stator airfoils turn the airflow, slow the airflow velocity (in the respective airfoil frame of reference), and yield a rise in the static pressure of the airflow. The configuration of the airfoil (along with its interaction with surrounding airfoils), including its peripheral surface provides for stage airflow efficiency, enhanced aeromechanics, smooth laminar flow from stage to stage, reduced thermal stresses, enhanced interrelation of the stages to effectively pass the airflow from stage to stage, and reduced mechanical stresses, among other desirable aspects of the invention. Typically, multiple rows of rotor/stator stages are stacked in axial flow compressors to achieve a desired discharge to inlet pressure ratio. Rotor and stator airfoils can be secured to rotor wheels or stator case by an appropriate attachment configuration, often known as a “root”, “base” or “dovetail” (see FIGS. 2-5 ).
[0015] A stage of the compressor 2 is exemplarily illustrated in FIG. 1 . The stage of the compressor 2 comprises a plurality of circumferentially spaced rotor blades 22 mounted on a rotor wheel 51 and a plurality of circumferentially spaced stator blades 23 attached to a static compressor case 59 . Each of the rotor wheels is attached to aft drive shaft 58 , which is connected to the turbine section of the engine. The rotor blades and stator blades lie in the flow path 1 of the compressor. The direction of airflow through the compressor flow path 1 , as embodied by the invention, is indicated by the arrow 60 ( FIG. 1 ). This stage of the compressor 2 is merely exemplarily of the stages of the compressor 2 within the scope of the invention. The illustrated and described stage of the compressor 2 is not intended to limit the invention in any manner.
[0016] The rotor blades 22 are mounted on the rotor wheel 51 forming part of aft drive shaft 58 . Each rotor blade 22 , as illustrated in FIGS. 2-6 , is provided with a platform 61 , and substantially or near axial entry dovetail 62 for connection with a complementary-shaped mating dovetail, not shown, on the rotor wheel 51 . An axial entry dovetail, however, may be provided with the airfoil profile, as embodied by the invention. Each rotor blade 22 comprises a rotor blade airfoil 63 , as illustrated in FIGS. 2-6 . Thus, each of the rotor blades 22 has a rotor blade airfoil profile 66 at any cross-section from the airfoil root 64 at a midpoint of platform 61 to the rotor blade tip 65 in the general shape of an airfoil ( FIG. 6 ).
[0017] To define the airfoil shape of the rotor blade airfoil, a unique set or loci of points in space are provided. This unique set or loci of points meet the stage requirements so the stage can be manufactured. This unique loci of points also meets the desired requirements for stage efficiency and reduced thermal and mechanical stresses. The loci of points are arrived at by iteration between aerodynamic and mechanical loadings enabling the compressor to run in an efficient, safe and smooth manner.
[0018] The loci, as embodied by the invention, defines the rotor blade airfoil profile and can comprise a set of points relative to the axis of rotation of the engine. For example, a set of points can be provided to define a rotor blade airfoil profile.
[0019] A Cartesian coordinate system of X, Y and Z values given in the Table below defines a profile of a rotor blade airfoil at various locations along its length. The airfoil, as embodied by the invention, could find an application as a 12 th stage airfoil stator vane. The coordinate values for the X, Y and Z coordinates are set forth in inches, although other units of dimensions may be used when the values are appropriately converted. These values exclude fillet regions of the platform. The Cartesian coordinate system has orthogonally-related X, Y and Z axes. The X axis lies parallel to the compressor blade's dovetail axis, which is at a angle to the engine's centerline, as illustrated in FIG. 7 for a rotor and FIG. 8 for a stator. A positive X coordinate value is axial toward the aft, for example the exhaust end of the compressor. A positive Y coordinate value directed normal to the dovetail axis. A positive Z coordinate value is directed radially outward toward tip of the airfoil, which is towards the static casing of the compressor for rotor blades, and directed radially inward towards the engine centerline of the compressor for stator blades.
[0020] For reference purposes only, there is established point-0 passing through the intersection of the airfoil and the platform along the stacking axis, as illustrated in FIG. 5 . In the exemplary embodiment of the airfoil hereof, the point-0 is defined as the reference section where the Z coordinate of the table above is at 0.000 inches, which is a set predetermined distance from the engine or rotor centerline.
[0021] By defining X and Y coordinate values at selected locations in a Z direction normal to the X, Y plane, the profile section of the rotor blade airfoil, such as, but not limited to the profile section 66 in FIG. 6 , at each Z distance along the length of the airfoil can be ascertained. By connecting the X and Y values with smooth continuing arcs, each profile section 66 at each distance Z can be fixed. The airfoil profiles of the various surface locations between the distances Z are determined by smoothly connecting the adjacent profile sections 66 to one another, thus forming the airfoil profile. These values represent the airfoil profiles at ambient, non-operating or non-hot conditions and are for an uncoated airfoil.
[0022] The table values are generated and shown to three decimal places for determining the profile of the airfoil. There are typical manufacturing tolerances as well as coatings, which should be accounted for in the actual profile of the airfoil. Accordingly, the values for the profile given are for a nominal airfoil. It will therefore be appreciated that +/−typical manufacturing tolerances, such as, +/−values, including any coating thicknesses, are additive to the X and Y values. Therefore, a distance of about +/−0.160 inches in a direction normal to any surface location along the airfoil profile defines an airfoil profile envelope for a rotor blade airfoil design and compressor. In other words, a distance of about +/−0.160 inches in a direction normal to any surface location along the airfoil profile defines a range of variation between measured points on the actual airfoil surface at nominal cold or room temperature and the ideal position of those points, at the same temperature, as embodied by the invention. The rotor blade airfoil design, as embodied by the invention, is robust to this range of variation without impairment of mechanical and aerodynamic functions.
[0023] The coordinate values given in TABLE 1 below provide the nominal profile envelope for an exemplary 12 h stage airfoil stator vane.
[0000]
TABLE 1
X-LOC
Y-LOC
Z-LOC
1.559
−0.898
0.001
1.559
−0.899
0.001
1.557
−0.903
0.001
1.554
−0.909
0.001
1.548
−0.917
0.001
1.532
−0.927
0.001
1.506
−0.927
0.001
1.473
−0.921
0.001
1.432
−0.914
0.001
1.377
−0.905
0.001
1.315
−0.895
0.001
1.248
−0.884
0.001
1.173
−0.873
0.001
1.09
−0.86
0.001
0.998
−0.844
0.001
0.902
−0.827
0.001
0.803
−0.807
0.001
0.7
−0.785
0.001
0.593
−0.76
0.001
0.483
−0.732
0.001
0.37
−0.699
0.001
0.255
−0.662
0.001
0.136
−0.62
0.001
0.02
−0.573
0.001
−0.096
−0.521
0.001
−0.209
−0.464
0.001
−0.319
−0.4
0.001
−0.425
−0.332
0.001
−0.528
−0.26
0.001
−0.628
−0.184
0.001
−0.726
−0.104
0.001
−0.82
−0.02
0.001
−0.911
0.067
0.001
−1
0.158
0.001
−1.081
0.249
0.001
−1.157
0.34
0.001
−1.226
0.429
0.001
−1.29
0.518
0.001
−1.348
0.605
0.001
−1.401
0.69
0.001
−1.45
0.774
0.001
−1.491
0.852
0.001
−1.527
0.925
0.001
−1.556
0.991
0.001
−1.579
1.05
0.001
−1.598
1.101
0.001
−1.613
1.146
0.001
−1.623
1.184
0.001
−1.631
1.217
0.001
−1.636
1.244
0.001
−1.638
1.266
0.001
−1.637
1.284
0.001
−1.633
1.296
0.001
−1.629
1.306
0.001
−1.623
1.312
0.001
−1.618
1.316
0.001
−1.612
1.319
0.001
−1.605
1.32
0.001
−1.595
1.32
0.001
−1.583
1.317
0.001
−1.569
1.311
0.001
−1.552
1.3
0.001
−1.532
1.284
0.001
−1.508
1.263
0.001
−1.481
1.238
0.001
−1.45
1.208
0.001
−1.414
1.172
0.001
−1.373
1.13
0.001
−1.326
1.082
0.001
−1.274
1.029
0.001
−1.216
0.97
0.001
−1.152
0.906
0.001
−1.085
0.84
0.001
−1.014
0.772
0.001
−0.94
0.702
0.001
−0.861
0.631
0.001
−0.779
0.558
0.001
−0.692
0.484
0.001
−0.601
0.409
0.001
−0.509
0.336
0.001
−0.415
0.264
0.001
−0.32
0.195
0.001
−0.224
0.128
0.001
−0.127
0.062
0.001
−0.029
−0.003
0.001
0.07
−0.067
0.001
0.168
−0.131
0.001
0.267
−0.195
0.001
0.366
−0.259
0.001
0.465
−0.321
0.001
0.562
−0.381
0.001
0.657
−0.437
0.001
0.748
−0.489
0.001
0.837
−0.539
0.001
0.923
−0.585
0.001
1.007
−0.629
0.001
1.088
−0.669
0.001
1.165
−0.705
0.001
1.237
−0.738
0.001
1.302
−0.766
0.001
1.36
−0.79
0.001
1.415
−0.81
0.001
1.463
−0.826
0.001
1.501
−0.838
0.001
1.531
−0.848
0.001
1.55
−0.86
0.001
1.559
−0.876
0.001
1.56
−0.885
0.001
1.56
−0.892
0.001
1.56
−0.895
0.001
1.559
−0.896
0.001
1.559
−0.897
0.001
1.588
−0.854
0.472
1.587
−0.855
0.472
1.586
−0.859
0.472
1.583
−0.864
0.472
1.577
−0.872
0.472
1.561
−0.882
0.472
1.537
−0.883
0.472
1.505
−0.877
0.472
1.464
−0.869
0.472
1.412
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1.297
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4.244
1.297
−0.734
4.244
1.067
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4.716
1.066
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4.716
1.066
−0.722
4.716
1.063
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4.716
1.057
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4.716
1.043
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4.716
1.025
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4.716
1
−0.727
4.716
0.97
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4.716
0.93
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4.716
0.884
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4.716
0.835
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4.716
0.78
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4.716
0.719
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4.716
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4.716
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4.716
0.51
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4.716
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4.716
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4.716
0.279
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4.716
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4.716
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4.716
0.03
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
−0.601
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4.716
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4.716
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0.032
4.716
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0.093
4.716
−0.876
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4.716
−0.937
0.215
4.716
−0.993
0.276
4.716
−1.047
0.335
4.716
−1.096
0.394
4.716
−1.142
0.452
4.716
−1.186
0.508
4.716
−1.224
0.561
4.716
−1.257
0.61
4.716
−1.285
0.654
4.716
−1.31
0.694
4.716
−1.33
0.729
4.716
−1.347
0.759
4.716
−1.36
0.784
4.716
−1.371
0.806
4.716
−1.379
0.825
4.716
−1.385
0.84
4.716
−1.389
0.852
4.716
−1.391
0.861
4.716
−1.392
0.869
4.716
−1.391
0.875
4.716
−1.388
0.879
4.716
−1.384
0.88
4.716
−1.378
0.878
4.716
−1.372
0.875
4.716
−1.364
0.87
4.716
−1.355
0.863
4.716
−1.343
0.852
4.716
−1.33
0.838
4.716
−1.313
0.821
4.716
−1.294
0.801
4.716
−1.272
0.776
4.716
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0.748
4.716
−1.215
0.715
4.716
−1.18
0.678
4.716
−1.141
0.636
4.716
−1.098
0.591
4.716
−1.049
0.542
4.716
−0.998
0.492
4.716
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0.44
4.716
−0.888
0.387
4.716
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0.333
4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
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4.716
0.111
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4.716
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4.716
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4.716
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4.716
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4.716
0.482
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4.716
0.55
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4.716
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4.716
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4.716
0.8
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4.716
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4.716
0.897
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4.716
0.941
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4.716
0.979
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4.716
1.008
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4.716
1.032
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4.716
1.049
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4.716
1.062
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4.716
1.066
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4.716
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1.067
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4.716
1.067
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4.716
1.067
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4.716
[0024] It will also be appreciated that the exemplary airfoil(s) disclosed in the above Table 1 may be scaled up or down geometrically for use in other similar compressor designs. Consequently, the coordinate values set forth in the Table 1 may be scaled upwardly or downwardly such that the airfoil profile shape remains unchanged. A scaled version of the coordinates in Table 1 would be represented by X, Y and Z coordinate values of Table 1 multiplied or divided by a constant.
[0025] While various embodiments are described herein, it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made by those skilled in the art, and are within the scope of the invention. | An article of manufacture having a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in a TABLE 1. Wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
[0002] Not Applicable
BACKGROUND
[0003] The present invention relates to paper cutters and more particularly, the present invention relates to a paper cutter that is able to perform as a letter opener which is part of a writing instrument.
[0004] The background information discussed below is presented to better illustrate the novelty and usefulness of the present invention. This background information is not admitted prior art.
[0005] Letter openers are available in many sizes and styles. The most popular style offers an elongated blade extending several inches from a holding means. The distal end of the blade conventionally has a point tapered to fit in an opening of an envelope. The cutting edge of the blade element is of varying sharpness as the blade can be formed of metal, but can also be formed of other materials, such as plastic, for example. Once the tapered point is placed under the flap of the envelope, the blade is forced through the fold of the envelope's flap, thus opening the envelope for inspection of its contents.
[0006] Letter openers provide for rapid and easy opening of various types of envelops and other types of mail. Letter openers also provide for envelopes to be opened neatly, eliminating the messy bits of protruding paper that usually result when an envelope is opened without the benefit of a letter opener. Despite the advantages they offer, letter openers are often conspicuously absent from a letter opening area. Letter openers are frequently found on well-appointed desks, but are often not found in areas of the home or workplace where a letter is most likely to be opened. As people arrive home from work they often collect their mail on their way into the home and sit down at the kitchen table or on a favorite easy chair to read their mail. These are places, however, where a letter opener is likely to be found. Likewise, when mail arrives at the office, even though there might be a dedicated mail handling person, who might be equipped with a letter opener, it is more likely that the sorted but unopened mail will be delivered to an addressee's desk where it is more likely then not that a letter opener will not be found. Even if all employees are issued a letter opener at the beginning of their employment the openers are soon misplaced or lost. In either case, at home or at work, when there is mail to be opened and no letter opener is at hand the person opening the mail may resort to using objects not designed to open letters, possibly resulting in excessive tearing of the envelope, damage to the contents of the envelope, and/or injury to the person opening the letter. The desirability of having a letter opener handy when and where it is needed is, thus, easily appreciated. Also appreciated is that letter openers are useful in ways other than opening envelopes.
[0007] Many people enjoy the monetary savings afforded by the use of redemption-type coupons. Usually such coupons are made ready for a shopping trip while a shopper is at home. Occasionally, however, a shopper comes across a coupon offer when away from home, while at work, for instance. If, for instance, the unexpected discovery of a cost-saving coupon results in a shopping trip on the way home from work to redeem the coupon, the coupon may still be attached to the newspaper, magazine, or advertising flyer in which the coupon was first seen. It is not to be expected that a pair of scissors would be handy at such an time, yet tearing the coupon away from the page on which it is printed could result in tearing the coupon and, thus, invalidating it for redemption. It is easy to understand how useful it would be to have a paper cutting instrument available for use.
[0008] Unlike letter openers, writing instruments, such as pens and pencils, are frequently found in many areas of the home, at work, in a motor vehicle, as well as in one's purse or briefcase, such as felt-tipped markers, wood and plastic pencils, mechanical pencils. More particularly, writing instruments, such as ball point pens, fountain pens, and retractable ink pens are likely to be found on people's desks or on, or near, a kitchen table or work area. In fact, it is nearly inconceivable that an office or a kitchen would not have a multitude of writing instruments. Moreover, most people carry a writing instrument on their person, or at least in their briefcases, schoolbags, or purses.
[0009] Therefore, it seems obvious that what is sorely lacking in the art is a letter opener which is attachable to, or otherwise formed with, a writing instrument in order to alleviate the inconveniences of using separate letter openers and writing instruments.
[0010] While there have been some efforts to provide for a writing instrument that also functions as a letter opener, none of these efforts has been successful in producing a writing instrument letter opener device that is able to function like a typical writing instrument. Due to the fact that the paper cutting element of the letter opener part is located on a wing-like extension that is either reversibly attached to an instrument or is formed as a wing-like extension of the pen barrel, these devices are bulky and awkwardly shaped. Thus, these devices are also heavier than a conventional pen and when placed in a front pocket of a shirt, the wing-like extension of the device would likely protrude from the pocket in an unattractive manner. Moreover, because of their bulk if these devices were to be placed in an ordinary pen or pencil jar they either would not fit or if they did fit they would likely become tangled with other pens or pencils in the jar. Similar problems would be encountered if one wanted to carry one of these oversized devices in one's purse or bag. Also, if made of a brittle material such as a hard plastic, the wing-like extensions are likely to be prone to breaking.
[0011] Another attempt to provide for a letter opener writing instrument comprises a letter opening device designed to be detachably positioned about a writing instrument. The letter opening device comprises a pair of gripping members or fingers forming a ring-like part to hold the device about a pen. The device also comprises an elongated member that depends from the ring-like part, the function of which is to engage the pen to a pocket, a belt, or the like. The distal end of the depending member is provided with cutting blade containing member. This unit is for use only on pens or pencils that are not equipped with a pocket clip; else the positioning of the cutter unit on the pen or pencil would be hindered by the presence of the pocket clip. Furthermore, in order for the cutting blade to be of useful size, the blade containing member must be large enough to protectively house the cutting blade, thus making the combination pen and letter opener bulky and unattractive, especially for those compelled to maintain a certain expected appearance. Additionally, because of the manner by which the cutting blade is fitted into the blade containing member, the device is not able to perform as a paper cutter, other than an envelop opener. Another problem inherent in this device is that there is no way to prevent the cutting blade from accidentally cutting material that is not meant to be cut, such as the lining of a jacket when the jacket is worn over the shirt with the pocket containing the pen.
[0012] Yet another effort, while more successful in maintaining the sleek shape of a pen while providing for a cutting blade to be associated with the writing instrument, requires the writing instrument to have an inner and an outer barrel. The inner barrel is operatively adapted to accommodate a cutting element and the outer barrel, while relatively of standard shape has an opening on one side to provide access to the cutting element housed in the inner barrel and also has a somewhat larger barrel circumference to accommodate the inner barrel. This intricate design coupled with the fact that each instrument requires an outer barrel and a modified inner barrel along with a cutting element increases both the likelihood of breakage and the cost of manufacture.
[0013] Notwithstanding the attempts described above, it is clear that there is still no device that offers the convenience of a letter opener writing instrument, that can be safely attached to a piece of clothing or the like without fear of cutting the clothing material, that offers the sleek, thin, attractively designed barrel of a fine pen or pencil, that is sturdy and of simple construction, while maintaining affordable manufacturing costs.
SUMMARY
[0014] The present invention satisfies the heretofore unmet needs in the art by setting forth a novel device that provides for a sleek, thin, attractively barreled, easy to use, and convenient-to-carry letter opener writing instrument. The device may be made out of any suitable material such as a fine metal or an inexpensive plastic, allowing the device to be as affordable or as expensive as desired. The device may comprise any type of writing instrument. The term writing instruments, of course, includes fountain pens, ball point pens, mechanical or non-mechanical pencils, markers, or stylii that are used to make a mark in form of an impression on contact. In addition to being used to open mail, the cutting means may be used to cut paper, such as cutting out important news articles, restaurant or entertainment reviews, theater schedules and address, and cost-saving coupons, for example. Moreover, because of its sleek, slim design the device can be safely and comfortably inserted into a shirt pocket and held there firmly by the device's pocket clip. Additionally the device may be conveniently carried in one's purse or briefcase.
[0015] The letter opener unit may be either an integral part of the writing instrument or, alternatively, it may be produced as a separate device that may be reversibly attached to any type of writing instrument. The cutting element of the device when it is produced as a separate unit is provided as an integral part of a pocket clip unit.
[0016] Pocket clip units are frequently attached to the case of a writing instrument by small metal bands sometimes referred to as clip bands. Clip bands may form a continuous band that is to be fitted over one end of the instrument. Alternatively, a clip band may be formed as a discontinuous band, that is, where the band has a slit in it. This configuration gives the band the ability to be fitted around a larger size range of devices. Pocket clip units are provided with an elongated finger that extends, in many instances, from the ring that is affixed to the barrel of a writing instrument. The elongated finger or clip arm, that is used to attach a writing instrument to a shirt pocket, often has a contoured protrusion on its distal end. To secure the letter opener writing instrument to a shirt pocket, or the like, the contoured protrusion of the clip arm of the pocket clip is slipped over the front piece of the pocket with the writing instrument typically, but not always, inserted inside of the pocket.
[0017] The letter opener part of the letter opener writing instrument comprises a pocket clip unit and a small cutting element located in the area of attachment between the pocket clip unit and the writing instrument barrel so that the cutting element is functionally positioned between the outer surface of the case of the writing instrument and the surface of the arm of the pocket clip unit that faces the surface of the case.
[0018] The length of the inner face of the clip arm and the opposing surface of the writing instrument's barrel defines an envelope accepting channel to guide an envelope toward the cutting element. To use the letter opener writing instrument, the distal end of the clip arm of the pocket clip is slipped into an opening defined by the front face of an envelope and the envelope flap to guide the envelope through the envelop accepting channel to the cutting element where the envelope is slit open by the cutting element to disclose the contents of the envelope. Alternatively, the top edge of an envelop may be guided by the envelop accepting channel to the cutting element where by pulling the top edge of the envelope along the cutting element, the top edge of the envelope is neatly sliced off, thus opening the envelop to disclose its contents.
[0019] Accordingly, this invention provides for a letter opener writing instrument device, comprising:
i) a writing instrument having a case, body, or barrel; ii) a pocket clip unit affixed to the writing instrument, and iii) a cutting element operatively attached to the writing instrument between the writing instrument and the pocket clip unit forming a pocket clip cutting element unit providing for paper to be cut by the letter opener writing instrument.
[0023] The letter opener writing instrument device may also further comprise a spacer that may be affixed to or formed as part of the pocket clip unit or, alternatively, may be affixed to or formed as part of the case of the instrument. The spacer may also be used as a support for the pocket clip unit.
[0024] The pocket clip unit may be fixedly attached to the case, barrel, or body of the instrument, or alternatively the pocket clip unit may be reversibly affixed to said case.
[0025] The letter opener writing instrument device may further comprise a stopper affixed either to the writing instrument or to the pocket clip to limit accessibility to said cutting blade. More particularly, the stopper provides protection against any damage that might otherwise be caused if a shirt pocket, or the like, came into contact with the cutting blade.
[0026] The letter opener writing instrument device additionally comprises a contoured protrusion affixed to a distal end of said pocket clip unit. This protrusion is to provide for the smooth insertion of the pen clip over a shirt pocket.
[0027] Furthermore, the pocket clip cutting element unit of the letter opener writing instrument comprises:
i) a pocket clip arm, said pocket clip arm having a first end, a second end, and a first surface; ii) a band to be fitted about a writing instrument, where a section of the band is functionally attached to the pocket clip unit proximate to said first end of said pocket clip arm; iii) the cutting element is functionally attached to the first surface of the pocket clip arm proximate the first end of the pocket clip arm, wherein the pocket clip cutting element unit may be reversibly positioned about the writing instrument providing for a letter opener writing instrument.
[0031] Additionally, a stand-alone pocket clip cutting element unit is also provided, comprising:
i) a pocket clip arm, the pocket clip arm having a first end, a second end, and a first surface; ii) a band for reversible placement about a writing instrument, the band functionally attached to the pocket clip arm proximate to the first end of the pocket clip arm; iii) a cutting element functionally attached to the first surface of the pocket clip arm proximate the first end of the pocket clip arm, wherein the pocket clip cutting element unit is reversibly positionable about a case of the writing instrument providing for a letter opener writing instrument.
[0036] The simple design of the device ensures a low manufacturing cost as well as ease of use. The device is small and lightweight and can be easily packaged for display and sale. The device can be fabricated in any desired size and may be made of any material having the properties desired, such as plastic, fiberglass, ceramic, wood, glass, or metal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] In order that these and other features and advantages of the present invention may be more fully comprehended and appreciated, the invention will now be described, by way of example, with reference to specific embodiments illustrated in the drawings and specific language will be used to describe the same. It should, nevertheless, be understood that no limitations of the scope of the invention are thereby intended, such alterations and further modifications in the illustrated device and such further applications of the principles of the invention as illustrated therein, being contemplated as would normally occur to one skilled in the art to which the invention pertains.
[0038] FIG. 1 is a side plan view of a preferred embodiment of the letter opener writing instrument device according to the present invention.
[0039] FIG. 2 is a plan view of the letter opener writing instrument device rotated 90 degrees to show a top view of the letter opener writing instrument device showing that the sleek styling and thin physical attributes expected from a fine writing instrument are inherent in the letter opener writing instrument device made according to the principles of the present invention.
[0040] FIG. 3 is another side plan view to illustrate the addition of a stopper to limit accessibility to the cutting element.
[0041] FIG. 4 a is a perspective stylized view of a preferred embodiment showing a streamlined, fashionable letter opener writing instrument made according to the principles of the present invention.
[0042] FIG. 4 b is a slightly exploded view of the pocket clip end of the letter opener writing instrument to provide another view of the positioning of the cutting element and also to illustrate a detachably attached pocket clip cutting unit.
DEFINITIONS
[0043] “Case” as used herein refers to the body of a writing instrument or the like. The case is also referred to as the body or barrel part of the instrument. In some models of writing instruments the case may comprise a first part and a second part where the first part of the case may be separated from the second part of the case to access the functional part of the instrument. The case may be removable, while in other models the case may not be removable.
[0000] A List of the Reference Numerals and the Parts of the Invention to which the Reference Numerals Refer
[0000]
10 Letter opener writing instrument device.
12 Barrel, case, or body of letter opener writing instrument device 10 .
12 a One case or body section.
12 b A second case or body section.
14 Writing end of exemplary letter opener writing instrument device 10 .
16 Optional point actuating button of exemplary device 10 .
20 A pocket clip unit which may or may not include cutting element 30 .
22 Pocket clip spacer; also referred to and used as a support, if desired.
24 Optional contoured protrusion at distal end of pocket clip arm 28 .
26 An attachment band of pocket clip unit 20 .
26 b A detachable attachment band.
28 Arm of pocket clip unit 20 .
30 A cutting element.
40 A stopper limiting accessibility to cutting element 30 to prevent contact between the cutting element and the material of a shirt pocket or the like.
50 A preferred embodiment of a letter opener writing instrument device make according to the principles of the invention disclosed herein.
[0059] It should be understood that like reference characters indicate like parts throughout the several figures and that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the present invention, or which render other details difficult to perceive, may have been omitted.
DETAILED DESCRIPTION
[0060] It should be appreciated that the disclosed invention is disposed to embodiments in many various sizes, shapes, and forms, such as large, medium, and small, thin and thick, long and short to accommodate various needs or desires. For example, large handed persons would likely appreciate a larger, longer, wider letter opener writing instrument device, whereas persons with small hands would likely be more comfortable with a smaller device that is easily held in their hands. Additionally, the device comes in a variety of shapes and forms to accommodate a variety of writing instruments, such as pencils, pens, markers, and the like. Today's market demands variety and choice, such as writing instruments in geometric shapes, helical type shapes, and all sorts of free form shapes. Some of these shapes are merely amusing or decorative, but others are functional in that they reduce hand strain or increase one's ability to maintain a firm grasp on the device. Therefore, the embodiments described herein are provided with the understanding that the present disclosure is intended to be simply illustrative and does not limit the invention to the embodiments described.
[0061] The present invention resides in a letter opener writing instrument that may also be used to perform paper cutting operations. As used herein, the phrase writing instrument is intended to broadly encompass those devices having marking and/or non-marking tips, such as pencils, ball-point, gel ink and rolling ball pens, fountain pens, felt markers, highlighter pens and markers, and stylii, such as are used with touch-sensitive screens.
[0062] The letter opener writing instrument according to the teachings of the present invention has a body comprising a barrel or case that usually provides accommodation for the writing mechanism. The barrel or case may comprise a single unit or may consist of parts that may be reversibly secured to each other. A pocket clip unit for securing the writing instrument to a shirt pocket, pad of paper, belt, or the like is secured to the cap or barrel of a writing instrument and typically comprises a dip arm having a small curved or angled protuberance at the end to aid in sliding the dip arm over the edge of a pocket, or the like. To provide a secure grasp of the pen to a shirt pocket, the dip arm may be biased toward the body of the device. There are many methods of biasing a dip arm. One example comprises simply bending the strip of metal that forms the clip arm into a U-shape, thus providing an action that is similar to a leaf spring. To secure the letter opener writing instrument to a shirt pocket, the arm of the pocket clip is inserted over the front piece of the pocket with the writing instrument typically, but not always, inside the pocket.
[0063] The letter opener writing instrument also comprises a cutting element operatively positioned between the pocket clip arm and the writing instrument body in the area in which the pocket clip unit is attached to the writing instrument. An envelop accepting channel is defined by the length of the inner face of the clip arm and the opposing surface of the writing instrument's barrel. The envelop accepting channel guides an envelop to be opened to the cutting element.
[0064] The letter opener writing instrument is used as an envelope opener by slipping the generally tapered end of the clip arm between the flap of a sealed envelope and the front panel of the envelop. The clip arm acts as a guide to feed the part of the envelope to be cut into the paper accepting channel where it is directed to the cutting element to be opened. Alternatively, the top edge of an envelope, or any other type of paper that needs to be cut, such as a coupon that needs to be cut out of a magazine, for example, may be guided through the envelope accepting channel to the cutting element whereby pulling the top edge of the item to be cut along the cutting element, the edge of the item is neatly sliced, thus opening the envelop to disclose its contents or freeing the coupon for use.
[0065] Referring now, with more particularity, to the drawings, FIG. 1 , a side plan view of a preferred embodiment of the letter opener writing instrument device, illustrates device 10 including barrel 12 which, in this example, is comprised of extended upper barrel section 12 a and shortened lower barrel section 12 b , which sections may be separable from each other. Device 10 further comprises functional end 14 , and, in this example, point actuating button 16 . Of course, as is well known in the art, writing instruments may, or may not, have a point actuating button. Writing instruments may alternatively have a barrel turning mechanism to provide point actuation, while others may have a spring device that may be actuated by pressing on the clip arm, for example, while still other writing instruments have no actuation mechanism as their functional point is always accessible. Pocket clip unit 20 comprises clip arm 28 including contoured protrusion 24 . In the example illustrated, clip arm 28 extends generally parallel to the side of barrel 12 and is arranged so that contoured protrusion 24 is positioned to be touching or nearly touching barrel body 12 .
[0066] In the embodiments exemplified in FIGS. 1-3 , pocket clip unit 20 is fixedly attached to writing instrument device 10 via dip arm support 22 which may be operatively attached to writing instrument body 12 by means of pocket clip attachment band 26 . In this example, pocket clip attachment band 26 is positioned about instrument 10 between barrel section 12 a and barrel section 12 b and support 22 is fixedly secured to the device between attachment band 26 and clip arm 28 . There are, of course, various other ways that pocket clip unit 20 may be affixed to device 10 . For instance, in some embodiments, support 22 may be formed integral as a unit with clip arm 28 , which unit may then be operatively affixed to a part of instrument 10 . This configuration is often seen on pens that have covers, where the support/clip arm unit is attached to the pen's cover. In other configurations, the support part is formed integral with the cover where the support is used as a means to attach the clip arm to the cover.
[0067] In addition to providing a means for dip arm 20 to be attached to writing instrument 10 , clip arm support 22 operates to provide a space or gap between clip arm 28 and writing instrument body 12 . As in a conventional writing instrument, the gap created by clip arm spacer 22 serves, at least in part, to provide the space required for the material of the shirt pocket, or the like, to fit between clip arm 28 and writing instrument body 12 when the device is carried in and supported by a shirt pocket or by some similar item.
[0068] Some writing instruments avoid the need for a spacer by shaping clip arm 20 to have a curve or bend, which curve provides for a space between the clip arm and the writing instrument body. Notwithstanding the means used to attach the pocket clip to the writing instrument, the structural configuration of the clip arm, or the structural configuration of the barrel of the writing instrument part of the invention, the principle of the present invention is to provide a letter opener/paper cutting writing instrument that has a cutting element positioned between the clip arm and the body portion of a writing instrument, to provide for the effective opening of an envelope and/or the cutting of paper.
[0069] As illustrated, cutting element 30 provides for the cutting of paper, as in the opening of an envelope, and is functionally positioned between clip arm 28 and body 12 within the space created, in this example, by clip arm spacer 22 . The spatial relationship between clip arm 28 and body 12 additionally makes available an envelope accepting channel for guiding the envelope or other paper to the cutting element. Cutting element 30 comprises a metal razor blade-like cutting edge or any other similarly functioning element that is equipped with a sufficiently sharp edge to cut paper.
[0070] As discussed above, clip arm unit 20 and cutting element 30 may be fixedly attached to writing instrument 12 , or alternatively, clip arm unit 20 and cutting element 30 may be formed together as a separate unit to be reversibly attached to any writing instrument. Providing clip arm 28 and cutting element 30 as a separate unit is especially useful when the unit is to be fitted over a writing instrument that is not equipped with a clip arm unit.
[0071] FIG. 2 , a top plan view of the writing instrument, illustrates that the addition of a cutting element between the pocket clip unit and the opposing surface of a surface of the writing instrument according to the teachings of the present invention does not change or detract from the sleek appearance or physical slimness expected in a fine writing instrument.
[0072] FIG. 3 illustrates the addition of stopper 40 to writing instrument 10 for the purpose of limiting access to the cutting element to prevent the cutting element from coming into contact with shirt pocket material, or the like. Stopper 40 may be made of any suitable material that will not interact adversely with the material of a shirt, a belt, or the like. Thus, stopper 40 may be constructed of materials, such as plastic, rubber, metal, wood, or the like and may be attached to the body of the letter opener writing instrument, as illustrated or, alternatively, stopper 40 may be affixed to the inside surface of clip arm 28 . When the letter opener pocket clip unit is manufactured as a separate, free-standing, replaceable unit, then the stopper must, of course, be affixed to the clip arm.
[0073] FIG. 4 a is a perspective view of a preferred embodiment 50 of the present invention showing a letter opener writing instrument with body case 12 made according to the principles of the present invention. The letter opener writing instrument device, as illustrated, is as handsome, streamlined, slender, and fashionable as could be expected from any fine writing instrument, and yet is able to operate as an envelope guide, a letter opener, and a paper cutter. This style letter opener writing instrument device avoids the need for a spacer/support by having clip arm 28 that is attached to attachment band 26 shaped so that the arm is directed a functional distance away from the writing instrument body. The device has cutting element 30 positioned between clip arm 28 and body portion 12 to provide for the safe, effective opening of an envelope. The letter opener writing instrument also includes stopper 40 functionally positioned on attachment band 26 between clip arm 28 and body portion 12 of the writing instrument. Stopper 40 limits access to the cutting element to prevent the cutting element from coming into contact with shirt pocket material or the like.
[0074] FIG. 4 b , a slightly enlarged view of preferred embodiment 50 provides another view of the relationship between pocket clip 28 , cutting element 30 , and stopper 40 . Additionally, FIG. 4 b shows one way to reversibly attach the pocket clip unit to the writing instrument, which in this example is the use of discontinuous attachment band 26 b.
[0075] The foregoing description, for purposes of explanation, uses specific and defined nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention, as has been discussed above. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Furthermore, the present invention is not limited to the described methods, embodiments, features or combinations of features but includes all the variation, methods, modifications, and combinations of features within the scope of the appended claims. Thus, the invention is limited only by the claims. | A letter opener writing instrument device comprising a writing instrument, a pocket clip affixed to the instrument, and a cutting edge operatively positioned between the instrument and pocket clip providing for the cutting of paper by the device. The device may further comprise a spacer and/or a stopper, both affixed between the instrument and the pocket clip, where the spacer may provide space and/or an attachment mechanism and the stopper limits accessibility to the cutting blade preventing damage to a shirt pocket or the like. The pocket clip cutting unit may be provided as a separate unit for its detachable attachment to a writing instrument. A writing instrument may be a fountain pen, ball point pen, mechanical or non-mechanical pencil, marker, and stylii, such as are used with touch-sensitive screens. The sleek, slim design, of the instrument provides for its attractive and comfortable insertion into a shirt pocket. | 1 |
CROSS REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application 61/027,795, filed Feb. 11, 2008.
FIELD OF THE INVENTION
The present invention relates to a multipurpose support device for supporting an item such as a laptop computer or a book. The multipurpose support device of the present invention is used while attached to a structural support, such as a mobile cart, a desk, a sofa or a wall.
BACKGROUND OF THE INVENTION
Many people spend a lot of time using a laptop computer. Most people use a laptop computer by leaving it on the top of a desk and read information on a laptop computer screen with their neck straight or bent downward depending on the position of the computer screen. This posture causes a lot of stress and strain on the user's neck. In addition, people tend to lean forward and keep their back away from the back of the chair. This posture causes a lot of stress and strain on the back and shoulder. People place their forearms, hands and wrists on top of the desk when they type on the keyboard of the laptop or use the mouse panel of the laptop. This type of posture causes a lot of stress on all joints of upper extremities. Working with a laptop computer for several hours a day with this unhealthy posture could make a person feel tired easily with pain at their neck, shoulder, back and wrists. This could lead to an injury of the spine, back, shoulder, neck, and wrists.
To avoid the aforementioned kind of pain or injury, a person should use a laptop computer in a relaxed posture with the least amount of stress and strain to the neck, back, shoulder and wrists. The most relaxed posture for using a laptop computer is sitting on a chair at a reclined angle. The laptop computer is placed in a proper holder with comfortable forearm and wrist supports, so that the user can see the laptop computer screen easily while sitting at a reclined angle with the neck and back rested on the chair back and user's elbows, wrists and hands rested on proper supports. This relaxed posture causes the least amount of stress to the spine, neck, shoulder, hands and wrists.
Similarly, it is important to adopt a proper posture when reading a book. Users often position a book on their laps or on top of a desk and bend over the book in order to read it. Oftentimes, a user will hold the spine of the book with one hand, while turning the pages with the other. In addition to creating fatigue and stress for the neck and shoulders, reading a book can also cause fatigue of the hands and fingers because of the need to grip the book and turn the pages.
Devices that are currently available in the marketplace provide a support for a laptop computer or book, but however do not allow the device to be adjusted in order to promote good posture of the user. In other words, the presently available commercial devices do not address the bad posture problems of users of laptop computers and readers of books. Hence, it is desirable to have a support device that is capable of holding a laptop computer or a book, while also promoting good posture.
SUMMARY OF THE INVENTION
An embodiment of the invention is directed to a multipurpose support device comprising: a base comprising a substantially horizontal surface; and a first support member that is coupled to the base, wherein the plane of the first support member is substantially perpendicular to the base, and wherein the base is movably connected to a structure, said structure providing a means for holding the multipurpose support device in a specified position. In an additional embodiment of the invention, a second support member is connected to the first support member wherein the second support member is movable relative to the base and the first support member, and the second support member comprises a plurality of wrist supports. In certain embodiments of the invention, the second support member is immovable relative to the base and the first support member.
An embodiment of the invention is directed to a method for using a multipurpose support device having a base comprising a substantially horizontal surface; a first support member coupled to the base, and a second support member that is connected to the first support member, and wherein the second support member comprises a plurality of wrist supports; the method comprising the following steps: positioning the bottom edge of a laptop computer on the first support member; positioning the top edge of the lap top on the base; resting the user's forearms on the forearm supports of the second support member; extending the wrist supports of the second support member towards the surface of the laptop computer; and resting the user's wrists on the wrist supports of the second support member.
An additional embodiment of the invention is directed to a method for using a multipurpose support device having a base comprising a substantially horizontal surface; a first support member coupled to the base, wherein the plane of the first support member is substantially perpendicular to the base, and wherein the base is movably connected to a structure, said structure providing a means for holding the multipurpose support device in a specified position, and further comprising securing members at the lateral outer edge of the base to which are attached flexible extender members; the method comprising the following steps: positioning an open book on the base; securing each lateral side of the book with the securing members; and positioning one or more selected pages of the book under the flexible extenders.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view illustrating an embodiment of the multipurpose support device of the invention.
FIG. 2 is a diagrammatic top view illustrating an embodiment of the multipurpose support device of the invention.
FIG. 3 is a diagrammatic side view illustrating an embodiment of the multipurpose support device of the invention.
FIG. 4 is a diagrammatic perspective view illustrating an embodiment of the multipurpose support device of the invention.
FIG. 5 is a diagrammatic perspective view illustrating an embodiment of the multipurpose support device of the invention.
FIG. 6 is a diagrammatic perspective view illustrating an embodiment of the multipurpose support device of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
As seen in FIG. 1 , a multipurpose support device 10 is shown holding a laptop computer 12 . The support device 10 comprises a member or base 14 that serves as the platform upon which a portion of the laptop computer 12 rests. The support device 10 further comprises a first support member 15 that is substantially perpendicular to base 14 and immovably connected to base 14 . The first support member 15 provides a surface upon which the bottom portion of the laptop computer may be placed. The multipurpose support device 10 further comprises a second support member 16 that is movably connected to member 15 . In order to prevent the bottom portion of the laptop computer from sliding off the surface of member 15 , a plurality of restraints 19 such as hooks may be employed. The location of the restraints may be changed to allow for better support of a laptop computer by allowing rearrangement of the restraints 19 on member 15 . Member 16 comprises a plurality of wrist supports 17 that may be extended by a user and placed on top of the laptop computer 12 , when the multipurpose support device 10 is in use. The position of member 16 may be adjusted so that the angle of member 16 relative to member 15 can be changed either along a vertical plane or a horizontal plane in accordance with a user's comfort. When the multipurpose support device is not in use, the wrist supports 17 may be placed within recessed spaces 18 located on member 16 . Additionally, the second support member 16 provides a user with a surface to rest their forearms. Member 16 may optionally comprise a strip of padded material (not shown) to promote comfort of the forearms when they are resting on member 16 . In certain embodiments of the invention, the second support member 16 may be immovably connected to member 15 .
As seen in FIG. 2 , the location and position of a first arm member 21 that is attached to the posterior surface, i.e., opposite surface to where the laptop computer would rest, of the base 14 is shown. The first arm member 21 functions to position the multipurpose support device 10 at an angle that is comfortably suitable for the user and which allows the user to maintain the proper posture when using the multipurpose support device. The first arm member 21 is movably connected to a second arm member 20 , which in turn may be connected to additional arm members, a surface such as a desk, a cart or a vertical member (not shown) to facilitate the fixed anchoring of the multipurpose support device 10 .
FIG. 3 shows a side elevation view of the multipurpose support device 10 with first arm member 21 connected to base 14 and second arm member 20 connected to first arm member 21 .
FIG. 4 is a perspective view of the multipurpose support device 10 comprising a first arm member 21 and a second arm member 20 , wherein the second arm member is connected to a vertical member 22 . The vertical member is contained within a housing 26 which comprises a shelf-like member 23 to which the vertical member 22 is connected by its base 24 . The bottom end of the housing comprises a floor 25 , to which are connected a plurality of wheels 27 . The wheels 27 allow a user to transport the multipurpose support device 10 and housing 26 to a convenient location. In the event that wheels 27 are employed, it is desirable to provide a mechanism to fix or lock the wheels (not shown) when the multipurpose support device 10 is conveniently positioned for use.
The presence of the first arm member 21 and second arm member 20 permits the user to adjust the position of the multipurpose support apparatus 10 , so that the user may comfortably position a laptop computer at a convenient distance and position in a manner while maintaining good posture. The profile of vertical member 22 may have a straight shape (as shown in FIG. 4 ) or a curved shape (not shown).
The multipurpose support device 10 is positioned relative to the user in a seated position so that the keyboard is approximately at the same plane as the user's forearms when typing. Additionally, the user's wrists are at the level of the wrist supports 17 . At the same time, the user's posture is that of a relaxed, reclining nature. In addition to the wrist supports 17 , an additional forearm support, such as a padded support (not shown) may be included with member 16 , so that the user's forearms may comfortably rest on the surface of member 16 , while the user's wrists are supported by the wrist supports 17 .
It will be seen from the following description, that the multipurpose support device 10 , particularly base 14 may be horizontally adjustable toward and away from the user, i.e., translationally. Moreover, the multipurpose support device is simultaneously pivotal along a horizontal axis parallel to base 14 . One embodiment of the multipurpose support device 10 for providing both translational and pivotal or rotational movement of the base 14 may comprise a first arm member 21 fixedly attached to the bottom surface of base 14 and having a plurality of sliding dovetail members (not shown). As will be appreciated by those persons of ordinary skill in the art, sliding dovetails are only exemplary of mechanical arrangements that permit base 14 to be movable relative to the housing 26 and the vertical member 22 .
From the above description it will be apparent that the multipurpose support device, on which the laptop computer 12 rests, may be moved relative to the user both pivotally and translationally, as well as vertically, thus accommodating users of different height, girth, and personal preference for the position of the laptop computer during keyboarding or using mouse panel as well as for maintaining the display at an appropriate height and angle for viewing.
It may be desirable when using a laptop computer 12 with the present invention to connect the computer to a source of AC power through an in-line transformer (not shown) and/or connect it to a printer (not shown). To accommodate the cords to the printer and/or power it may be desirable to hold the cords in a convenient position. For example, a channel or trough (not shown) could be formed in one surface of a solid stanchion or if the stanchion is hollow, such as a pipe, suitable holes could be provided through which the ends of the cord could enter and exit near the member 14 and the floor 25 of the housing 26 . Alternatively, a simple clamp or Velcro belt could be used to hold the cords in place (not shown).
In certain embodiments of the invention, one or more sliding plates (not shown) may be added to the back of the base 14 , which can be slid out to enable the user to place books or sheets of paper on the sliding plates when using the multipurpose support device 10 .
As shown in FIG. 5 , a user 30 can place the laptop on the anterior surface of base 14 , sit on a chair with a slightly reclined angle 31 , rest the back and neck on the chair, pull and adjust the multipurpose support device 10 to a comfortable position and angle to rest the elbows on the chair arms and rest the forearms on member 16 and rest the wrists on the wrist supports 17 . With this posture, the user's neck, back, elbows, forearms, and wrist are fully supported and rested on various supports, thus reducing the chance of pain and injury to the users.
In certain embodiments of the invention, a plurality of adjustable sliding plates of suitable dimensions (not shown) can be added to the anterior surface of the base 14 to raise the bottom portion of the laptop computer away from base 14 in order to make room for a power cord or other wires to be plugged into the back end of the laptop computer.
In an embodiment of the invention, two side clamps are added to the surface of the base 14 to enable the user to use the multipurpose support device for reading a book or magazine. In FIG. 6 , the base 101 is analogous to the base 14 depicted in FIGS. 2-5 .
As best illustrated in FIG. 6 , the book holder embodiment of the multipurpose support device of the invention 100 comprises a base 101 having an upper edge member 104 , a lower edge 106 , a first side edge 108 , a second side edge 110 , a front side 112 and a back side 114 . Attached to the lower edge 106 , is a first support member 113 that is fixedly connected to the lower edge 106 and is substantially perpendicular to the base 101 . The upper edge member 104 and the first support member 113 each have a slot 116 present therein. Each of the slots 116 generally extends along the length of the upper edge member 104 and member 113 . Each of a pair of vertical plates 118 is removably extended into the slots 116 . Each of the plates 118 has an outer edge 120 biased outwardly away from the center of the base 101 . The plates 118 also each have an inner edge 124 biased towards the center of the base 101 . The inner edges 124 of the plates 118 face one another. To each of the plates 118 , a movable plate 119 is attached via connectors 121 . The plates 119 are capable of being moved along a vertical plane along the plates 118 .
Each of a pair of securing members 126 is attached to the outer edges 120 of the plates 118 . The securing members 126 are adapted for attaching a book to the plates 118 . Each of the securing members 126 preferably comprises a clip 133 biased towards the inner edge 124 of the plates 118 . The clip 133 is used to clamp down the lateral edge of the book pages on to the base 101 . In certain embodiments of the invention, the clip 133 may be transparent, which allows the user to be able to see and read the content on the portion of the page that is clamped under the clip 133 .
In use, the plates 118 are extended outwardly from the base 101 so that the base 101 is of a size required for a book to be fixed on the base 101 . The securing members 126 are used to attach a book or other reading material to the plates 118 so that the book is placed in an open position. Each of the securing members comprises a vertical rod 128 to which is attached a flexible finger-like extender 130 . The flexible extenders 130 may be used to maintain the pages of the book in place during use. Each of the plates 119 can be moved along a vertical plane, i.e., up and down in order to accommodate tall or short books.
The securing member 126 on one side of the device may be used to secure the pages that have already been read. The securing member 126 on the opposite side of the panel may be used to secure those pages that are not anticipated to be read during a particular session. The collection of pages to be read in a particular session may be positioned between the securing member 126 and the flexible extender 130 . Adjustments of amounts of pages positioned under the securing members 126 and the amounts of pages comprising reading-session pages positioned under the flexible extender 130 are made as desired in relation to reading times or anticipated reading periods. Lastly, during reading, the user can slide a page out from under one flexible extender 130 and slide it under the opposite flexible extender 130 . Optionally, a string or wire 132 can be extended from the upper edge 104 of the panel 101 across the center line of the book and locked at the lower edge 106 . Conversely, the string 132 may be extended from the lower edge 106 , across the center line of the book and locked at the upper edge 104 . The center string 132 is especially useful when the user reads the book on the supporting surface in a lying-down and facing-up position.
The first arm member 21 and second arm member 20 , as well as other structures that the second arm member may be connected to (as set forth in FIGS. 2-5 ), such as a desk, a cart or a vertical member are the same as previously described for the laptop support embodiment of the invention may be incorporated in the embodiment of the invention shown in FIG. 6 .
From the various embodiments described and shown herein, it will be obvious that many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described in the various embodiments in this specification and that the scope of the invention is to be defined by the appended claims. | The invention is directed multipurpose support device for supporting an item such as a laptop computer or a book. The support device has a base that is adapted to be coupled to a structural support, such as a mobile cart, a desk, a sofa or a wall. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to the self-tiling process of finding Iterated Function Systems (IFS) for modeling natural objects, and more particularly to an electro-optical system for performing the self-tiling process in order to find an optimal IFS for modeling a given object.
An affine transformation is a mathematical transformation equivalent to a rotation, translation, and contraction/expansion with respect to a fixed origin and coordinate system. In computer graphics, affine transformation can be used to generate fractal objects which have significant potential for modelling natural objects, such as trees, mountains and the like.
The Collage Theorem allows one to encode an image as an IFS. See, M. F. Barnsley et al., "Solution of an Inverse Problem for Fractals and Other Sets," available from the School of Mathematics, Georgia Institute of Technology, Atlanta, Ga. 30332. An IFS is a set of j mappings (M 1 , M 2 , . . . M j ), each representing a particular affine transformation, that have a corresponding set of j probabilities (P 1 , P 2 , . . . P j ). The j probabilities can be thought of as weighting factors for each of the corresponding j mappings or transformations. See, e.g., L. Demko et al., "Construction of Fractal Objects with Iterated Function Systems," Computer Graphics, Vol. 19(3), pages 271-278, July, 1985, SIGGRAPH '85 Proceedings.
An IFS "attractor" is the set about which the random walk eventually clusters. The use of an IFS attractor to model a given object can provide significant data compression. However, this method is practical only if there exists a reasonably easy way to find the proper IFS to encode the object.
Informally, the object can be viewed as the settheoretic union of several sub-objects that are (smaller) copies of itself. The original object can be tiled with two or more sub-objects and the original object reproduced as long as the tiling scheme completely covers the original object, even if this means that two or more of the tiles overlap. If these conditions are met, an IFS can be determined or found whose attractor will be the original object. The accuracy of the resultant image is directly proportional to the exactness of the self-tiling process.
The self-tiling process of finding a proper IFS has been digitally automated with a simulated thermal annealing algorithm to adjust the parameters. The process starts with a rough tiling, and compares its initial tiled image with the object to be modeled. The measure of how well the tiled image matches the object is provided by computing the associated Hausdorff distances. The goal is to minimize the Hausdorff distance at each iteration. This process is repeated until a satisfactory match is achieved.
Thus, digital computation has been employed to perform contractive affine transformations of the original object and to compose a tiled image from a collection of these transformed images. The conventional digital process involves a great amount of computation on affine transformations and Hausdorff distances, and so it is slow.
SUMMARY OF THE INVENTION
It would be advantageous to provide a finder of an IFS for a given object which is not computationally intensive and which is relatively fast. These and other advantages are obtained by the invention, wherein an optical processor is provided for finding a proper IFS to model a given object. The optical processor includes means for providing an input image of the object to be modelled, and means for directing the input image through a plurality of optical branches.
Each optical branch includes means for optically performing an affine transformation on the input image. Thus, each branch includes means for selectively optically rotating the input image, means for selectively optically magnifying or demagnifying the input image, and means for selectively optically translating the input image so as to perform the desired affine transformation in the respective optical branch.
The optical processor further comprises means for combining the respective transformed images from the respective optical branches at an output image plane to provide a tiled image of the object. The proper IFS may be formed by adjusting the respective optical rotating, magnifying or demagnifying, and/or translating means until the output tiled image converges to a suitable likeness of the input image.
The process of finding the proper IFS can be automated by providing means for comparing the input image with the output tiled image, providing servomechanisms for setting the various optical rotating, magnifying and translating means, and systematically changing the parameters to find the best match between the tiled image and the input image.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become more apparent from the following detailed description of exemplary embodiments thereof, as illustrated in the accompanying drawings, in which:
FIG. 1 illustrates an electro-optic system for finding a proper IFS in accordance with the invention.
FIG. 2 is a simplified block diagram illustrative of an automated electro-optic system for finding an optimal IFS in accordance with the invention.
FIG. 3 is a simplified flow diagram illustrative of an exemplary algorithm for controlling the system of FIG. 2 to find an optimal IFS.
FIG. 4 is a simplified schematic diagram illustrative of a coherent optical processor useful for processing the optical output image of the systems of FIGS. 1 and 2.
FIG. 5 is a simplified schematic diagram illustrative of an non-coherent optical processor useful for processing the optical output image of the systems of FIGS. 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention provides an electro-optical system to perform self-tiling optically, and provides a very efficient real-time interactive system for finding a proper IFS for a given object. Furthermore, the process can be automated by the addition of an image comparison algorithm and servomechanisms to position the optical elements.
FIG. 1 shows an electro-optical system 50 in accordance with the invention. An image of the object to be modeled is presented at the input image plane IO. For example, the image of the object, say a maple leaf, is recorded on a photographic film, and the film is placed at the image plane IO. A light source such as that used in a slide projector may be used to illuminate the film.
The input image undergoes several (three are shown in FIG. 1) affine transformations, by branching the light of the input image into several optical branches including light paths 60, 70 and 80, employing beamsplitters B1, B2, and B3 to perform the optical branching. The branching ratios of the beamsplitters is such that image light of equal intensity is provided at each branch.
Beamsplitters for performing the functions of devices B1, B2 and B3 are well known in the art. See, for example, W. J. Smith, "Modern Optical Engineering," pages 94-95, McGraw-Hill (1966).
To illustrate the optical affine transformations, consider the object image light traversing the first branch 60. The object is imaged onto the intermediate image plane I1 through the imaging zoom lens L1 that provides a magnification or demagnification as required by the subject affine transformation. This corresponds to a scaling operation for the subject affine transformation. The amount of rotation is controlled by the setting of the rotating prism P1. This prism could be a Harting-Dove or a Pechan prism. The required translation for the affine transformation is generated by shifting the translating mirror M1. Conventional means are provided to position the optical elements P1, L1 and M1 at desired settings or positions.
The optical system 50 is designed with sufficient depth of focus to ensure that a slight change of path length will not introduce significant blur. The image thus formed at the first image plane I1 represents the original object having undergone an affine transformation. This transformed image is then relayed to the output image plane I4 via relay mirror M4 and through the relay lens L4.
The second optical branch 70 receives input image light via beamsplitters B1 and B2, and also includes a rotating prism P2, and imaging lens L2, and a translating mirror M2. These optical elements provide the rotation, scaling and translating required for the affine transformation performed by the second optical branch 70. The image thus formed at the second image plane I2 has undergone a second affine transformation. The transformed image light is combined with the transformed image light from the first optical branch 60 at beamsplitter B4.
The third optical branch 80 receives input image light via beamsplitters B1, B2 and B3, and also includes a rotating prism P3, an imaging lens L3 for imaging the input image light at the third image plane I3, and a translating mirror M3. These optical elements provide the rotation, scaling and translation required for the affine transformation performed by the third optical branch 80. The image thus formed at the third image plane I3 has undergone a third affine transformation. The transformed image light is combined with the transformed image light from the first and second optical branches 60 and 70 at beamsplitter B5. Conventional means are provided to position the optical elements P3, L3 and M3 at desired setting or positions.
A tiled image is formed at the fourth image plane I4 when the images formed in the different optical branches are combined through the mirror M4 and the beamsplitters B4 and B5. Since the tiled image is formed optically, one can observe the changing of the tiled image while adjusting the setting of the rotating mirrors, the zoom lenses and the translating mirrors. The settings that yield the best tiled image determines the proper IFS for the given object, i.e., the IFS is defined by the probabilities associated with each branch and the particular amounts of rotation, scaling and translation performed by each optical branch. Thus, the system provides a very efficient man-in-the-loop real-time interactive system.
This system can be automated with the addition of an image processor, e.g., an image detector array at the fourth image plane I4 for recording and digitizing the tiled image, and a suitable algorithm (described below) for evaluating the goodness of the match between the input image and the tiled image, and appropriate servomechanisms for positioning the various optical elements in each branch in response to control signals. An input image processor can be provided to record and digitize the input object image, permitting direct digital comparison of corresponding pixel values comprising the input (reference) image and the tiled output image.
FIG. 2 is a simplified block diagram of such an automated IFS finder system 90. Elements in FIG. 2 correspond to like numbered or designated elements in FIG. 1. The IFS finder system 90 also includes a beamsplitter 102 which splits a portion of the input image light away as a reference object image. Depending on the particular technique employed to compare the input image with the tiled output image, i.e., digital or optical comparison, the reference object image may either be detected and digitized by an image detector array (shown in phantom as block 104) or directed to an optical processor (described below with respect to FIGS. 4 and 5) for comparison with the output tiled image. If a digital comparison is utilized, then the detector array 104 may comprise, for example, a CCD imager, Model TK2048M, marketed by Tektronix, Inc., Beaverton, Oreg.
The input object image is then passed through three optical branches which perform three respective affine transformations on the input image, identically to the processing described with regard to FIG. 1. The respective transformed images are combined and imaged at the output plane I4, as described with respect to FIG. 1.
The tiled output image is processed by image processor 110, whose output is coupled to the IFS controller 100.
If a digital image comparison is utilized by the system 90, then the image processor 110 comprises an image detector array for recording and digitizing the tiled output image, and providing a digital data representation thereof to the IFS controller 100. The controller in this case receives a corresponding digital data representation of the input object image, and compares the two images pixel-by-pixel to determine the differences between the images. To determine a difference value for the comparison, a running total may be kept of the number of pixel locations in which the respective images have different values.
As an alternative to the digital image comparison, an optical image comparison may be employed by the IFS finder system 90. The image processor 110 performs an optical comparison of the reference object image and the tiled output image. In this case, no detector array 104 is needed, the reference image being directed to the image processor 110. Two exemplary optical processors suitable for the function of processor 110 are described with respect to FIGS. 4 and 5.
The IFS controller 100 is responsive to information received from the image processor 110, and controls the settings and positions of the optical elements through the various servomechanisms 61, 63, 65, 71, 73, 75, 81, 83 and 85. The controller 100 may comprise, for example, a digital computer for processing the detector information (i.e., the algorithm for determining "goodness") and determining the proper settings, and associated peripheral devices for providing the control signals to the various servomechanisms.
To control the settings of the respective rotating prisms 61, 71, 81, the prisms may be mechanically mounted in respective rotatable fixtures, which may in turn be positioned by the respective servomechanisms 61, 71 and 81. There are many known servomechanisms suitable for the purpose, including stepper motors with or without position encoders.
The lenses L1, L2, L3 are adjustable over a range of magnification and/or demagnification; a zoom lens may be employed, for example. The respective lens devices L1, L2, L3 may be actuated by respective mechanisms or actuators 63, 73, 83, each of which comprises a servomechanism such as a stepper motor drive, to adjust the zoom lens elements to provide the desired magnification/demagnification.
The translatable mirrors M1, M2, M3 are mounted for translating movement along the respective optical paths. One exemplary type of translating equipment suitable for the purpose includes a leadscrew driven carriage which carries the respective mirror, and a servomechanism to serve as the respective element 65, 75 or 85, such as a stepper motor drive which turns the leadscrew to place the respective mirror at a desired position. If the necessary range of movement of the mirrors M1, M2 and M3 is sufficiently large, it may be necessary also to mount the mirror M4 and the respective beamsplitters B4 and B5 on respective translational apparatus so that the respective element M4, B4 and B5 moves in parallel synchronism with its corresponding element M1, M2 and M3.
One exemplary algorithm used for iteratively varying the system parameters to find the IFS with a good match, will vary one parameter at a time systematically, and generate an array of results, i.e., the differences between the tiled images and the object. The computer can be used to automatically store the parameters and the corresponding results. The computer can, after systematically varying the parameters, find the optimal result, i.e., the minimum of the differences, and its corresponding parameters, i.e., the optimal IFS.
The automated process starts with a trial design of the tiling. This initial tiled image is compared to the object by taking the difference between the two. The goal is to minimize the difference. Because of the high speed of the optical affine transformation process, it is possible to vary the parameters of the affine mappings in a systematic way to find the best match. This process requires more iterations, but much less digital computation. Overall, it will be much faster than a conventional purely digital process that calculates Hausdorff distances and which uses the simulated thermal annealing algorithm for automation.
In the purely digital, conventional process, it is necessary to involve rather tedious calculations of Hausdorff distances, because the relatively slow digital process does not permit searching through all parameters systematically. The method of calculating Hausdorff distances is described, for example, in "Fractals and Self Similarity," J. E. Hutchinson, Indiana University Mathematics Journal, Vol. 30, No. 5, 1981, pages 718-720.
FIG. 3 illustrates a simplified flow diagram of an exemplary algorithm for operating the system of FIG. 2 to find an optimal IFS. At step 120 the system is set to an initial configuration, i.e., the rotating prisms, the lenses and the translatable mirrors are set to an initial position. Next, the difference is obtained between the output tiled image and input image of the object. The difference can be obtained by a digital comparison of corresponding pixel values, for example. Other techniques may also be employed to obtain a comparison value representing the difference (ΔI), including the coherent optical processing described below with respect to FIG. 4 or the incoherent optical processing described below with respect to FIG. 5. In the digital comparison, the goodness of the match can be defined as the sum of the differences of corresponding pixels of the tiled output image at image plane I4 and the reference object image.
At step 124 the difference value is recorded in memory with an identification of the corresponding IFS configuration. If any more prescribed configurations of the system remain untried (step 126), the IFS finder system is set at a new configuration (step 128), and steps 122 and 124 are repeated. Once all prescribed configurations of the system have been tried, then the stored array elements are compared (step 130) to obtain the minimum difference value. The corresponding configuration for this minimum difference value is determined to be the optimal IFS (step 132).
Instead of taking the difference of the tiled image and the object digitally, the evaluation of the tiling process can also be done optically. For example, a liquid crystal light valve can be used to convert the output tiled image into a coherent light source. The tiled image can be correlated with the original object using traditional coherent optical processing. The use of liquid crystal light valves in optical data processing, including image subtraction, is known in the art. See, for example, "Application of the Liquid Crystal Light Valve to Real-Time Optical Data Processing," W. P. Bleha et al., Optical Engineering, Vol. 17, No. 4, July-August 1978, pages 371-384. Coherent optical processing of images to perform image subtraction is also described in "Real-time image subtraction using a liquid crystal light valve," E. Marom, Optical Engineering, Vol. 25, No. 2, February 1986, pages 274-276. The entire contents of both references are incorporated herein by this reference.
The coherent processing for image subtraction is a well known technique. For example, as shown in FIG. 4, the output image I4 from the IFS finder system 90 (FIG. 2) and the reference object image are projected by respective lenses 140 and 141 onto the backside of the liquid crystal light valve (LCLV) 143 through a Ronchi grating 144, a grating with equal width opaque and transparent stripes. The composite image of the output tiled image and reference image is read out by a coherent light beam (a laser beam) from the front side of LCLV and imaged onto the image plane IF through lens 146. A beamsplitter 145 directs the coherent light beam onto the front side of the LCLV 143, and the reflected light beam is transmitted through the beamsplitter 145 to lens 146. A filtering slit 147 is used to select out an odd order of the composite image so that the filtered image on the image plane I5 is just the difference of I4 and the reference object. Using this optical comparison technique, the goodness of the match is indicated by the sum of the pixel intensities at image plane I5 (FIG. 4); the higher the sum, the poorer is the match.
Another technique to minimize the involvement of digital processing and to avoid the complication of coherent optical processing is to use a liquid crystal light valve (LCLV) in non-coherent optical processing for image comparison. In this embodiment, the output image at image plane I4 in FIG. 1 is used for the writing beam of the light valve, and a projected object beam is used for a readout, instead of the usual uniform beam. The light valve output is then focused to a detector. The light valve is designed so that the detector signal indicates the degree of match between the tiled image and the object.
FIG. 5 is a simplified schematic block diagram illustrating non-coherent optical processing to compare the reference object image and the transformed output image. The transformed output image at image plane I4 (FIG. 1) is relayed through lens 156 to the rear side of the light valve 154, and serves as the writing beam. The reference object image is projected through the lens 150 and the beamsplitter 152 onto the front side of the liquid crystal light valve 154. The light valve 154 is designed such that the reflectivity of the light valve at a given point on the front side of the light valve is proportional to the intensity of the writing beam at a point on the rear side of the light valve opposite the point on the front side. Thus, the reflected light collected by the detector 160 via the beamsplitter 152 and the imaging lens 158 will reach a maximum when the tiled output image at image plane I4 matches the reference object.
The optical affine transformation described here performs only scaling, rotation, and translation. These are the features used in typical IFS applications. The general affine transformation which includes a shearing effect can be done optically, too, if a more complicated optical system is used; for example, including deformed mirrors in the system can create a shearing effect.
It is understood that the above-described embodiments are merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope of the invention. | An electro-optical system that implements the self-tiling process of fining proper Iterated Function Systems for modeling natural objects. The system can operate in two different modes, a real-time interactive mode and an automated mode. The purpose of the system is to speed up the process of finding a proper IFS for a given object to be modeled. The system makes use of optical processing, including optical means for rotating, magnifying/demagnifying and translating an input image. Optical beamsplitters are used to combine transformed images to produce a tiled output image. In one embodiment, an automated controller evaluates the goodness of the match between the tiled image and the input image and generates control signals which cause adjustment of the settings of the optical means. The process is repeated automatically until the match is sufficiently good. The invention can also be operated in a manual, man-in-the-loop mode. | 6 |
The invention herein described was made in the performance of work under a NASA contract and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, Public Law 85-568 (72 Stat. 435; 42 USC 2457).
BACKGROUND OF THE INVENTION
The present invention pertains to gas turbine engines and, more particularly, to a method of operating same to reduce carbon monoxide and unburned hydrocarbon emissions.
The present era of environmental awareness has spurred governmental regulations limiting the permissible exhaust emissions from gas turbine engines. Some of the more severe requirements relate to carbon monoxide (CO) and unburned hydrocarbon (HC) emissions. These emissions have traditionally been the greatest at ground idle conditions where the combustor inlet temperature and pressure, and the combustor fuel-to-air ratio, are relatively low.
As gas turbine powered aircraft are designed for operation from shorter runways, the emissions problem will become more acute. The reason is that short-field aircraft must be overpowered (i.e., higher installed thrust-to-aircraft weight ratio) compared to the more conventional take-off and landing aircraft. For example, during taxi operation the engine power setting must be reduced abnormally to avoid overloading the aircraft brakes, particularly on icy runways. As the engine throttle is pulled back to this abnormal position, the combustor inlet temperature drops (due to lower work input of the compressor) resulting in inefficient burning and increased exhaust emission levels. A similar condition exists during the landing cycle if the aircraft maintains a holding pattern, since there again the power level must be abnormally low (on a percentage thrust basis) due to the high installed thrust level.
The problem is further compounded, however, since not only does the low combustor inlet temperature result in increased exhaust emissions, but it also degrades the aircraft anti-icing system effectiveness. Some aircraft and engine surfaces are normally heated by air bled from the combustor inlet and if this air is too cool the heating process does not function properly.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the present invention to provide a method of operating a gas turbine engine in order to reduce CO and HC emissions at low power settings.
It is a further object of the present invention to provide an improved gas turbine engine having reduced CO and HC emissions at low power settings.
These and other objects and advantages will be more clearly understood from the following detailed description, drawings and specific examples, all of which are intended to be typical of rather than in any way limitng to the scope of the present invention.
Briefly stated, the above objects are accomplished in a gas turbine engine wherein hot air is bled from the engine at a first location and reintroduced back into the engine at a second location, with the necessary constraints that the temperature of the air at the first location exceeds that of the second and wherein the re-entry location is at least as far upstream as the combustor inlet. Thus, as the hot air is recycled the combustor inlet temperature rises rapidly for a given engine thrust level so as to reduce CO and HC exhaust emissions.
In the preferred embodiment, a conduit is provided to transfer hot air from a source such as the compressor discharge, combustor discharge or turbine discharge upstream to the compressor inlet, for example. A valve within the conduit, and operated by means of a signal from the engine fuel control system or power lever, is provided to control the rate of recirculation of the heated air. Alternatively, it may be possible to dispense with such a control valve by finding a combination of hot air sources and re-entry locations which would permit the bleed air to flow at low power settings and not at high power settings. In such event, a simple check valve would preclude reverse circulation.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as part of the present invention, it is believed that the invention will be more fully understood from the following description of the preferred embodiment which is given by way of example with the accompanying drawings in which:
FIG. 1 represents a schematic, partial cross-sectional view of a gas turbine engine incorporating the subject invention;
FIG. 2 is an enlarged cross-sectional view of a portion of the gas turbine engine of FIG. 1;
FIG. 3 is a gas turbofan engine partial cross-sectional schematic, similar to FIG. 1, depicting an alternative embodiment of the present invention; and
FIG. 4 is an enlarged cross-sectional view similar to FIG. 2 depicting an alternative embodiment of a portion of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings wherein like numerals correspond to like elements throughout, reference is first directed to FIG. 1 wherein an engine depicted generally at 10 and embodying the present invention is diagrammatically shown. This engine may be considered as comprising generally a core engine 12, a fan assembly 14 including a stage of fan blades 16, and a fan turbine 18 which is interconnected to the fan assembly 14 by shaft 20. The core engine 12 includes an axial flow compressor 22 having a rotor 24. Air enters inlet 26 and is initially compressed by fan assembly 14. A first portion of this compressed air enters the fan bypass duct 28 defined, in part, by core engine 12 and the circumscribing fan nacelle 30 and discharges through a fan nozzle 32. A second portion of the compressed air enters inlet 34, is further compressed by the axial flow compressor 22 and is then discharged to a combustor 36 where fuel is burned to provide high energy combustion gases which drive a turbine 38. The turbine 38, in turn, drives the rotor 24 through a shaft 40 in the usual manner of a gas turbine engine. The hot gasses of combustion then pass to and drive the fan turbine 18, which, in turn, drives the fan assembly 14. A propulsive force is thus obtained by the action of the fan assembly 14 discharging air from the fan bypass duct 28 through the fan nozzle 32 and by the discharge of combustion gases from a core engine nozzle 42 defined, in part, by plug 44. The foregoing description is typical of many present-day gas turbine engines and is not meant to be limiting, as it will become readily apparent from the following description that the present invention is capable of application to any gas turbine engine and is not necessarily restricted to gas turbine engines of the turbofan variety. The foregoing description of the operation of the engine as depicted in FIG. 1 is, therefore, merely meant to be illustrative of one type of application for the present invention.
For most gas turbine engine combustors it has been found that the amount of gas emissions at idle (or below idle) engine operating conditions can be reduced by increasing the temperature of the air entering the combustor. In the present invention, the temperature of the air entering the combustor is increased by recycling the heated air in any of several ways now to be described. Generally, a portion of the air is bled from the engine at a first location and reintroduced back into the engine at a second location subject to two constraints:
(1) the temperature of the air (the motive fluid) passing through the engine must be higher at the bleed source (the first location) than at the re-entry location (the second location); and
(2) the re-entry location must be at least as far upstream as the inlet to the combustor.
For example, consider the arrangement of FIG. 1 wherein air is bled from the discharge 45 of compressor 22 and routed by means of conduits 46, 48 to the core compressor inlet 34 where it is reintroduced back into the primary flow stream. Since the temperature at the compressor discharge is greater than that at the inlet by virtue of the work addition through the compressor, the average compressor inlet temperature is increased. When the engine cycle is rebalanced in the known manner to supply a specific idle or subidle thrust, the net result is an increase in combustor inlet temperature of an amount in excess of the increase in inlet temperature. This, in turn, reduces CO and HC emissions significantly.
A simple estimate of the effectiveness of the concept on a commercially available high bypass-ratio gas turbofan engine indicates that a 50° F (27.8° C) increase in core compressor inlet temperature at a 5 percent thrust idle condition will increase the combustor inlet temperature by 75° F (41.7° C). This, in turn, decreases the CO emissions by approximately 28 percent, even after accounting for an increased fuel flow of about 4 percent required to rebalance the cycle. The magnitude of the compressor discharge bleed required to raise the compressor inlet temperature by 50° F is about 14 percent of the total air passing through the core compressor. It is to be noted that these estimates do not include the effect of bleed on the cycle, but just include the inlet temperature effect. The effect of compressor bleed by itself without recirculation is to raise turbine inlet temperature and the combustor fuel-to-air ratio required to supply a given level of idle thrust. This will further contribute to reduced emissions and the two effects will complement each other. Thus, the improvement in idle emissions achieved by raising the compressor inlet temperature is in addition to the effect of compressor discharge bleed.
In principle, the magnitude of the increases in compressor inlet and discharge temperatures can be made any reasonable value depending on the particular engine involved, the power setting in consideration, and practical considerations such as maximum temperature limits of the compressor inlet, the size of the ducting required, and the means necessary for extracting the bleed air and reintroducing it into the compressor inlet.
The obvious choice for the bleed extraction location in contemplation of modifying existing engines is at the compression discharge location (45 of FIG. 1) as discussed hereinabove, by utilizing extraction ports already in the engine for customer purposes such as aircraft cabin pressurization or anti-icing. However, several other sources may be tapped for the hot air depending upon the amount of flow and temperature rise desired. Means for bleeding this hot air are indicated by the dotted lines feeding conduit 48 in FIG. 1. Specifically, they include compressor interstage bleed 50, combustor inlet bleed 52, combustor discharge bleed 54, turbine interstage bleed 56 and turbine discharge bleed 58. Clearly, extraction from the turbine area where the air is at a much higher temperature will provide a much greater increase in compressor inlet and exhaust temperature for a given bleed flow rate. For example, if combustor discharge bleed air at a temperature of 800° F (426.7° C) were used in the previous example, the amount of bleed air required to increase the compressor inlet temperature by 50° F (27.8° C) would be only approximately 4.5 percent of the total air available passing through the engine. Note also that the cycle rematching effect will be different for each extraction location.
FIG. 1 depicts the obvious choice for the re-entry location, at the core compressor inlet 34. While the concept is depicted only schematically in FIG. 1, the geometry of the reintroducing means may vary depending upon individual engine differences and design preferences. For example, FIG. 2 shows one possible arrangement wherein the bleed air is ducted into the flow splitter 60 separating the core inlet duct 34 from the fan bypass duct 28. Therein, the bleed air is fed into a plenum 62 within the splitter and ejected therefrom through means such as representative apertures 64 to mix with the incoming air of inlet 34. Alternatively, as is best shown in FIG. 4, the hot bleed air could be routed from the bleed location to the interior 65 of one of a plurality of hollow frame struts 66 (which typically support the splitter 60 in its proper spacial relationship with the core engine 12) by means of a conduit 67 and ejected therefrom through a plurality of apertures 69. In any event, the design should provide for the suitable mixing of the gases with the primary core engine stream and such mixing should occur early in the compression process.
Means such as valve 68 is provided in conduit 48 to permit the hot bleed air to be reintroduced into the compressor inlet airstream only at the abnormally low power settings discussed hereinabove. Typically, it is anticipated that such a valve would be controlled through the main engine fuel control means 70 which, in turn, is controlled by the pilot through throttle quadrant 72. The particular type of valve and its method of control are well within the capability of engine designers and the details need not be elaborated herein. One example which may be adapted to the present invention is the torque and power sensing and control system taught in U.S. Pat. No. 3,106,062 which is assigned to the assignee of the present invention and the subject matter of which is incorporated herein by reference.
In some cases it may be possible to dispense with valve 68 by finding a hot air source which is at a higher pressure than the re-entry point at low power settings, and at a low pressure at high power settings. Such an arrangement is depicted in FIG. 3 where bleed air is extracted downstream of the turbine at 73 and reintroduced in the early compressor stages at 74. Such an arrangement is possible since the pressure level in the early compressor stages is subatmospheric at low power settings, and any bleed flow would naturally occur from right to left at FIG. 3, whereas the flow would reverse itself and flow rearward (left to right) at higher power settings. This undesirable rearward flow may be prevented by means such as a simple check valve 76, if desired.
Therefore, a method has been provided for reducing CO and HC emissions in a gas turbine engine by bleeding a portion of the motive fluid (for example, air) from a first location and reintroducing it back into the engine motive stream at a second location as long as the bleed air is at a higher temperature than the motive stream at the re-entry location, and as long as the re-entry location is at least as far upstream as the combustor inlet.
It will become obvious to one skilled in the art that certain changes and variations can be made to the above-described invention without departing from the broad inventive concepts thereof. For example, while the routing of bleed flow has been depicted only schematically in FIGS. 1 - 3, it will be recognized that such piping and ducting may be either internal or external to the engine while still being within the scope of the present invention. Furthermore, the present invention is applicable to other types of gas turbine engines including, but not limited to, those of the turbojet and boosted turbofan varieties. It is intended that the appended claims cover these and all other variations in the present invention's broader inventive concepts. | A method of reducing carbon monoxide and unburned hydrocarbon emissions in a gas turbine engine by bleeding hot air from the engine cycle and introducing it back into the engine upstream of the bleed location and upstream of the combustor inlet. As this hot inlet air is recycled, the combustor inlet temperature rises rapidly at a constant engine thrust level. In most combustors, this will reduce carbon monoxide and unburned hydrocarbon emissions significantly. The preferred locations for hot air extraction are at the compressor discharge or from within the turbine, whereas the preferred re-entry location is at the compressor inlet. | 8 |
RELATED APPLICATIONS
This application is a continuation in part of co-pending application Ser. No. 13/373,974 filed Dec. 8, 2011.
FIELD OF THE INVENTION
The present invention is directed to a series of glycerin based polymers that have been designed to have very specific substitution patterns, herein referred to as regio-specific substitution (RSS) and also contain silicone. Natural oils are triglycerides produced by plants and animals as a mechanism to store energy in the form of neutral fats. While being very successful as a store of energy for cells, these products are oily and do not possess the derived aesthetics for widespread use in cosmetics. The compounds of the present invention provide properties including skin feel and thermo-sensitive properties (i.e. alteration in properties as the temperature increases). The properties of the natural triglycerides are controlled by the fatty (alkyl) group contained therein and normally are predominantly oleyl groups (C18). Nature does not provide much of a variation in the groups.
The use of silicone incorporated into the proper portion of the molecule allows for the synthesis of polymers with highly desirable properties when applied to hair and skin, properties totally lacking in natural products. We have surprisingly found that by linking triglycerides into polymer backbones and controlling the location of the different alkyl and silicone groups along that backbone, the performance and structure can define tuned. To improve the performance and properties of triglycerides, several polymeric silicone containing polymers mimics the desired properties of triglycerides, while providing outstanding skin feel, hair conditioning and other properties. The properties of these polymers can be controlled and tuned by judicial control of the polymerization conditions. Glycerin polyesters containing silicone and different pendent alkyl groups with varying fatty chain length will provide a unique multi-dimensional polymer. This polymer will has “compartments” of solid and liquid pendant group domains if the proper pendant groups are chosen and provide a low surface tension and skin feel provided by the silicone. This unique multi-dimensional, high definition polymer will have very unique physical properties, including unique shear and flow behaviors. These polymers will provide outstanding and unique skin feels when used in cosmetic applications.
BACKGROUND OF THE INVENTION
Triglycerides are common natural materials, their structure is:
Triglycerides are esters that are the reaction product of glycerin and fatty acids.
Triglycerides are very common in nature and are commonly used in cosmetic products to provide physical properties and ascetics. Triglycerides are commonly called oils, fats, butters and waxes. These terms are used to describe the physical and chemical composition of the triglyceride. Butters, oils and fats are all triglycerides. The major physical difference between butters, oils and fats are their melt and titer points: Fats have a titer point of over 40.5° C., oils have a titer point of below 40.5° C., and butters have a titer below 40.5° C. but above 20° C. Oils are liquid at room temperature and we now use this word to describe any compound that is a liquid and is insoluble in water. As a result, Jojoba is referred to as oil, despite the fact it is really a liquid wax.
Because oils, fats, butters and waxes are complex mixtures of homologues of similar chemical structures, it is difficult to obtain a true melting point. As the lower molecular weight fractions melt, they act as solvents to dissolve the higher molecular weight products. This results in a very wide melting “range” for these compounds. For this reason, titer point is generally determined on fats, oils, waxes and butters.
Titer is defined as the re-solidification point of the melted oil, fat butter or wax. The procedure is to heat the product to be tested until it is completely liquid, then to slowly cool with stirring. This is done until the temperature stays constant for 30 seconds, or begins to rise. The titer point is the highest temperature indicated by this rise.
Triglycerides are the tri-ester of glycerin with three equivalents of fatty acid. Fatty acids are defined as those acids having alkyl or alkylene groups being C-5 and higher. The reaction is as follows:
Triglycerides occur commonly in nature, but lack the desired aesthetics for many personal care applications. It is the pursuit of improving the feel of these commonly occurring natural triglycerides that are the materials of interest in the present invention.
U.S. Pat. No. 2,914,546 to Barsky et al teaches interesterification of mixed glyceryl compounds.
U.S. Pat. No. 6,306,906 to Wohlman and O'Lenick teach a process for conditioning hair and skin which comprise contacting the skin or hair with an effective conditioning concentration of a of the reaction product of meadowfoam oil and an ester selected from the group consisting of beeswax, jojoba oil, carnauba wax, and candelilla wax.
U.S. Pat. No. 6,180,668 to Wohlman and O'Lenick disclose a series of “reconstituted meadowfoam oils”, used on skin for moisturizing and emollient applications. The term reconstituted as used hereon refers to a process in which meadowfoam oil and one or more oils of natural origin are transesterified under conditions of high temperature and catalyst to make a “reconstituted product” having an altered alkyl distribution and consequently altered chemical and physical properties.
These referenced patents are incorporated herein by reference.
None of these patents provide polyester derivatives of mixed fatty esters of glyceryl as envisioned by the present invention. Specifically, they are not polymeric materials that have the benefit of unique physical properties due to molecular weight increase, no skin penetration due to high molecular weight, and the combination of liquid and solid domain groups critical to the properties of the present invention.
Fatty acids of differing chain lengths and structures will have different physical properties. A triglyceride containing two different fatty chain length with have physical properties of a blend of the two fatty acids. If the fatty acids are confined to a domain of the polymer (pendant groups are located in regio-specific positions of the polymer backbone), a multi-domain polymer is formed. This multi-domain polymer will have highly organized “pockets” or domains of solid fatty groups, surrounded by liquid domains. The physical properties of the multi-domain polymer will be extremely different than the random triglyceride. By judicious control of the placement of these domains results in a high definition polymer. The preparation of polymers with highly desired aesthetics requires that different sections of the molecule have controlled alkyl groups. Addition of all the groups in the reaction mixture results in a random alkyl substitution pattern and loss of the desired aesthetics. Only by careful stepwise reaction can the products having exact structural properties be assured, thereby assuring performance in highly sophisticated formulations.
THE INVENTION
Object of the Invention
The current invention is directed toward a series of regiospecific polyesters that are synthesized from glycerin. These regiospecific polyesters will have very unique physical properties and have a wide variety of solubilities.
SUMMARY OF THE INVENTION
It has been discovered that not only the polymer make up, i.e. the monomers that make up the polymer backbone, but also the polymer design can be controlled and used as an efficient tool in tuning the ascetics and performance of a polymer. The polymers of the current invention are synthesized by a step growth polymerization, specifically a polycondensation polymerization. A simple example of a polycondensation polymerization is shown below:
In this simple example, the polymerization is the reaction between a di-acid and a di-alcohol. The polymerization is an equilibrium reaction that gives off water as a byproduct. The polymerization proceeds to high molecular weight by the removal of water as steam. It is common practice in polymer chemistry to actively control the molecular weight of the polymer by controllable techniques. One of these techniques is the use of mono-functional monomers during the polymerization process. Mono-functional monomers or so-called “chain terminators”, will react during the polymerization process like every other monomer. The major difference between a mono-functional monomer and a multifunctional monomer is that unlike a typical multifunctional monomer, a mono-functional monomer has only one reactive group. The moment that the mono-functional monomer reacts onto the polymer backbone the polymer chain loses the ability to continue to grow because it has no more react-able functional groups. The chain terminator reaction is as follows:
Chain terminators get their names because once they react, the polymerization stops so they are always on the end of the polymer chain.
We have found that by the use of mono-functional monomers can be used to design a polymer that is regospecific, (also refereed to as regio-specific substitution (RSS)). Regiospecific refers to a polymer that has regions of different pendant groups. A polymer can be synthesized that has two or more regions by utilizing mono-functional monomers. The polymer chain ends are controlled by the use of mono-functional monomers, while the internal pendant groups can be reacted onto the polymer backbone by the use of a different fatty acid. The regions of the polymer are shown below:
As shown above, the polymer's pendant groups can be controllably placed into two different regions. These regions will then allow the polymer to act like a block copolymer. Regio-specific polymers will have drastically different properties, i.e. different melt point, crystallinity, and solubility than the same polymer made in a random approach.
This regiospecific polymer is obtained by the multi-step polymerization approach. In the first step a try functional alcohol is reacted with a di-acid and a mono-functional acid as shown below:
As seen above, the polymerization occurs as a typical polycondensation polymerization. The polymerization will proceed until one of the monomers is completely consumed. Once the polymerization has reached a desired chain length, the polymerization can be terminated by the addition of a “chain terminator”. Chain terminators are monofunctional monomers that will react onto the polymer chain end and prevent the polymer from growing. The chain terminator reaction is shown below.
As seen above, once the chain terminators react with the growing polymer chain, the chain loses the ability to continue to react.
This new technique provides a way to selectively add end groups onto the polymer chain ends. Since the chain terminators are held until the end of the polymerization, they are protected from trans-esterfication reaction with other alcohols involved in the polymerization process. The polymer produced is designed specifically to maximize the performance of the polymers. These polymers are classified as High Definition Polymers. The term “High Definition Polymers” refers to a class of polymers that have specific structures that affect the polymer performance. A glycerin polyester of the current invention that has both a solid and liquid pendant and terminal groups and will produce a High Definition Polymer that has structured liquid and solid domains.
DETAILED DESCRIPTION OF THE INVENTION
One aspect of the present invention is very specific polyesters that fall into one of three categories (1-3)
(1) Glycerin Polyester
A polyester conforming to the following structure:
wherein,
R 1 is an alkyl containing 8 to 26 carbons, or mixtures thereof;
R 3 conforms to the following structure:
R 4 is an alkyl containing 8 to 26 carbons or mixtures thereof;
n is an integer ranging from 5 to 15;
x is an integer ranging from 2 to 50.
Preferred Embodiment
In a preferred embodiment R 1 and R 4 are different.
In a more preferred embodiment one of R 1 and R 4 is solid and the other is liquid, (as used herein, liquid is meant pourable at 25° C., by solid is meant solid at 25° C.).
In a more preferred embodiment R 1 is an alkyl having 18 carbons.
In a preferred embodiment x ranges from is 5 to 15.
In a more preferred embodiment R 4 is an alkyl having 18 carbons.
In a more preferred embodiment R 3 is an alkyl having 7 carbons.
(2) Glycerin Copolyester
A polyester conforming to the following structure:
wherein,
R 1 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 2 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 3 conforms to the following structure:
R 4 is an alkyl containing 8 to 26 carbons or mixtures thereof;
n is an integer ranging from 5 to 15;
x is an integer ranging from 2 to 50.
Preferred Embodiment
In a preferred embodiment R 1 , R 2 and R 4 are different.
In a more preferred embodiment one of R 1 R 2 and R 4 is solid and the other two are liquid.
In a most preferred embodiment one of R 1 R 2 and R 4 is liquid and the other two are solid.
In a more preferred embodiment R 1 is an alkyl having 18 carbons.
In a preferred embodiment x ranges from is 5 to 15.
In a more preferred embodiment R 4 is an alkyl having 18 carbons.
In a more preferred embodiment R 3 is an alkyl having 7 carbons.
(3) Glycerin Copolyester
A polyester conforming to the following structure:
wherein,
R 1 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 2 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 3 conforms to the following structure:
R 4 is an alkyl containing 8 to 26 carbons or mixtures thereof;
n is an integer ranging from 5 to 15;
x is an integer ranging from 2 to 50.
Preferred Embodiment
In a preferred embodiment R 1 , R 2 , R 3 and R 4 are different.
In a more preferred embodiment one of R 1 R 2 , R 3 and R 4 is solid and the other three are liquid.
In a most preferred embodiment one of R 1 R 2 , R 3 and R 4 is liquid and the other three are solid.
In a more preferred embodiment R 1 is an alkyl having 18 carbons.
In a preferred embodiment x ranges from is 5 to 15.
In a more preferred embodiment R 4 is an alkyl having 18 carbons.
In a more preferred embodiment R 3 is an alkyl having 7 carbons.
Another aspect of the present invention is a process for conditioning hair and skin which comprises contacting the hair or skin with an effective conditioning concentration of a very specific polyesters that fall into three categories (a-c).
(a) Glycerin Polyester
A process for conditioning hair and skin which comprises contacting the hair or skin with an effective conditioning concentration of a polyester conforming to the following structure:
wherein,
R 1 is an alkyl containing 8 to 26 carbons, or mixtures thereof;
R 3 conforms to the following structure:
R 4 is an alkyl containing 8 to 26 carbons or mixtures thereof;
n is an integer ranging from 5 to 15;
x is an integer ranging from 2 to 50.
Preferred Embodiment
In a preferred embodiment said effective conditioning concentration ranges from 0.1% to 45% by weight.
In a more preferred embodiment said effective conditioning concentration ranges from 1% to 20% by weight.
In a preferred embodiment R 1 and R 4 are different.
In a more preferred embodiment one of R 1 and R 4 is solid and the other is liquid, (as used herein, liquid is meant pourable at 25° C., by solid is meant solid at 25° C.).
In a more preferred embodiment R 1 is an alkyl having 18 carbons.
In a preferred embodiment x ranges from is 5 to 15.
In a more preferred embodiment R 4 is an alkyl having 18 carbons.
In a more preferred embodiment R 3 is an alkyl having 7 carbons.
(b) Glycerin Copolyester
A process for conditioning hair and skin which comprises contacting the hair or skin with an effective conditioning concentration of a polyester conforming to the following structure:
wherein,
R 1 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 2 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 3 conforms to the following structure:
R 4 is an alkyl containing 8 to 26 carbons or mixtures thereof;
n is an integer ranging from 5 to 15;
x is an integer ranging from 2 to 50.
Preferred Embodiment
In a preferred embodiment said effective conditioning concentration ranges from 0.1% to 45% by weight.
In a more preferred embodiment said effective conditioning concentration ranges from 1% to 20% by weight.
In a preferred embodiment R 1 , R 2 and R 4 are different.
In a more preferred embodiment one of R 1 R 2 and R 4 is solid and the other two are liquid.
In a most preferred embodiment one of R 1 R 2 and R 4 is liquid and the other two are solid.
In a more preferred embodiment R 1 is an alkyl having 18 carbons.
In a preferred embodiment x ranges from is 5 to 15.
In a more preferred embodiment R 4 is an alkyl having 18 carbons.
In a more preferred embodiment R 3 is an alkyl having 7 carbons.
(c) Glycerin Copolyester
A process for conditioning hair and skin which comprises contacting the hair or skin with an effective conditioning concentration of a polyester conforming to the following structure:
wherein,
R 1 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 2 is an alkyl containing 8 to 26 carbons or mixtures thereof;
R 3 conforms to the following structure:
x is an integer ranging from 2 to 50;
R 4 is an alkyl containing 8 to 26 carbons or mixtures thereof;
n is an integer ranging from 5 to 15.
Preferred Embodiment
In a preferred embodiment said effective conditioning concentration ranges from 0.1% to 45% by weight.
In a more preferred embodiment said effective conditioning concentration ranges from 1% to 20% by weight.
In a preferred embodiment R 1 , R 2 , R 3 and R 4 are different.
In a more preferred embodiment one of R 1 R 2 , R 3 and R 4 is solid and the other three are liquid.
In a most preferred embodiment one of R 1 R 2 , R 3 and R 4 is liquid and the other three are solid.
In a more preferred embodiment R 1 is an alkyl having 18 carbons.
In a preferred embodiment x ranges from is 5 to 15.
In a more preferred embodiment R 4 is an alkyl having 18 carbons.
In a more preferred embodiment R 3 is an alkyl having 7 carbons.
Raw Materials
Fatty Acids
Fatty acids useful in the practice of the present invention are items of commerce commercially available from Cognis.
Fatty acid Names
Fatty acids useful as raw materials in the preparation of compounds of the present invention are commercially available from a variety of sources including Procter and Gamble of Cincinnati Ohio. The structures are well known to those skilled in the art.
R—C(O)—OH
Saturated
Common
Molecular
Example
R Formula
Name
Weight
1
C 7 H 5
Caprylic
144
2
C 9 H 19
Capric
172
3
C 11 H 23
Lauric
200
4
C 13 H 27
Myristic
228
5
C 14 H 29
Pentadecanoic
242
6
C 15 H 31
Palmitic
256
7
C 17 H 35
Stearic
284
8
C 17 H 35
Isosteric
284
9
C 19 H 39
Arachidinic
312
10
C 21 H 43
Behenic
340
12
C 26 H 53
cetrotic
396
13
C 33 H 67
geddic acid
508
Unsaturated
Common
Molecular
Example
R Formula
Name
Weight
14
C 17 H 33
Oleic
282
15
C 17 H 31
Linoleic
280
16
C 17 H 29
Linolenic
278
17
C 15 H 29
Palmitoleic
254
18
C 13 H 25
Myristicoleic
226
19
C 21 H 41
Erucic
338
Glycerin
Glycerin is an item of commerce and is available from a variety of sources including Cognis of Cincinnati Oh. It conforms to the following structure:
Glycerin is propane-1,2,3-triol and has a CAS number of 56-81-5.
Silicone Polymers
Dicarboxylic silicone polymers useful as raw materials in the synthesis of the compounds of the present invention are commercially available from Siltech LLC and are sold under the Silmer tradename. They conforms to the following structure;
x is an integer ranging from 2 to 50.
Example
X
Molecular Weight
20
2
662
21
3
736
22
10
1,255
23
12
1,403
24
15
1,626
25
20
1,996
26
25
2,367
27
30
2,737
28
40
3,478
29
45
3,849
30
50
4,219
Glycerin Chain Terminator
Glycerin fatty esters were prepared by SurfaTech Corporation, of Lawrenceville, Ga. They are prepared by the esterification of glycerin with fatty acids (examples 1-18).
They conform to the following structure:
wherein;
R 1 is an alkyl having 8 to 26 carbons.
Fatty Acid
Glycerin
Example
Example
Grams
Grams
32
2
197.2
52.8
33
7
215.1
34.9
34
8
215.1
34.9
35
14
214.9
35.1
Glycerin Mixed Chain Terminator
Glycerin mixed alkyl fatty esters were prepared by SurfaTech Corporation, of Lawrenceville, Ga. They are prepared by the esterification of glycerin with two different fatty acids (examples 1-18). They conform to the following structure:
wherein;
R 1 is alkyl having 8 to 26 carbons;
R 2 is alkyl having 8 to 26 carbons, with the proviso that R 2 is not the same as R 1 ;
R 1
R 2
Glycerin
Example
Example
Grams
Example
Grams
Grams
36
7
107.6
8
107.6
34.9
37
8
107.9
14
107.1
35.0
38
14
129.1
2
78.7
42.2
39
2
150.4
7
75.2
24.4
General Procedure
A specified number of grams glycerin is added to a specified amount of fatty acids (examples 1-18). The reaction mixture is heated to 160-180° C. Water is removed by vacuum during the reaction process. The reaction is monitored by the determination of acid value. The acid value will diminish as the reaction proceeds. The reaction is cooled once the acid value fails to change over an additional two hours at elevated temperature. The product is used without purification.
Polymerization
A specified number of grams glycerin is added to a specified amount of fatty acids (examples 1-18) and diacids (examples 20-30). The reaction mixture is heated to 160-180° C. Water is removed by vacuum during the reaction process. The reaction is monitored by the determination of acid value. The acid value will diminish as the reaction proceeds. Once the acid value reaches a desired value, a specified amount of chain terminator (examples 36-39) is added into the reaction flask. The reaction is cooled once the acid value fails to change over an additional two hours at elevated temperature. The product is used without purification.
Chain
Gly-
Terminator
R 4
Silicone
cerin
Example
Example
Grams
Example
Grams
Example
Grams
Grams
40
33
11.6
7
12.4
30
221.9
4.0
41
33
4.4
7
14.3
30
226.6
4.6
42
34
19.0
8
20.4
26
204.0
6.6
43
34
7.4
8
23.8
26
211.2
7.7
44
33
19.0
14
20.3
26
204.1
6.6
45
33
7.4
14
23.6
26
211.3
7.7
46
36
19.0
7
20.4
26
204.0
6.6
47
36
7.4
7
23.8
26
211.2
7.7
48
36
11.6
8
12.4
30
221.9
4.0
49
36
4.5
8
14.5
30
229.5
1.6
50
36
11.6
14
12.4
30
222.0
4.0
51
36
4.4
14
14.2
30
226.7
4.6
52
35
46.5
2
30.5
21
156.6
16.3
53
35
19.2
2
37.8
21
172.7
20.3
54
37
43.2
7
46.6
21
145.0
15.1
55
37
17.6
7
56.8
21
157.1
18.4
56
38
15.9
8
20.7
26
206.7
6.7
57
38
6.1
8
23.9
26
212.3
7.7
58
39
16.2
14
12.1
30
217.7
4.0
59
35
6.3
14
14.1
30
225.0
4.6
Applications Examples
These polymers have a wide variety of applications including, but not limited to, the modification of physical properties. Solid triglycerides or butters are very attractive in the cosmetic industry. The use of a regiospecific glycerin polyester is a very efficient and attractive way to produce a butter with a luxurious feel, because of the ability to customize the structure as described herein.
These glycerin polyesters' physical properties, including solid state and skin feel, can be selectively tuned by the selection of R groups. Take for example two glycerin polyesters conforming to the same structure shown below:
In the first polyester: R 2 is a stearic group, R 4 is a isostearic group. The R groups of the second polyester are: R 2 is a isostearic group, and R 4 is a stearic group. In these two polyesters have the same general structure but drastically different physical structures. Both polymers have both a solid and a liquid R group but will have completely different physical properties. Example one is comprised of internal (R 4 ) isostearic groups, which will produce a liquid region. This liquid region makes up 63.9% wt of the total mass of the polymer. R 2 is a stearic group and will produce a solid region and represents 17.0% wt of the polymer. This polymer is amorphous and will have a lubricious skin feel providing a conditioning effect. The latter polymer is comprised of internal (R 4 ) stearic groups, which will produce a solid region. This solid region comprises of 63.9% wt of the polymer's mass. The R 2 groups of this polymer make up the liquid region and makes up 17.0 wt % of the polymer's mass. This polymer is a hard solid that will provide structural integrity to any cosmetic application. | The present invention is directed to a series of silicone containing polymeric glyceryl esters that have two different molecular weight ester chains, one solid and one liquid, which when combined into a single molecule make a polymer that is solid, but has very unique flow properties. These materials find applications as additives to formulations in personal care products where there is a desire to have a structured film (provided by the solid fatty group) and flow properties, (provided by the liquid fatty group). These compounds by virtue of their unique structure provide outstanding skin feel. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a system for controlling power window regulators on vehicles, particularly cars. The power window regulators currently installed on cars are known to comprise control switches, usually push-button-operated, for controlling electric motors housed inside the respective doors, for raising or lowering the window. The said control switches usually present a number of settings enabling the window to be raised or lowered both partially and fully in automatic manner. Furthermore, the driver usually has a number of control switches for operating the window regulators on different doors. The control logic by which the window regulator motors are controlled is housed in a block to which the said various switches are connected. Consequently, a relatively large number of connecting wires are required between the said switches and the control system, as many as the contact terminals relative to the various settings on the control switches.
SUMMARY OF THE INVENTION
The aim of the present invention is to provide a system for controlling vehicle power window regulators, which is easier and cheaper to produce as compared with the current system, and which provides for the same operating performance, as well as long-term reliability. Further aims and advantages of the system according to the present invention will be revealed in the following description.
With this aim in view, according to the present invention, there is provided a system for controlling vehicle power window regulators, which system comprises, at least for the doors on the driver and front-seat-passenger side, control switch means, and an electric control motor; which system also comprises a control system designed to receive electric control signals from the said switch means for controlling the said motor; characterised by the fact that it comprises means for coding the said control signals from the said switch means, and respective decoding means on the said control system, for eliminating or reducing the number of connecting elements between each said switch means and the said control system.
BRIEF DESCRIPTION OF THE DRAWINGS
A non-limiting embodiment of the present invention will be described with reference to the accompanying drawings, in which:
FIG. 1 shows an electric diagram of the power window regulator control system according to the present invention, and applied to the doors on the driver and front-seat-passenger side;
FIG. 2 shows a simplified electric diagram of the control system in the FIG. 1 diagram.
DETAILED DESCRIPTION OF THE INVENTION
Numbers 10, 11 and 12 in FIG. 1 respectively indicate (as shown by the dotted lines) a block mounted on the driver-side door, a block mounted on the front-passenger-side door, and a block mounted some distance from the other two, for example, inside the engine compartment or dash-panel on the vehicle, and housing a contro system 13. Block 10 comprises a known type of d.c. electric motor 14 for controlling the window on the driver-side door; a dual four-position switch 15 for controlling the window on the driver-side door; and a two-position switch 16 for controlling the window on the front-passenger-side door. The said switches 15 and 16 may be located normally on the armrest on the driver-side door. The said dual switch 15 presents a first contact element 17, which may be operated for connecting its common terminal to two terminals, B and A, for respectively raising the window partially and fully in automatic manner. When the said contact element 17 (shown schematicallY with the end bent) is operated for contacting terminal A, it also remains connected to terminal B. The said dual switch 15 also presents a second contact element 18 identical to contact element 17 and designed to connect its center terminal to terminals C and D, for respectively lowering the window partially and fully in automatic manner. The fixed center terminals on dual switch 15 are connected to input 1 on control system 13, whereas a ground wire 3 from block 12 is connected, via a resistive divider 19, to terminals A, B, C and D. In more detail, the said wire 3 is connected, via resistor 20, to terminal A; terminal A is connected, via resistor 21, to terminal B; terminal B is connected, via resistor 22, to terminal D; and terminal D is connected, via resistor 23, to terminal C.
The common terminal on switch 16, for controlling the front-passenger-side window, is connected to input 2 on control system 13, whereas switch terminals E and F are connected to ground wire 3 via a resistive divider 19'. In more detail, the said wire 3 is connected, via resistor 24, to terminal E, which is, in turn, connected to terminal F via resistor 25. Ground wire 3 is also connected to a lamp 26 for lighting the said switches 15 and 16; which lamp 26 is, in turn, connected to a positive supply terminal over wire 4 to block 12, and via a switch 28 controlled by the light control switch on the vehicle. Block 11 presents a number of elements similar to those of block 10, and comprises a d.c. electric motor 14' for controlling the front-passenger-side window in substantially known manner; and a switch 16' which, via resistive divider 19', connects the ground on block 12 to input 7 on control system 13. Via wire 5 from block 12, switch 28 also supplies a lamp 26', in turn, connected to the ground on block 12 over wire 6.
As described in more detail later on with reference to FIG. 2, control system 13 houses four relays for controlling electric motors 14 and 14' in opposite directions. The relays controlling electric motor 14 are numbered 30 and 31, and control respective switches 40 and 41, between the common terminals of which electric motor 14 is connected. The idle terminals, 42 and 43, are connected to the ground on block 12 via a calibrated series resistor 44 of relatively low power, e.g. 33 milliohms. The signal at the terminals of resistor 44 is analysed by control system 13 via wire 45. The normally-open terminals of switches 40 and 41 are connected to a positive supply terminal.
Control system 13 also presents a further two relays, 32 and 33, for controlling respective switches 46 and 47, between the common terminals of which electric motor 14' is connected. Idle terminals 48 and 49 of switches 46 and 47 are also grounded via a calibrated resistor 44' similar to resistor 44, and the signal at the terminals of which is detected by control system 13 via wire 45'. The normally-open terminals of switches 46 and 47 are also connected to a positive terminal. The positive supply terminal is also connected to the supply of control system 13 via a switch 36 activated by the vehicle ignition key. FIG. 2 shows a schematic diagram of control system 13. Via a filtering block 49, for eliminating short-pulse input disturbance, wire 1 is connected to the complementary, negative and positive, inputs of four pairs of threshold comparators 50, 51, 52, 53, each pair of which constitutes a range comparator, the outputs of which are connected to the inputs of a respective AND gate. The reference signals for the other inputs of the said comparators are picked up successively by a resistive divider 54 connected between a positive supply terminal and ground. A further resistor 55 is connected between the positive supply terminal and wire 1, downstream from block 49. The output of range comparator 50 is connected to the anode of diode 56, the cathode of which is connected to the clock (CK) input of a D type flip-flop 57. The said flip-flop 57 presents output Q connected to input D, and output Q connected, via resistor 58, to the base of an NPN transistor 59, the emitter of which is grounded, and the collector of which is connected to a positive supply terminal via coil 60 of relay 30. A diode 61 is connected parallel with the said coil 60. The output of range comparator 50 is also connected to the cathode of diode 62, the anode of which is connected to the reset R input of flip-flop 57. The positive supply terminal is also connected to the said R input via a resistor 63. The output of range comparator 51 is connected to the clock (CK) input of a D type flip-flop 65, which presents output Q connected to input D, and output Q connected to the anode of diode 66, the cathode of which is connected to the clock (CK) input of flip-flop 57. The outputs of range comparators 52 and 53 are connected to respective flip-flops 57' and 65', similar to flip-flops 57 and 65 already described, the corresponding circuit components being indicated using the same reference numbers plus a ' sign. In this case, the collector of transistor 59' is connected to coil 60' of relay 31.
Wire 45 from calibrated resistor 44 is connected to a known type of block 68 (enclosed by the dotted line) designed to detect arrest of the electric motor (in the example shown, electric motor 14) the armature current of which goes through the said resistor 44. The said block 68 is formed according to the principle described in Italian Patent Application No. 83618-A/84 of Apr. 16, 1984, and mainly comprises an amplifier block, a peak detecting block, and a threshold comparator block. In more detail, wire 45 is connected, via a condenser 70 for eliminating direct current components, to the negative input of a differential amplifier 71, the positive input of which is connected to the intermediate connection between two resistors 73 and 74 connected between a positive supply terminal and ground. A resistor 75 is connected between the positive and negative inputs of amplifier 71, which presents a further resistor 76 connected, for feedback, between its output and the said negative input. Via an amplifier 77 and condenser 78, the output of amplifier 71 is connected to the cathode of diode 79, the anode of which is grounded, and to the anode of diode 80, the cathode of which is grounded, via the parallel connection of condenser 81 and resistor 82, and connected to one input of threshold comparator 83, the other input of which is connected to the intermediate connection between two resistors 85 and 86 series-connected between a positive supply terminal and ground. The output of comparator 83, which is also the output of detecting block 68, is connected to the reset R inputs of flip-flops 65 and 65', and to the cathodes of respective diodes 90 and 90', the anodes of which are connected to the reset R inputs of flip-flops 57 and 57' respectively.
Wire 2 to control system 13 is connected, via a filtering block 49' similar to block 49, to the complementary inputs of two pairs of threshold comparators also constituting range comparators 92 and 93, the other reference inputs of which are connected, as already seen in connection with comparators 50, 51, 52 and 53, to the intermediate connecting points of a resistive divider 94 connected between a positive supply terminal and ground. A resistor 95 is connected between a positive supply terminal and wire 2, downstream from block 49'. Wire 7 to control system 13 is also connected, via a block 49" similar to block 49', to the complementary inputs of range comparators 92 and 93. A resistor 96 is connected between a positive supply terminal and wire 7, downstream from block 49". The output of range comparator 92 is connected to the signal inputs and the reset R input of flip-flop 98, the output of which is connected, via resistor 99, to the base of an NPN transistor 100, the emitter of which is grounded, and the collector of which is connected to a positive supply terminal via coil 101 of relay 32. A diode 102 is connected parallel with the said coil 101. Similarly, the output of range comparator 93 controls coil 101' of relay 33, the corresponding circuit components being indicated using the same reference numbers plus a ' sign. Wire 45' from calibrated resistor 44' is connected, via a detecting block 68' similar to block 68, to the reset R inputs of flip-flops 98 and 98'.
Operation of the power window regulator control system according to the present invention is as follows.
For partially lowering the window on the driver's side, the driver sets dual switch 15 to a first setting wherein terminal C is connected. The level of the signal sent along wire 1 to control system 13 is therefore determined by all of resistors 20, 21, 22 and 23 being connected on resistive dividier 19. In control system 13, the value of this signal is detected as falling within the range defined by threshold comparator pair 50, which is therefore the only pair issuing a signal produced by setting switch 15 to position C. The output signal from range comparator 50 activates flip-flop 57 which, in turn, via transistor 59, activates relay 30 which, by activating switch 40 (FIG. 1), operates electric motor 14 in the direction designed to lower the window. The window continues moving down as long as the driver keeps terminal C connected on dual switch 15. When, on the other hand, switch 15 is released, the output signal from range comparator 50 is cut off and, via resistor 63 and diode 62, a reset signal is supplied to flip-flop 57, which de-activates relay 30, thus causing electric motor 14 to be arrested due to short-circuiting of the terminals by swiches 40 and 41 in the position shown in FIG. 1. In the event of the window sliding down to the bottom limit position, with dual switch 15 still connected to terminal C, electric motor 14 is arrested and, as block 68 no longer detects the oscillation frequency (about 300 Hz) of the armature current produced during normal operation of the motor, the output signal from block 68 is cut off, flip-flop 57 is reset, and relay 30 de-activated so as to cut off supply to motor 14.
For fully lowering the window automatically, the driver sets dual switch 15 to a second setting wherein terminal D is connected, at the same time short-circuiting terminal C. In this case, the level of the signal sent along wire 1 is determined by resistors 20, 21 and 22 of resistive divider 19. This different level is detected as falling within the range of threshold comparator pair 51, which is therefore the only pair to issue an output signal. The output signal from range comparator 51 activates flip-flop 65 which, via diode 66, activates flip-flop 57 and relay 30 as already described, thus activating switch 40 for supplying electric motor 14 in the same direction as before, for lowering the window. Subsequent release of dual switch 15 in no way affects operation of electric motor 14 in that flip-flops 65 and 57 remain active. Subsequent to arrest of the window in the bottom limit position, and arrest of electric motor 14 being detected by block 68 as already described, the said flip-flops 65 and 57 are reset, and switch 40 is returned to the FIG. 1 position, thus cutting off supply to electric motor 14. For partially raising the window, the driver sets dual switch 15 to the first setting wherein terminal B is connected, and an output signal is only supplied by range comparator 52. This activates flip-flop 57' so as to activate relay 31 which, via switch 41, supplies electric motor 14 in the opposite direction to previously. For fully raising the window automatically, dual switch 15 is set to the second setting wherein terminal A is connected and an output signal only supplied by range comparator 53. Operation of the output signals from range comparators 52 and 53 is the same as for those from range comparators 50 and 51.
For operating the window regulator on the front-passenger-side door, the driver sets switch 16 so as to connect terminal E or F and so produce a signal on wire 2 the level of which is detected as falling within the range of comparator 93 or 92. In the first case, wherein switch 16 is set so as to connect terminal E, an output signal is supplied by range comparator 93, the rising edge of which alters the output of flip-flop 98' so as to activate relay 33, which, via switch 47, raises the window. Subsequent to release of the said switch 16, the falling edge of the signal from range comparator 93 resets flip-flop 98' so as to de-energise relay 33 and so arrest electric motor 14'. In the second case, wherein switch 16 is set so as to connect terminal F, an output signal is supplied by range comparator 92, the rising and falling edges of which respectively activate and de-activate flip-flop 98, thus energising or de-energising relay 32 which either reverses or arrests electric motor 14'. The normal oscillating frequency of the armature current on the said electric motor 14' is detected via wire 45' from calibrated resistor 44'. Therefore, upon electric motor 14' being arrested, flip-flops 98 and 98' are reset and relays 32 and 33 deenergised via block 68', as already described in connection with block 68.
For operating the front-passenger-side window, electric motor 14' may be controlled directly by the passenger, using switch 16', which, via resistive divider 19' and terminals E and F, operates over wire 7 (FIG. 2) connected to the same range comparators 92 and 93 for detecting the selected terminal.
The advantages of the power window regulator control system according to the present invention will be clear from the foregoing description. Firstly, it provides for eliminating the various connecting wires between blocks 10 and 11 and block 12 containing control system 13, and corresponding to the various settings of control switches 15, 16 and 16', the various settings of each said switch being coded by means of a respective electric signal level, and supplied to control system 13 over a single connecting wire, thus enabling considerable cost cutting in terms of component manufacture, as well as simplifying both manufacture and assembly. Secondly, for fully raising or lowering the window automatically, operation need no longer be maintained, often excessively, for a given length of time, thus risking excessive strain on the components, in that supply to the electric motors controlling the windows is cut off immediately, upon arrest of the motors being detected by circuits 68 and 68'.
To those skilled in the art it will be clear that changes may be made to the embodiment of the control system as described and illustrated herein without, however, departing from the scope of the present invention. For example, in place of a resistive divider, the means for coding the switch settings may consist of other components, such as diodes, series-connected, for example, so as to form a divider, or transistors. In place of the range comparator blocks described herein, the means for decoding the signal received over the single wire connecting the switch means to the control system, for detecting the switch setting, may consist of an analogue-digital converting block followed by a microprocessor for match-checking the control switch settings against given output signal logic level combinations. The means for coding the control switch setting may comprise conveyed-wave or radiofrequency transmission means for transmitting an electric signal or a combination electric signal depending on the control switch setting. The decoding means on control system 13 may comprise respective conveyed-wave or radiofrequency receiving means for receiving the transmitted electric signal. In the latter case, the connecting elements between the control switches and the control system may be dispensed with entirely.
Filtering block 49 may comprise a straightforward resistor-condenser component, or a Schmitt trigger block for merely retarding the rising edge of the signal. Or, it may comprise a shift register on which the input signal is only supplied to the output after a given delay time determined by a given number of clock pulses. Dual switch 15 may be a mercury type with two settings in either direction. The system described may also be applied for controlling the window regulators on all four vehicle doors. In this case, block 10 on the driver-side door will conveniently comprise a further two switches for controlling the window regulators on the rear doors, whereas control system 13 will present a further two portions similar to those consisting of connecting wires 2 and 7, with a respective detecting block 68'. In the embodiment of the present invention described herein, the two protectors for each electric motor may also be dispensed with, in that supply cut-off upon arrest of the motors is detected and controlled by block 68. | A system for controlling the power window regulators of at least the doors on the driver and front-seat passenger sides of a vehicle includes control switches having settings corresponding to at least the fully and partly open and closed positions of the windows. The control switches provide electric control signals corresponding to the switch settings. The regulator control system also includes at least one electric control motor and a motor control system which controls the motor in dependence upon the control signals received from the switches. The signals are coded in correspondence to the switch settings, for example, by differing voltage levels, and are supplied along a minimum number of wires (optimally a single wire for all the switches corresponding to each motor) to a decoder in the motor control system. The regulator control system is advantageous in the elimination of the plurality of wires previously required for individually connecting each switch position to the motor control system. | 8 |
BACKGROUND OF THE INVENTION
Numerous arrangements have been proposed for latching a magazine in a pistol so that the magazine is held in place during operation and is releasable from the pistol for withdrawal and replacement.
Most magazine latches are positioned on, or readily accessible from, one side or the other of the pistol. The operator must learn to use his left or his right hand to operate each particular latch. Some latch positions and method of operation favor right-handed operators and do not favor left-handed operators. Also, some magazine latches can be converted from full-time right-hand operation to full-time left-hand operation, but these do not permit simultaneous full-time operation by either hand.
None of the so-called ambidextrous magazine latches function in the manner of the present invention.
SUMMARY OF THE INVENTION
Broadly, the present invention is an ambidextrous lever arrangement in which a hand-engaging operable latch head which protrudes from each side of the pistol is mounted on and acted upon by a resilient spring-loaded unit positioned in the pistol handle frame. A magazine-engaging projection on the latch head extends into a slot in the magazine to hold the magazine in operable position. Applying hand pressure to either side of the latch head causes it to move away from the magazine a sufficient distance to move the projection out of the magazine and release it.
It is a feature of the invention that the latch head is readily operable from either side of the pistol with either the right or left hand, without the necessity of having to disassemble the magazine latch and reassemble it to operate from the opposite side of the pistol.
It is also a feature that the width of the grip frame permits the latch head to be pivotably operated in selected embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the pistol having the latch arrangement of the invention;
FIG. 2 is a partial sectional view showing the latch in the handle frame cavity;
FIG. 3 is a section along line 3--3 of FIG. 2;
FIG. 4 is a section along line 4--4 of FIG. 2;
FIG. 5 is a view similar to FIG. 3 showing the latch head being twisted to release the magazine;
FIG. 6 is an exploded view of two (2) latch head sections;
FIG. 7 is an enlarged sectional view of FIG. 8 showing an alternative embodiment;
FIG. 8 is a sectional view of the alternative embodiment;
FIG. 9 is a partial sectional view of a further embodiment of the invention;
FIG. 10 is a sectional view of the further embodiment;
FIG. 11 is a partial sectional view of a fourth embodiment of the invention;
FIG. 12 is a partial sectional view of the fourth embodiment;
FIG. 13 is a partial sectional view of a fifth embodiment of the invention;
FIG. 14 is a sectional view taken along line 14--14 of FIG. 13; and
FIG. 15 is a view similar to FIG. 13 showing the operation of the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1-6, pistol 10 includes slide 11, slide lock 12, manual safety 13, frame 14, trigger guard frame portion 15, trigger 17, magazine 18 and magazine latch head 19.
Magazine latch head 19 is mounted in an elongated cavity 22 in frame 14 adjacent trigger guard frame portion 15. Latch head 19 consists of two (2) headpieces 23, 24 with headpiece 23 carrying magazine latch projection 27. Headpieces 23, 24 each have complementary superimposable interfitting portions 28, 29 respectively (FIG. 6).
Portions 28, 29 are held together in their assembled position by elongated spring 31 which is mounted in mounted slot 32 in the lower portion of frame cavity 22 and is urged in the direction of arrow A (FIG. 2). The upper end of spring 31 is held under tension in indented recesses 33, 34 of portions 23, 24 respectively. Slot recesses 33, 34 are superimposed one above the other as assembled (see FIG. 3). Frame cavity 22 includes an upper spring guide slot 37 which guides spring 31 as it is deflected away from the magazine through twisting of head 19 (see FIG. 5).
With particular reference to FIG. 3, latch projection 27 projects into magazine opening 38 and holds magazine 18 in the pistol handle. The head 19 rests against pistol frame 14 under urging of spring 31. When it is desired to remove the magazine 18, the head 19 is twisted by placing a hand on portion 23 (or 24) to push (or pull) the head 19 generally away from magazine 18, causing the head 19 to rotate about one of the frame pivot positions 39, 41 depending on which side (portion 23, 24) of head 19 is pushed (or pulled). Spring 31 moves back in guide slot 37 and magazine latch projection 27 moves clear of slot 38 to release magazine 18 (FIG. 5) Pivot positions 39 and 41 are spaced apart a sufficient distance to provide for proper pivoting action of the latch head. After removal of magazine 18, the head 19, as urged by spring 31, is returned to its rest or latched position.
Turning now to FIGS. 7 and 8, and a second alternative embodiment, a unitary latch head 19a is substituted for head 19. Latch head 19a is positioned in frame cavity 22a and carries latch projection 27a. Latch head 19a has in its center portion a detent-receiving opening 43. Detent 44 has detent nose 46, detent recess 47 and detent coil spring 48. Detent chamber 49 in frame 14 houses detent 44 and coil spring 48 to urge latch head 19a against frame 14. The operation of this embodiment is similar to the embodiment of FIGS. 1-6 in that the operator applies a force to either end of latch head 19acausing the head 19a to twist and rotate about pivot 39 (or 41) allowing latch projection 27a to move to the left (FIG. 8) and release magazine 18.
Turning now to FIGS. 9 and 10, latch head crosspiece 19b includes cylindrical central portion 46a and two (2) cylindrical end pieces 47a, 48a. Head crosspiece 19b is mounted in frame cavity 22b. Head crosspiece 19b has a recess 50 for nesting pivotable latch member 49a. Latch member 49a is pivotably mounted on pivot 51 and its lip portion 52 extends through opening 38 in magazine 18. Urging latch member 49a and head 19b against frame 14 is spring-loaded detent 44a.
In operation, movement of either end 47a, 48a of head 19b away from magazine 18 will cause head 19b to pivot about pivot 39 (or 41). As the pivoting of head 19b continues, latch head 19b is pulled back by central part 46a (FIG. 9) to withdraw lip portion 52 from interference with the magazine. Once manual force on head 19b has been diminished or released, spring-loaded detent 44a causes the head 19b to move back to its locked position (FIG. 10).
FIGS. 11 and 12 illustrate a further embodiment including latch head 19c with central portion 46c and two (2) end pieces 47c, 48c. Central portion 46c has recess 50a in which latch member 61 sits. Latch member 61 includes body portion 62 and magazine latch extension 63. Spring 64 in body portion recess 66 urges latch member 61 which in turn is pressed against latch head 19c. Operation of the embodiment of FIGS. 11 and 12 is the same as the other embodiments.
Finally, FIGS. 13-15 show a further embodiment including latching head 19d which has two head portions 70 and 71 positioned in frame cavity 72. Head portion 71 includes neck section 71a which fits telescopically into head recess portion 70a. Coil spring 73 urges head portions 70 and 71 apart. The limit of movement of portion 71 outwardly is recess end stop 72a. Other head portion 70 moves outwardly until its travel limit groove 75 engages pin 76.
Latch member 77 includes magazine latch extension 78 and latch member spring 79 urging extension 78 into opening 38 of magazine 18. Latch member 77 has a notch surface 81 which, depending on its direction of movement, engages a cam surface 82 of head portion 71 or the cam surface 83 of head portion 70.
When either or both head portions 70, 71 are moved by hand force inwardly toward one another, cam surfaces 82 or 83 contact and thereafter cam against latch surface 91 causing latch member 77 to move to its unlatched position (FIG. 15). When hand force is removed, the head portions 70, 71 are urged apart by action of two (2) springs 73, 79 to accomplish the latched mode. Spring 79 urges latch member 77 and its notch surface 81 against head portion surface 82 or 83 (or both) which in turn urges head portions 70 and 72 apart. The action of two (2) springs lessens the likelihood of the latch not returning to its latched mode after it has been operated to its unlatched mode. | An ambidextrous magazine latch arrangement for a pistol in which a hand-operable cross lever is positioned by resilient means against a frame portion of the pistol handle with lever ends protruding on either side of the handle. The lever has a latch protrusion which protrudes into the magazine to hold the magazine. By applying hand pressure to either lever end the lever twists against the resilient means to withdraw the latch protrusion out of the magazine to release the magazine. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method for manufacturing a composite fiber component, in particular for aerospace, to a molding core for manufacturing such a composite fiber component and to a composite fiber component having at least one stringer which is manufactured by means of such a molding core and/or such a method.
BACKGROUND OF THE INVENTION
[0002] Although the present invention can be applied to any composite fiber components, said present invention and the problem on which it is based are explained in more detail below with reference to planar, stringer-reinforced carbon fiber plastic (CFK) components, for example skin panels of an aircraft.
[0003] It is generally known to reinforce carbon fiber plastic skin panels with carbon fiber plastic stringers in order to withstand the high loads in the field of aircraft together with the lowest possible additional weight. In this context, essentially two types of stringers are distinguished: T and Ω stringers.
[0004] The cross section of T stringers is composed of a base and a web. The base forms the connecting surface to the skin panel. The use of skin panels which are reinforced with T stringers is widespread in aircraft construction.
[0005] Ω stringers have an approximately hat-shaped profile, with the ends of said profile being connected to the skin panel. In the cured state of Ω stringers they can either be adhesively bonded onto the panel which is also cured or they can be cured at the same time as the panel wet on wet. The latter is desirable because it is more favourable in terms of processing technology. However, in order to carry out wet on wet manufacture of skin panels which are reinforced with Ω stringers, supporting cores or molding cores are necessary in order to secure the dimensionally unstable fiber semi-finished products in the desired Ω shape and support them during the manufacturing process. Skin panels with Ω stringers have, compared to T stringers, the advantage of a better infiltration capability during an infusion method in order to introduce a matrix, for example an epoxy resin, into the fiber semi-finished products. Compared to other known methods for manufacturing composite fiber components such as, for example, the prepreg method, infusion methods can be cost-effective because they permit the use of more cost-effective fiber semi-finished products.
[0006] When manufacturing Ω stringers, there is the problem, however, that the material which is used at present for the supporting core or molding core is costly and can be difficult to remove after the Ω stringers have been constructed so that the material which remains in the stringers disadvantageously increases the overall weight of the aircraft.
SUMMARY OF THE INVENTION
[0007] It is one of the objects of the present invention to make available a more cost-effective and lightweight composite fiber component, in particular for aerospace.
[0008] Accordingly, a method for manufacturing a composite fiber component, in particular for aerospace, includes the following method steps:
forming a molding core comprising a hollow profile made of segments in order to establish an external geometry of the molding core, wherein the segments of the molding core each extend in the direction of the longitudinal axis of the molding core and are each constructed so as to be pivotable about an axis running in the longitudinal direction of the molding core, between a folded position and an unfolded position of the hollow profile of the molding core, wherein the segments are constructed so as to be coupled to one another via connections in one piece in order to form the hollow profile; positioning at least one fiber semi-finished product at least in certain sections on the constructed molding core in order to shape at least one molded section of the composite fiber component to be manufactured; and
[0011] applying heat and/or pressure to the at least one molded section in order to manufacture the composite fiber component.
[0012] Furthermore, a molding core for manufacturing a composite fiber component, in particular a stringer on a base component in aerospace, includes a hollow profile which is made in one piece from segments in order to establish an external geometry of the molding core, wherein the segments of the molding core each extend in the direction of the longitudinal axis of the molding core and can each be pivoted about at least one axis running in the longitudinal direction of the molding core, between a folded position and an unfolded position of the hollow profile of the molding core.
[0013] Furthermore, a composite fiber component having at least one stringer, in particular for aerospace, is provided, which is manufactured by means of the molding core according to the invention and/or the method according to the invention. The present invention thus has the advantage over the approaches mentioned at the beginning that the composite fiber component can be manufactured by means of a cost-effective molding core. Instead of costly conventional materials, a molding core is advantageously used which is composed of a hollow profile with segments which can be pivoted with respect to one another, and which core can be easily removed from the mold by pivoting the segments which results in a reduction in the cross section. A further advantage is the re-usability of such a molding core.
[0014] In one embodiment the segments of the molding core are coupled to one another by connections in order to be pivoted with one another between the folded position and the unfolded position of the hollow profile and in order to form a closed hollow profile. These connections permit the segments to be pivoted about the longitudinal axis of the molding core, with the connections being constructed in one piece together with the segments. In this context, the segments and the connections form a closed hollow profile. The latter can easily be manufactured in a cost-effective way from plastic in an extrusion process.
[0015] In an alternative embodiment, the segments of the molding core are constructed together with their pivotable connections as an open profile, for example made of a plastic, which profile is welded in order to form a closed hollow profile. This results in a particular advantage, in that open profiles can generally be manufactured more easily and with tighter tolerances because the inner surfaces can be produced better by means of supporting tools and molds.
[0016] The manufacture of the open profile also provides an advantage in that the connections are embodied in a prestressed fashion such that the hollow profile which is formed from them is provided with a particular position, either the folded position or the unfolded position.
[0017] In one further alternative embodiment, the connections are constructed from a different material from the segments, said material being better suited to the requirements made of a flexible connection and desired prestresses. This other material can be introduced, for example, by means of coextrusion.
[0018] In a further embodiment, at least one segment has at least two subsegments which are pivotably connected in their longitudinal direction by means of a second connection. As a result, the hollow profile can be folded in such a way that only the corner regions have a type of linear contact, in the form of sliding rails, with the interior of the molded section when said hollow profile is removed from the mold, a lower frictional resistance being obtained as it is pulled out.
[0019] It may be particularly advantageous here if a subsegment is extended in its width beyond the second connection as a projection for forming a stop. As a result the unfolded position can be assumed precisely without overshooting of its end position.
[0020] The assumption of the respective position can be implemented by applying an internal pressure to the molding core according to the invention. The internal pressure may be regulated by a set point value in such a way that reproducible positions can be assumed by the hollow profile.
[0021] In a further embodiment, in the folded state the molding core according to the invention is covered by a core sleeve, for example a hose. This hose has such a circumference that it can easily be fitted over in the “folded molding core” state and subsequently extends smoothly around the folding core in the “unfolded molding core” state. Alternatively, a shrink-fit hose which can be fitted by the application of heat can be used. The hose forms a separating and/or sealing layer between the composite fiber component and the molding core. As a result, no undesired exchange of substances during the curing process is brought about and the removal of the molding core from the mold is made easier.
[0022] According to one embodiment of the invention, reinforcement means in the region of junctions of the external geometry which are to be constructed with sharp edges in the molding core which is to be constructed are arranged inside and/or outside the core sleeve. These corner profile parts can also be components of the segment ends or connections.
[0023] The separating layer may be applied to the core sleeve and reduce adherence of the cured composite fiber component. This facilitates removal of the core sleeve after the at least partial curing of the section of the composite fiber component which has been produced by means of the molding core.
[0024] Fiber semi-finished products are to be understood as fabrics, overlays and fiber mats. The latter is provided with a matrix, for example an epoxy resin, and subsequently cured, for example using an autoclave.
[0025] According to a further embodiment of the invention, the molding core is arranged on a base part made of composite fiber semi-finished products and/or at least partly surrounded by fiber semi-finished products in order to construct at least one section of the composite fiber component. As a result, base parts, for example skin panels, pressure domes etc. can be constructed with Ω stringers. As an alternative or in addition to this it is also possible to manufacture separate composite fiber components which are entirely defined in terms of their shape by the molding core.
[0026] When an Ω stringer is manufactured for example, the core sleeve is pulled out of it in the longitudinal direction of the stringer. Consequently, said sleeve, like the core, no longer contributes to the overall weight of the aircraft and the payload of the aircraft can thus be increased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The present invention is explained in more detail below using preferred exemplary embodiments and with reference to the attached figures of the drawings, in which:
[0028] FIG. 1 is a schematic perspective view of an exemplary embodiment of a composite fiber component during manufacture in accordance with a method according to the invention;
[0029] FIG. 2 is a schematic sectional illustration of a general molding core of the composite fiber component according to FIG. 1 ;
[0030] FIG. 3A is a schematic sectional illustration of an inventive molding core of the composite fiber component according to FIG. 1 in a folded position;
[0031] FIG. 3B is a schematic sectional illustration of the inventive molding core according to FIG. 3A in an unfolded position;
[0032] FIG. 4A is a sectional illustration of a first exemplary embodiment of the inventive molding core according to FIG. 3A in the folded position;
[0033] FIG. 4B is a sectional illustration of the first exemplary embodiment of the inventive molding core according to FIG. 4A in the unfolded position;
[0034] FIG. 5 is a perspective illustration of the first exemplary embodiment of the inventive molding core according to FIG. 4A ;
[0035] FIG. 6A is a sectional illustration of a second exemplary embodiment of the inventive molding core in a first position;
[0036] FIG. 6B is a sectional illustration of the second exemplary embodiment of the inventive molding core in a second position; and
[0037] FIG. 7 is a schematic perspective view of the composite fiber component according to FIG. 1 during the removal of an inventive molding core in accordance with the method according to the invention.
[0038] In the figures, the same reference numbers refer to identical or functionally identical components unless otherwise stated.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 1 shows a schematic perspective view of an exemplary embodiment of a composite fiber component 1 during manufacture in accordance with a method according to the invention.
[0040] Two molding cores 4 which have an approximately trapezoidal cross section and whose manufacture will be explained further below are arranged with their base 5 resting on a base part 2 . The base part 2 has at least one layer of a fiber semi-finished product.
[0041] In a further step, further fiber semi-finished products are positioned on the molding cores 4 . The fiber semi-finished products 3 rest here with a central section on the external surface of the molding cores 4 and with their ends on the base part 2 , that is to say for example on the skin of an aircraft.
[0042] It is possible to use various fabrication methods to manufacture the composite fiber component. The infusion method may be selected in order to introduce a matrix, that is to say for example epoxy resin, into the fiber semi-finished products 3 . The prepreg method can be equally well used here.
[0043] In a further step, the base part 2 is cured with the molding cores 4 and the fiber semi-finished products 3 in an oven or autoclave, depending on the method, with the application of heat and pressure.
[0044] The fiber semi-finished products 3 are cured, for example, in a suitable oven or autoclave (not illustrated) to form stringers 20 . The at least partially cured composite fiber component 1 consequently has the two Ω stringers 20 after the curing process.
[0045] FIG. 2 shows a schematic, general sectional illustration of an inventive molding core 4 of the composite fiber component 1 according to FIG. 1 in a cross section.
[0046] The molding core 4 , details of whose design will be given further below, has a cross section 6 which is formed in a mold 8 and is given the desired shape, here an approximately trapezoidal shape, in said mold in a conventional fashion, for example with the application of heat and pressure. In this example, the molding core 4 is surrounded by a core sleeve 9 which completely encloses the molding core 4 . It prevents direct contact between the molding core 4 and the composite fiber component 1 . Possible undesired exchange of material between 1 and 4 is thus prevented and the later removal of the molding core 4 from the mold is facilitated since it cannot adhere to the composite fiber component 1 . It is important here that the core sleeve 9 should reliably withstand the process temperature and the process pressure. The core sleeve 9 bears with its inner side 11 directly on the surfaces of the molding core 4 , and in this example its outer side 10 is coated with a separating layer (not shown) which can also be composed of an additional sleeve. The separating layer serves for later separating the core sleeve 9 from the composite fiber component 1 if the core sleeve 9 is also to be removed after the removal of the molding core 4 from the mold.
[0047] The molding core 4 according to the invention is composed of individual segments 16 a . . . d which extend in the longitudinal direction of the molded section 14 ( FIG. 1 ). A cross section through such a molding core 4 is illustrated schematically in FIGS. 3A and 3B .
[0048] In this context, the dashed outline of the cross section 6 of the unfolded molding core 4 or of a hollow profile 15 is indicated. The side surfaces of this hollow profile 15 are formed by the segments 16 a . . . d . In the folded position A of the molding core 4 which is shown in FIG. 3A , the segments 16 a . . . d are connected in an articulated fashion by means of first connections 18 a . . . d at their corner points or corner joints. Furthermore, the segments 16 a , 16 b and 16 d are each divided into two subsegments 17 a / 17 b , 17 c / 17 d and 17 e / 17 f which are themselves connected in an articulated fashion by means of second connections 19 a . . . c at central points (central joints) here. In each case one of the respective two subsegments 17 a / 17 b , 17 c / 17 d and 17 e / 17 f is lengthened beyond the respective second connection 19 a . . . c and forms in each case a projection 21 a . . . c.
[0049] In this folded position A, the second connections 19 a . . . c are folded towards the centre of the hollow profile 15 . This results in a folded profile which has a smaller cross section than the hollow profile 15 . On the one hand, FIG. 3 clearly shows that the first connections 18 a and 18 b of the molding core 4 each have only linear contact in the form of sliding rails with the interior of the molded section 14 , which can easily be thought of instead of the cross section 6 , and this may be advantageous when removing, that is to say pulling out, the molding core 4 from the molded section 14 . On the other hand, FIG. 3 clearly shows that in the folded position A the molding core 4 is smaller than the hollow profile 15 and is thus smaller than the cross section of the molded section 14 , so that it can easily be removed from the mold.
[0050] In order to form the unfolded position B, a pressure is applied to the interior 22 formed by the segments 16 a . . . d , which unfolds the segments 16 a . . . d as shown in FIG. 3B . In this unfolded position B, the free ends of the projections 21 a . . . c rest on the respective corresponding subsegment 17 a , 17 d , 17 e , and they each form a stop for this position.
[0051] A first exemplary embodiment of an inventive molding core 4 with pivotable segments 16 a . . . d is illustrated in a way corresponding to the FIGS. 3A and 3B in FIGS. 4A and 4B , with FIG. 5 showing a perspective illustration of the first exemplary embodiment. FIG. 4A shows the folded position A and FIG. 4B shows the unfolded position B.
[0052] The segments 16 a . . . d are manufactured in one piece with the first connections 18 a . . . d and the subsegments 17 a . . . f are manufactured in one piece with the second connections 19 a . . . c from one substance. The connections 18 a . . . d and 19 a . . . c are constructed here as film hinges. These film hinges are matched in terms of their geometry (width and thickness) in this example in such a way that sufficient prestress is ensured and movement always takes place in the elastic region of the hinge material. As a result, the properties, in particular the prestress and the necessary folding moment, remain constant over a plurality of folding processes. Consequently, re-use is possible. The film hinges are matched in such a way that the projections 21 a . . . c all reach their stops simultaneously (with the same internal pressure). The geometry of the molding core 4 is configured in such a way that the projections 21 a . . . c cannot impede one another. The configuration of the thickness of the connections 18 a . . . d and 19 a . . . c permits a prestress to be applied to the segments 16 a . . . d and subsegments 17 a . . . f in such a way that a specific sequence is achieved during the folding and unfolding processes.
[0053] In order to construct sharp corners, FIG. 5 shows two reinforcement means 13 in the form of corner profiles. The latter can be provided subsequently on the respective edges of the hollow profile 15 . It is also possible for the segments 16 a . . . d and/or the subsegments 17 a . . . f and/or the connections 18 a . . . d to be constructed in a lengthened form in order to form such corner profiles.
[0054] The hollow profile 15 which is formed from the segments 16 a . . . d has a closed cross section and is therefore referred to as a closed hollow profile 15 . The hollow profile 15 can be manufactured, for example, by extrusion.
[0055] An alternative second exemplary embodiment in the form of an open profile 24 is shown by FIGS. 6A and 6B in two positions for different prestresses.
[0056] The open profile 24 has, in addition to the abovementioned points, the advantage that during manufacture the individual connections can be embodied precisely in order to generate desired prestresses. Furthermore, the extrusion is possible in different positions, of which FIGS. 6A and 6B show two possibilities.
[0057] Furthermore, the open profile 24 can, in contrast to a closed one, be manufactured with tighter tolerances.
[0058] The open profile 24 is processed after its manufacture to form a closed profile 15 by virtue of the fact that in the example shown here two semi-segments 25 a, b are joined to form one segment, for example the segment 16 c from FIGS. 3A , 3 B, 4 A, 4 B. This can be done, for example, by welding, with third connections 23 a, b which correspond to one another and are in the form of longitudinal projections being arranged on the free edges of the semi-segments 25 a, b lying opposite one another in this example.
[0059] FIG. 7 shows a schematic perspective view of the finished composite fiber component 1 according to FIG. 1 with molded sections 14 which are constructed as stringers 20 .
[0060] On the left-hand side, a molded section 14 is shown in which one end of the hollow profile 15 of the molding core 4 is indicated, said end being connected to a connecting device 26 with a line 27 for the application of the internal pressure p. The other end of the hollow profile 15 is closed off with a closure in the folded state. This is necessary in order to permit removal from the mold in the direction of the lower end of the figure. The junction region with the unfolded state (length of the junction is approximately twice the width of the molding core) cannot be used for molding. Correspondingly, the molding core must project far beyond the end of stringers 20 .
[0061] By varying the internal pressure p, the hollow profile 15 can be unfolded and folded. However, it is also possible to provide it with a further connecting device 26 . The internal pressure p can be measured at a suitable point in order to regulate it. An opening in the core sleeve 12 is also arranged outside the molded section 14 .
[0062] During removal from the mold, an internal pressure (vacuum) which is such that the hollow profile 15 assumes the folded position A is applied to the hollow profile 15 via the connecting device 26 .
[0063] If the removal from the mold is performed, for example, subsequent to curing in a pressure vessel/autoclave within this pressure vessel, it is possible to apply a correspondingly high vacuum of, for example, 10 bar. This can be taken into account if a geometry of a hollow profile 15 is used in which the simple atmospheric vacuum is not sufficient for the folding. Such a process can be automated.
[0064] It is furthermore possible to apply pressure to the outer side of the hollow profile 15 between the inner side of the molded section 14 or inner side of the core sleeve 9 and the outer side of the hollow profile 15 in order to fold the hollow profile 15 . This pressure can also be applied in a way which supports the internal pressure p.
[0065] The molding core 4 which is folded in this way can be pulled out of the cured molded section 14 and used again. The core sleeve 9 is likewise pulled out, which can be done in a particularly simple and easy way if a separating layer is present. The composite fiber component 1 can then be further processed. If reinforcement means 13 are used, they can likewise also be pulled out or remain in the composite fiber component 1 .
[0066] A method for manufacturing a composite fiber component, a corresponding molding core and a corresponding composite fiber component are thus provided which permit a significant reduction in material costs compared to the use of conventional materials for the supporting or molding core. The molding core is removed completely, allowing the weight of the composite fiber component to be reduced compared with the prior art. It is possible to expect that the molding core 4 will be re-used repeatedly and subsequently recycled, permitting a reduction in costs.
[0067] The invention is not restricted to the specific method for manufacturing a composite fiber component in the field of aircraft which is illustrated in the figures.
[0068] For example, the present inventive idea can thus also be applied to composite fiber components in the field of sports equipment or motor sports.
[0069] In addition, the individual sequence of individual method steps of the manufacturing method according to the invention can be varied in a wide variety of ways. The configuration of the individual method steps can also be modified.
[0070] Furthermore, the geometry of the molding core can be modified in a variety of ways.
[0071] In addition, it is also possible to use a plurality of molding cores in order to construct a single molding core which is wrapped with composite fiber matting. This fulfils the aim of providing a more complex geometry by means of the large number of molding cores. Consequently, relatively complex composite fiber components can be manufactured.
[0072] It is thus possible, for example, also to divide the segment 16 c ( FIGS. 3A , 3 B, 4 A, 4 B) into two subsegments with a central joint. A plurality of subsegments of one segment are also conceivable. | Method for manufacturing a composite fibre component ( 1 ) the method comprising the following method steps: forming a moulding core ( 4 ) comprising a hollow profile ( 15 ) made of segments ( 16 a . . . d ) in order to establish an external geometry of the moulding core ( 4 ), wherein the segments ( 16 a . . . d ) of the moulding core ( 4 ) each extend in the direction of the longitudinal axis of the moulding core ( 4 ) and are each constructed so as to be pivotable about an axis running in the longitudinal direction of the moulding core ( 4 ), between a folded position (A). and an unfolded position (B) of the hollow profile ( 15 ) of the moulding core ( 4 ), wherein the segments ( 16 a . . . d ) are constructed so as to be coupled to one another via connections ( 18 a . . . d, 19 a . . . c ) in one piece in order to form the hollow profile ( 15 ); at least one fibre semifinished product ( 3 ) is positioned at least in certain sections on the constructed moulding core ( 4 ) in order to shape at least one moulded section ( 14 ) of the composite fibre component ( 1 ) to be manufactured; and heat and/or pressure is applied to the at least one moulded section ( 14 ) in order to manufacture the composite fibre component ( 1 ). | 1 |
BACKGROUND OF THE INVENTION
The technical area of the invention is the fleece guidance system in a machine processing textile fibers, in particular in a draw-frame followed by a calendar. The invention also relates to the replacement part of the sliver funnel which is part of the fleece guidance and is located directly before the calendar disks, in particular in such a manner as to be replaceable. Finally, a process is proposed by means of which the fiber sliver is introduced with lateral guidance into the nip in the above-mentioned sliver guidance system without requiring any adaptation of the calendar disks to different fiber types or fleece qualities.
To explain a conventional fiber fleece guidance system in a machine processing textile fibers, reference is made to the example of EP 593 884 A1. It is shown therein that a sliver funnel is provided in proximity of the calendar disks or rollers, said funnel having a fleece axis which is at an angle relative to the connecting plane of the axes of rotation of the calendar disks. A long fiber sliver channel which is often provided with slits to allow air to escape lets out into the rear outlet area of the sliver funnel. The (collected) fibers fed through the fiber sliver channel are introduced into the tapering funnel area of the sliver funnel, are compressed therein and guided up against one of the rotating calendar disks with its forward end in order to convey the fiber sliver to the nip of the calendar disks where it is calendared. In this conventional design, it is current practice to make the fiber sliver funnel so as to be replaceable and for the width of the calendar disks to be adapted to the textile fiber. In order to obtain guidance of especially fine textile fibers, lateral legs are attached to the sliver funnel at its forward end, extending past the nip beyond the calendar disks. Since the width of the calendar disks can be changed, the width of the above-mentioned legs must be adaptable to the width of the calendar disks, and this is achieved by means of an adjusting washer between the legs (beaks) in order to adapt the width between them to the calendar disks and to fix them at the same time, aligning them at a right angle to the earlier-mentioned connecting plane between the axes of rotation.
OBJECTS AND SUMMARY OF THE INVENTION
The present invention has therefore as a principal object to reduce the adjusting effort of sliver funnels and to facilitate the adjusting tasks provided for the utilization of different fiber materials, or even to dispense with these tasks. Additional objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
The objects are achieved through the invention in that the fleece guidance system is provided with the above-mentioned funnel insert, but in that this insert is provided at its forward end on both sides of the forward opening with lateral guidance segments. The guidance segments have a central plane which is essentially at a right angle to the previously mentioned connecting plane between the two axes of rotation of the calendar disks in order to guide the fiber sliver precisely in the direction of the nip and to guide the fiber sliver to that location laterally between the calendar disks in the intake zone of said calendar disks.
The guidance is further improved if the guiding segments are made in the form of prongs which adapt themselves to the form of the calendar disks in the intake zone.
In this fleece guidance system it is no longer necessary for lateral guiding segments to extend past the calendar disks and the calendar disks can remain unchanged, whatever the type and quality of the fibers being calendared.
The sliver funnel which is used in the fleece guidance system has the mechanical guiding segments at its forward end where the fiber sliver channel opens and the central plane of the guiding segments are at an angle relative to the axis of the fiber sliver channel. The angle may be from 30° to 60°.
Each of the prongs plays a mechanical guiding role with its inner side in the intake zone of the calendar disks up to the nip. Each prong is provided with a flattened area which is aligned with one calendar disk and is adapted to its form.
Since one prong is provided on each side of the fiber sliver channel outlet, the width (in the direction of the nip) of each prong is less than half the width of the calendar disks. Centered between the calendar disks, the fiber sliver channel extends with its opening in the area of which a mechanical lateral guidance begins.
So that the sliver funnel can be brought close to the calendar nip, it is provided in its central area with a cylinder segment opening to provide room for the rotation of one of the calendar disks and to install the sliver funnel in a tilted position relative to the connecting plane between the rotational axes of the calendar disks so that they can be exchanged, since it is a wear part subjected to greater wear.
Surprisingly, thanks to the above-mentioned lateral guidance of the fiber sliver on the sides of the sliver, the calendar disks no longer need to assume guidance tasks by themselves alone, nor is their width any longer critical since the mechanical guidance is assumed by the sliver funnel precisely as prescribed by the diameter of the forward outlet of the guidance channel. For this reason the process is realized starting at the outlet where the fiber sliver is guided mechanically from four sides and is aligned towards the nip; two of these sides are provided by the rotating calendar disks, the other two sides, at a right angle to the latter, are provided by the mechanical lateral guides, the prongs.
Due to good mechanical guidance from the sides of the sliver funnel it becomes possible, according to the invention, to use only one type of calendar disks. Nevertheless, the fiber sliver being conveyed to the calendar is given better guidance before the nip and into it. The intake of air can be reduced, independently of the width of the calendar disks. At the same time the lateral escaping of fiber sliver in the vicinity of the calendar is blocked. Close adaptation of the mechanical lateral guidance to the form of the calendar disks is especially advantageous here.
It is an independent idea, within the framework of the mechanical lateral guidance, to use the calendar rollers as scanning rollers and to design one of these disks as bing fixed (only rotatable) and the other disk rotatable and capable of movement relative to the fixed disk. In this manner, the thickness of the fiber sliver is scanned in the calendar and can be converted into an electrical signal based on the distance between the movable calendar roller and the fixed calendar disk. According to this idea, it is no longer required to use lateral legs for mechanical guidance, nor is it required that the calendar disks be at a fixed distance from each other, since the mechanical lateral guidance is provided autonomously to a great extent by the prongs which are fixedly positioned at the sides of the sliver funnel.
The prongs may be made in one piece with the sliver funnel.
With the invention the need for legs extending laterally beyond the calendar disks is eliminated and therefore the distance between them need also not be changed to be adapted to the calendar disks in use at the time. Mechanical guidance is ensured in the intake area and is independent of the width of the calendar disks; Nevertheless, the width of the mechanical guidance may be adapted to the width of a special type of calendar disks, but this must be considered as being an exceptional case.
The invention is explained and completed below through several examples of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the forward end of a fiber sliver itinerary, without showing the fiber sliver channel. The sliver funnel 30 which extends with a prong zone 32 between the calendar disks 100a, 100b which define the nip K between them in which the fiber sliver is calendered are shown;
FIGS. 2a and 2b show two lateral views of the sliver funnel 30 of FIG. 1; and
FIGS. 3 and 4 show two perspective views of the sliver funnel 30 according to the FIGS. 2a and 2b or FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not as a limitation of the invention. In fact, features illustrated or described as part of one embodiment can be used on another embodiment to form still a third embodiment. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.
FIG. 1 shows the sliver funnel 30 as the forward end of the fleece itinerary which is fed via a sliver guiding channel that is usually provided with air escape slits and is not shown here. It is of the usual configuration. The sliver funnel 30 has a rear section 30h (at the rear), a central section 30m (center) and a forward area 30v (in front) which are clearly shown in FIGS. 2a and 2b. The rear section is cylindrical and has several cylindrical steps to be inserted in a matching holding device so that it can easily be removed. An inserted sliver funnel 30 is fixed in its position above the calendar disks 100a, 100b by means of locking screws. The locking screws press down on one of the cylindrical sections 30a.
The axis 34a of the sliver funnel, which is the central axis of an opening 31 that tapers in the form of a funnel, defines the constricting convergence of the entering fiber sliver. It is usually selected for a particular fiber type and fiber quality, i.e. it is prescribed by technological requirements.
The axis 34a of the sliver funnel 30 is at an angle relative to the plane 90 which connects the two axes 101a and 101b of the calendar disks 100a, 100b. This plane is generally horizontal, and is slightly inclined in FIG. 1. The plane 90 also contains the nip K through which the fiber sliver must be guided in the direction of the straight line 34 of the drawing, while being calendared (compressed) by the calendar disks 100a, 100b. The intake area 99 of the calendar is defined between the nip K and the frontal opening 31a of the conically tapering sliver funnel opening 31.
The fiber sliver is introduced along axis 34a into the conically tapering opening 31 in the operation of the calendar device and leaves the sliver funnel 30 at the forward opening 31a which can also be seen in FIGS. 2a, 2b and 3. The fiber sliver runs in the direction of the calendar disks, is there deflected by the rotation of these disks and is conveyed in the direction of the nip K. The intake zone 99, which is here described in other words tapers according to the cylindrical form of the calendar disks 100a, 100b. The direction of sliver movement tends towards the straight line 34 as shown in FIG. 1.
In addition to the guiding system of the calendar disks, a lateral guide is provided as shown in FIG. 1 in the form of a wedge-shaped prong 32 and which can be seen more clearly in a perspective view in FIGS. 3 and 4. The two prongs 32 and 33 are two substantially wedge shaped and tapering guide segments each of which has an inner wall 32a, 33a starting at both sides of the output opening 31a of channel 31. They guide the fiber contact with mechanical contact in the intake area 99 to the nip K without regard to the width of the calendar disks 100a, 100b and without the presence of lateral guiding assists or locks extending beyond the calendar disks 100a, 100b. In this manner, the lateral guidance 32a, 33a is provided in the intake area 99.
The wedge-shaped tapering prongs 32, 33 have flatter areas 32b, 32c and 33b, 33c such as shown in FIGS. 2a and 2b, as well as in FIGS. 3 and 4. These flatter areas are adapted to the form of the calendar rollers so that as close an attribution as possible is provided without any contact between the sliver funnel 30 and the calendar disks.
The wedge-shaped prongs 32, 33 are linear in their forward area, and the corresponding line segments 32e, 33e can be identified clearly in FIG. 4. Starting at these lines 32e, 33e, which are as close as possible in front of the nip K, the prongs widen in their outer area towards the rear, towards opening 31a in a curved manner 32d, 33d, whereby it is possible to cause the curvature to depend on which cylindrical part 33m which makes up the central area of the sliver funnel 30.
A half-round platform area 35 oriented towards the back starts at an edge 35a which is parallel with the nip K and is located on the level of the outlet opening 31a of the guiding channel 31 of the sliver funnel 30. It delimits the rear end of the prong-shaped guidance segments 32, 33 and marks the beginning of an approximately rectangular surface 31b (visible in FIG. 3) which supports the oval outlet 31a of the channel, defined in one direction as being approximately parallel with the plane 90 connecting the axes of rotation 100a and 100b of the calendar disks. The width of this inclined surface 31b is approximately equal to the distance between the inner surfaces 32a, 33a of the prongs 32, 33 in order to provide the best possible guidance for the emerging fiber sliver.
The straight forward edge 32e, 33e of the guidance segments 32, 33 (prongs) is shown in FIG. 2a in such a manner that it continues backwards at its outer end with two different curvature gradients 32d so that the prongs 32, 33 become larger in the rear area than in the area close to the nip K. If the prongs taper to a point, the danger of breakage is higher in the forward area and for this reason care should be taken in practical application that the forward line areas should converge to a point to provide mechanical lateral guidance for the fiber sliver as closely as possible to the nip K for the fiber sliver, but that the extension of the above-mentioned lines 32e, 33e not be too short so that the prongs are held in the forward area so as to form a line and not resemble arrow points.
A cylindrical opening 30a constitutes the prolongation of the prongs 32, 33 on one side of the sliver funnel 30. With this the sliver funnel can be brought into immediate proximity of the nip in that it is "saddled up" on one of the calendar disks without contact. A sliver funnel 30 laid out in this manner defines a guiding axis 34a which is at an angle relative to plane 90 as shown most clearly in FIG. 1 with an angle of approximately 45°. The central plane 34 of the guidance segments 32, 33 which are again at an angle relative to the guide axis 34a is tangential to the calendar disks in nip K and thereby is perpendicular to the connecting plane 90 of the axis of rotation 100a, 100b of the calendar disks. The full guidance of the fiber sliver in the funnel area 31 exists as soon as the fiber sliver emerges from opening 31a and thus becomes only a bilateral guidance system 32a, 33a on the inside of the prongs, and the two other lateral guides are provided by the calendar disks so as to form a substantially closed guide in the intake zone 99.
In this manner the fiber sliver, although it leaves the all-around guidance which exists in the fiber guiding channel 31, nevertheless continues to be guided in a mechanically defined manner until it has gone to--and through--the calendar nip K.
The mechanical guidance makes it possible for the width of the calendar disks to be selected independently of the type and quality of the sliver, so that the calendar disks no longer need to be replaced even though the sliver funnel 30 is replaced as a part which is adapted in a modular building-block system to the fiber sliver to be processed.
Because of the mechanical lateral guidance in the intake area 99 towards the nip K, it is possible to enter the position relationship of the calendar disks 100a, 100b and to make one of these disks, e.g. disk 100b as in FIG. 1, so as to be able to change position as could be made possible by a lever arm 102 which is prestressed by being spring-loaded and which swivels the disk 100b out by S when the fiber sliver enters the nip K. The swiveling motion provides a measurement of the thickness d(t) and thereby of the mass m(t) of the fiber sliver running through the calendar nip K while lateral guidance by the prongs 32, 33 is maintained.
The above-mentioned movement is shown in FIG. 1 with the angle α by which the rotational axis 101b of the calendar disks 100b shifts, in a first approximation in a direction of movement V which is in the connecting plane 90. The angle α may however also contain components of which at least one is to extend in direction V while another component may be oriented at a right angle to V, i.e. in direction of axis 34.
The calendar disks 100a, 100b thus become measured-value indicators which make it possible to determine the thickness and mass of the calendared sliver directly, without requiring an additional measuring device or additional scanning rollers in the outlet area; the fiber sliver may be deposited in a storage area or container directly after the calendar disks., even though its thickness or mass were measured before that.
The devices by means of which the movements of the second calendar disk 100b relative to the first calendar disk 100a can be measured are conventional devices, and usually a movable target which changes location relative to an inductively measuring distance indicator will be used for this so that the distance between target and distance indicator, and thereby the distance between the movable calendar disk 100 and the calendar disk 100a which remains fixed in plane 90, is measured.
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 and spirit of the invention. It is intended that the invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. | A fleece guidance system is provided to convey a fiber fleece to the nip of a pair of calendar rollers. The system includes a funnel having a fiber sliver channel defined therethrough which tapers towards an opening adjacent the nip of the calendar rollers. The channel has a longitudinal axis therethrough which is angled relative to a plane through the axes of rotation of the calendar rollers. Oppositely facing guiding segments are configured on the funnel on opposite sides of the opening. The segments have a forward edge which extends into the nip and define lateral guiding surfaces for the fiber sliver exiting from the opening. A plane through the forward edge of the guiding segments and the opening is essentially perpendicular to a plane through the axis of rotation of the calendar rollers. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to and benefit of Chinese Patent Application No. 201320089712.6, entitled “SYSTEM AND METHOD FOR REDUCING BACK PRESSURE IN A GAS TURBINE SYSTEM”, filed Feb. 15, 2013, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The subject matter disclosed herein relates to gas turbine systems and, more specifically, a system for reducing back pressure on the turbine.
Gas turbine engine systems benefit from improved efficiency. Gas turbine designs minimize inefficiencies in order to extract as much work as possible from a combustible fuel. Specifically, the gas turbine system uses the combustible fuel to create hot, pressurized exhaust gases that flow through a turbine. The turbine uses the momentum of the exhaust gases to create rotational energy for use by a load (e.g., a generator). As the exhaust gases exit the turbine into an exhaust section, they may create undesirable back pressure. The back pressure may reduce the gas turbine system's efficiency, causing the system to use more energy to move the exhaust gases out of the turbine.
BRIEF DESCRIPTION OF THE INVENTION
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a system, including an exhaust duct configured to flow an exhaust gas, and an air injection system coupled to the exhaust duct, wherein the air injection system comprises a first air injector configured to inject air into the exhaust duct to assist flow of the exhaust gas through the exhaust duct.
In a second embodiment, a system including, a controller having instructions to control air flow through an air injection system into an exhaust duct to reduce back pressure associated with flow of the exhaust gas through the exhaust duct.
In a third embodiment, a method including, receiving the air flow from a compressor of a gas turbine engine, routing the air flow through the air injection system into the exhaust duct downstream of a turbine of the gas turbine engine, and reducing the back pressure with the air flow.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 is a schematic of a gas turbine system using an air injection system;
FIG. 2 is a cross-sectional view of an exhaust duct along line 2 - 2 in FIG. 1 that illustrates an air injector stage with rakes;
FIG. 3 is a cross-sectional view of the exhaust duct along line 2 - 2 in FIG. 1 that illustrates an air injector stage with rakes;
FIG. 4 is a cross-sectional perspective view of the exhaust duct along line 4 - 4 in FIG. 1 that illustrates an air injector stage with air injector nozzles;
FIG. 5 is a cross-sectional perspective view of the exhaust duct along line 4 - 4 in FIG. 1 that illustrates an air injector stage with air blades;
FIG. 6 is a cross-sectional perspective view of the exhaust duct along line 6 - 6 in FIG. 1 that illustrates an air injector stage with air injector nozzles; and
FIG. 7 is a cross-sectional perspective view of the exhaust duct 18 along line 7 - 7 in FIG. 1 that illustrates the air injector stage with air injector nozzles and air blades.
DETAILED DESCRIPTION OF THE INVENTION
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
The present disclosure is generally directed towards a gas turbine system with an air injection system that reduces back pressure on a gas turbine. Specifically, the air injection system helps move back-pressure-causing-exhaust gases away from the gas turbine engine. This improves efficiency by reducing the work used by the gas turbine engine to expel exhaust gases. In certain embodiments, the air injection system includes multiple air injector stages that move the exhaust gas away from the gas turbine engine. Each injector stage may include one or more air injectors. The air injectors may include air blades or air injector nozzles. The injectors or air blades are designed to minimize air blockage and maximize air energization. In operation, the air injectors and air nozzles entrain surrounding and/or upstream air that is then energized with a small amount of compressed air. In this manner, the air injectors and air blades can move large volumes of air at high velocities. These air blades and nozzles may be modified in various ways to include changing their shape; the angle at which they inject air; sizes; quantity; and spacing between the duct and neighboring air injectors. Furthermore, the air injectors may interact in different ways with the exhaust duct. For example, some air injectors may project into the exhaust duct while others are flush or recessed with exhaust duct walls.
FIG. 1 is a schematic of a gas turbine system 10 using an air injection system 12 . The gas turbine system 10 includes the air injection system 12 , a gas turbine 14 , a load 16 , and exhaust duct work 17 with an exhaust stack 18 . The air injection system 12 may advantageously improve the efficiency of the gas turbine system 10 . Specifically, the air injection system 12 may move excess compressed air from the gas turbine 14 to the exhaust duct 17 (including the exhaust stack 18 ) to reduce back pressure on the gas turbine 14 . The air injector system 12 may include one or more air injector stages 46 , 48 , 50 , and 52 (or modules) that are mountable in or part of the exhaust duct work 17 , each having one or more air injectors 13 . Each injector 13 injects air to help flow the exhaust gases in a downstream direction to reduce back pressure.
The gas turbine engine 14 includes a compressor 20 , combustor 22 , fuel nozzle 24 , and turbine 26 . In operation, the compressor 20 draws air into the gas turbine 14 and compresses it for combustion. As illustrated, the compressor includes multiple rotors or compression stages 28 , 30 , and 32 each having a plurality of compressor blades. While only three rotors or stages are shown, a compressor 20 may include additional rotors or stages (e.g., 1, 2, 3, 4, 5, 6, 10, or more). Each stage 28 , 30 , and 32 uses the blades to progressively compress the air to a greater pressure. After passing through the compressor 20 , the air enters the combustor 22 . In the combustor 22 , the air combines and combusts with fuel from the fuel nozzle 24 . The combustion of the air and fuel creates hot pressurized combustion gas that then travel through the turbine 26 .
The turbine 26 , like the compressor 20 , includes several rotors or turbine stages 34 , 36 , and 38 , each having a plurality of turbine blades. While only three rotors or stages are shown, a turbine 26 may include additional rotors or stages (e.g., 1, 2, 3, 4, 5, 6, 10, or more). The movement of the combustion gases through the turbine 26 , causes the turbine blades and rotors to rotate. The rotation of the rotors or turbine stages 34 , 36 , and 38 cause shaft 40 to rotate, which then drives a load 16 (e.g., a generator). As the hot and fast moving combustion gases pass sequentially through the turbine stages 34 , 36 , and 38 , the gases restricts exhaust gas 42 due to the stations walls 19 , turns and general flow restriction, thereby collecting back pressure on the flow of exhaust gases 42 progressively expand, cool, and slow before entering the exhaust stack 18 as slower moving exhaust gas 42 . The exhaust duct 17 generally conforms or the flow of exhaust gas 42 , and generally slows the flow of traveling through the turbine 26 . The back pressure causes the gas turbine 14 to work harder and burn more fuel to counter the back pressure. Advantageously, the gas turbine system 10 may include an air injection system 12 that reduces the back pressure and increases efficiency. In particular, the air injectors system 12 is configured to energize or add momentum to the flow of exhaust gas to counter the effects of the flow restriction.
The air injection system 12 includes a controller 44 ; air injector modules or stages 46 , 48 , 50 , and 52 ; compressed air supply 54 ; pressure collecting valve assembly 56 ; pressure releasing valve assembly 58 ; and sensor 59 . Advantageously, the air injection system 12 may use compressed air from the gas turbine 14 to reduce the back pressure caused by the exhaust gas 42 . As explained above, the compressor 20 compresses air for combustion in the combustor 22 . The compressor 20 may create more pressurized air than the gas turbine 14 can use during combustion. Instead of wasting this excess pressurized air, the air injection system 12 uses the pressurized air in the air injector stages 46 , 48 , 50 , and 52 to reduce back pressure.
The air injection system 12 uses the valve assemblies 56 and 58 to control the flow of the compressed air from the compressor 20 into the air injector stages 46 , 48 , 50 , and 52 . The controller 44 includes a processor 45 , memory 47 , and instructions stored on the memory 47 executable by the processor 45 . The controller 44 operates with and receives data from the sensor 59 (e.g., exhaust gas velocity, pressure in exhaust duct 17 ). The controller then processes this data with the processor 45 and executes instructions stored in the memory 47 . While only one sensor 59 is illustrated other embodiments may include multiple sensors measuring properties at different locations in the exhaust duct 17 . In operation the controller 44 executes instructions to open and close the valves 60 , 62 , and 64 in the valve assembly 56 to selectively flow excess pressurized air from respective compressor stages 28 , 30 , and 32 into the compressed air supply 54 . While only three valves are illustrated, more valves in different configurations are possible. For example, the valve assembly 56 may include (1, 2, 3, 4, 5, 10, 15 or more valves). In some embodiments, each valve may control pressurized air release from a respective compression stage in the compressor 20 . In other embodiments, a single valve may control pressurized air release from a single stage, all stages, or some of the stages. In still other embodiments, valves may only connect to some of the stages (e.g., the stages with the most pressure or suitable pressure for the exhaust duct 17 ).
The compressed air supply 54 may include an air distribution manifold, storage tank, conduits, or any combination thereof. In certain embodiments, the supply 54 may simply represent, or include the source of compressed air, i.e., the compressor 20 itself. The valve assembly 56 receives the compressed air from the supply 54 and routes it to the air injector stages 46 , 48 , 50 , and 52 . The valve assembly 58 includes valves 66 , 68 , 70 , and 72 . Each valve corresponds to a respective air injector stage 46 , 48 , 50 , and 52 . In other embodiments there may be more air injector stages (e.g., 1, 2, 3, 4, 6, 8, 14, or more) and a corresponding number of valves (e.g., 1, 2, 3, 4, 6, 8, 14, or more). In still other embodiments, there may be fewer valves than the number of air injector stages (e.g., one valve for all of the air injectors). In operation, the controller 44 executes instructions to open and close valves 66 , 68 , 70 , and 72 to provide compressed air into the respective air injector stages 46 , 48 , 50 , and 52 . The air injector stages 46 , 48 , 50 , and 52 then direct the compressed air into air injectors 13 . The air injectors 13 use the compressed air to increase the speed or momentum of the exhaust gas 42 as it travels though the exhaust duct 17 (including exhaust stack 18 ), reducing back pressure on the gas turbine 14 . The controller 44 executes instructions to selectively control the valves to adjust the quantity flow rate, and distribution among the various stages and injectors 13 . For example, the controller 44 may execute instructions to progressively increase exhaust gas speed between the stages 46 , 48 , 50 , and 52 by increasing the amount of compressed air in each stage. In other embodiments, the controller 44 may execute instructions to increase the speed of the exhaust gas 42 in the stage closest to the turbine 26 (e.g., stage 46 ) and then progressively reduce compressed air injection into the later stages 48 , 50 , and 52 . In each configuration the injectors 13 in each stage 46 , 48 , 50 , and 52 (or module) helps to energize the exhaust flow to counteract the flow restriction as the exhaust gas 42 travels through the exhaust duct. Furthermore, each stage 46 , 48 , 50 , and 52 (or module) may energize/interact with the flow in different ways. For example, the stages 46 , 48 , 50 , and 52 (or module) may have air injectors 13 that protrude into the flow, are flush with the exhaust duct 17 , or are angled with respect to the flow. By projecting into the flow the air injector 13 may more effectively energize the center of the flow. In contrast, the injectors 13 that are flush with the exhaust duct 17 may more effectively energize the outer portions of the flow. Furthermore, the angle of the air injectors 13 with respect to the flow may more effectively energize the flow in a direction out of the exhaust duct 17 . Thus depending on the embodiment a stage 46 , 48 , 50 , and 52 (or module) may adjust how the air injector(s) 13 interact with the flow (i.e., energize the flow center, flow edges, or the direction of flow movement).
FIG. 2 is a cross-sectional view of the exhaust duct 17 along line 2 - 2 in FIG. 1 , illustrating an embodiment of the air injector stage 46 with rakes 90 , 92 , and 94 . While only three rakes are shown, there may be more rakes depending on the embodiment (e.g., 1, 2, 3, 4, 5, 10, 15, or more). As illustrated, the exhaust duct 17 is rectangular with four side walls 96 , 98 , 100 , and 102 . In other embodiments, the exhaust duct 17 may be circular, square, oval, hexagonal, etc. In the present embodiment, the rakes 90 , 92 , and 94 are between the side walls 96 and 98 and spaced apart by distances 104 , 106 , 108 , and 110 . The distances 104 , 106 , 108 , and 110 may change, depending on the embodiment, to achieve particular flow characteristics. For example, the distances 104 and 110 may be small in order to place the rakes 90 and 94 near the side walls 100 and 102 . In other embodiments, the rakes 90 , 92 , and 94 may be spaced closer together. The rakes 90 , 92 , and 94 may also have different orientations to include vertical orientations between the walls 100 and 102 . In still other embodiments, the rakes may be oriented diagonally between the walls 96 , 98 , 100 , and 102 .
The rakes 90 , 92 , and 94 include one or more air injectors 13 , e.g., air injector nozzles 112 . Each rake 90 , 92 , and 94 may include one or more nozzles 112 (e.g., 1, 2, 3, 4, 5, 10, 25, or more). In some embodiments, the number of nozzles 112 may differ between rakes 90 , 92 , and 94 . For example, rake 94 may have twelve nozzles 112 while rakes 90 and 92 have four each. The nozzles 112 may also differ in shape and size with respect to each other. Shapes may include circular, chevron, rectangular, square, half-moon, and ellipse, among others. In other embodiments, the nozzles 112 may progressively change in size across the rake to improve flow velocity characteristics of the exhaust gas between the side walls 96 , 98 , 100 , and 102 of the exhaust duct 17 . For example, smaller nozzles 112 that emit pressurized air at a high velocity may be closer to the sides of the exhaust duct 17 where the flow may be slowest, while lower pressure nozzles 112 are near the center of the exhaust duct 17 . In still other embodiments, the spacing and sizes of the nozzles 112 may be equal. This may improve exhaust gas 42 flow through the exhaust duct 17 . Moreover, there are many possible combinations using the variables of nozzle size, nozzle shape, nozzle number, nozzle spacing, and rake spacing.
FIG. 3 is a cross-sectional view of the exhaust duct 17 along line 2 - 2 in FIG. 1 , illustrating the air injector stage 46 with rakes 140 , 142 , and 144 . The rakes 140 , 142 , and 144 include air blade slots 146 , 148 , 150 , and 152 . The air blades 146 , 148 , and 150 function like the air nozzles 112 in FIG. 2 , and provide air to energize or push exhaust gases 42 through the exhaust duct 17 . Furthermore, the air blades 146 may more uniformly energize the flow. In the present embodiment, the rakes 140 , 142 , and 144 extend between the side walls 100 and 102 in a vertical orientation. The rakes 140 , 142 , and 144 may change orientation (e.g., horizontal, diagonal), and change distances 154 , 156 , 158 , and 160 between each other and the side walls 96 , 98 , 100 , and 102 , depending on the embodiment. Furthermore, the rakes 140 , 142 , and 144 may include more than one air blade. As illustrated rake 140 includes two air blades 150 and 152 , while rakes 142 and 144 have one air blade 146 and 148 , respectively. Different embodiments may include more air blades in each rake (e.g., 1, 2, 3, 4, 5, 6, or more), or different numbers of rakes (e.g., 1, 2, 3, 4, 5, 6, or more). For example, rake 140 may have two blades while rake 144 has five and rake 142 has three. Finally, the shape of the air blade may differ (e.g., straight, wave-like, zigzag, etc.). For example, the blade 148 forms a wave-like slot, while the remaining blades 146 , 150 , and 152 form a straight rectangular slot.
FIG. 4 is a cross-sectional view of the exhaust duct 17 along line 4 - 4 in FIG. 1 , illustrating the air injector stage 48 with air injector nozzles 180 . As illustrated, the nozzles 180 are flush with the side walls 96 , 98 , 100 , and 102 . Accordingly, the air injector nozzles 180 may impact the portions of the flow closest to the side walls 96 , 98 , 100 , and 102 . The air injector stage 48 may form various configurations with the air nozzles 180 using the variables of shape, angle, size, quantity, and spacing. For example, the side walls 96 , 98 , 100 , and 102 may have the same or different numbers (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) of nozzles 180 . For example, side wall 96 may have three nozzles 180 , while the remaining walls 98 , 100 , and 102 have six, seven, and four nozzles 180 , respectively). Each of these nozzles 180 may form a variety of shapes, such as circular, chevron, rectangular, square, half-moon, and ellipse among others. Furthermore, the air injector stage 48 may place differently shaped nozzles 180 at different locations (e.g., on some or all of the side walls 96 , 98 , 100 , and 102 ).
The air nozzles 180 may also form an angle 182 with respect to the side walls 96 , 98 , 100 , and 102 in the direction of the exhaust gas flow. The angle of the air nozzles 180 may change how they energize the flow (i.e., smaller angles may energize flow in a direction parallel to the exhaust duct 17 while a large angle will increasingly energize the flow in a direction perpendicular to the exhaust duct 17 ). The angle 182 may be any angle between approximately 0 and 90 degrees (e.g., approximately 10-30, 20-70, 45-65 degrees). For example, the angle 182 may be approximately 18, 20, or 30 degrees. In some embodiments, the air nozzles 180 on the side wall 96 may form an angle of approximately 90 degrees, while the air nozzles 180 on side wall 100 are at approximately 45 degrees. In still other embodiments, each of the air nozzles 180 may form an angle 182 that differs from the others.
As discussed above, the air nozzles 180 may form different sizes and be spaced differently with respect to each other. As illustrated, the side wall 102 includes different sizes of air nozzles 180 . The different sizes of the air nozzles 180 may increase or decrease air flow in portions of the air injector stage that optimize the flow of the exhaust gas 42 . The air nozzles 180 on the side wall 102 are spaced apart by distances 184 , 186 , 188 , 190 , and 192 . The spacing between the air nozzles 180 may change the profile of the exhaust gas 42 flow through the air injector stage 48 . For example, the air injectors 180 may provide greater air flow near the side walls 96 and 98 by decreasing the distances 184 , 186 , 190 , and 192 and increasing the distance 188 , thereby providing greater energization of the exhaust gas 42 flow along the side walls 96 and 98 . In other embodiments, the opposite may occur by decreasing distance 188 and increasing distances 184 , 186 , 190 , and 192 .
FIG. 5 is a cross-sectional perspective view of the exhaust duct 17 along line 4 - 4 in FIG. 1 , illustrating the air injector stage 48 with air blades 210 . The blades 210 like the nozzles in FIG. 4 move exhaust gas 42 through the exhaust duct 17 . The air blades 210 like the nozzles in FIG. 4 are flush with the exhaust duct 17 and will therefore impact the portions of the flow closest to the side walls 96 , 98 , 100 , and 102 . The air blades 210 may form various configurations by changing the shape, angle, and quantity. The air blades 210 may form different shapes, including wave-like, zigzag, and straight rectangular slots. The air blades 210 may project from side walls 96 , 98 , 100 , and 102 . This angle 212 may be any angle between approximately 0 and 90 degrees (e.g., approximately 10-30, 20-70, or 45-65 degrees). For example, the angle 212 may be approximately 10, 20, or 30 degrees. In certain embodiments, one of the air blades 210 may have an angle 212 of approximately 90 degrees with the side wall 96 , while the other air blades 210 have an angle 212 of approximately 30 degrees with respective side walls 98 , 100 , and 102 . In still other embodiments, each of the air blades 210 may form an angle 212 that differs from the others. Furthermore, each side wall 96 , 98 , 100 , and 102 may include more than one air blade 210 or some walls may have no air blades 210 .
FIG. 6 is a cross-sectional perspective view of the exhaust duct 17 along line 6 - 6 in FIG. 1 , illustrating the air injector stage 50 with air injector nozzles 240 . As illustrated, the nozzles 240 project from the side walls 96 , 98 , 100 , and 102 . In other embodiments, air blades instead of the nozzles 240 may project from the side walls 96 , 98 , 100 , and 102 . By projecting into the flow the air nozzles 240 (or air blades) may more effectively energize the center of the flow.
The air injector stage 50 may form various configurations with the air nozzles 240 using the variables of shapes, angles, sizing, quantity, and spacing. For example, the side walls 96 , 98 , 100 , and 102 may have the same or different numbers (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) of nozzles 240 on each wall. For example, side wall 96 may have three nozzles 240 , while the remaining walls 98 , 100 , and 102 have four, five, and six nozzles 240 respectively. In some embodiments, some walls may exclude nozzles 240 . Each of these nozzles 240 may form a variety of shapes to include circular, chevron, rectangular, square, half-moon, and ellipse shaped nozzles, among others. Furthermore, the air injector stage 50 may place differently shaped nozzles 240 at different locations (e.g., on different side walls 96 , 98 , 100 , and 102 ).
The air nozzles 240 may also form an angle 242 with respect to the side walls 96 , 98 , 100 , and 102 in the downstream direction of the exhaust gas flow. The angle of the air nozzles 240 may change how they energize the flow (i.e., smaller angles may energize flow in a direction parallel to the exhaust duct 17 while a large angle will increasingly energize the flow in a direction perpendicular to the exhaust duct 17 ). The angle 242 may be any angle between approximately 0 and 90 degrees (e.g., approximately 10-30, 20-70, or 45-65 degrees). For example, each nozzle 240 may have an angle 242 of approximately 10, 20, or 30 degrees. In some embodiments, the air nozzles 240 that connect to side wall 96 may form an angle of approximately 90 degrees, while the air nozzles 240 that connect to side wall 98 are at approximately 45 degrees. In still other embodiments, each of the air nozzles 240 may form an angle 242 that differs from the others.
As discussed above, the air injector stage 50 may change spacing and sizing between nozzles 240 . The different sizing of air nozzles 240 may increase or decrease air flow in portions of the air injector stage 50 to optimize the flow of the exhaust gas 42 . The air nozzles 240 may also change spacing with respect to each other. For example, the nozzles 240 are spaced from one another by distances 244 , 246 , 248 , and 250 . The spacing between the air nozzles 240 , like the size of the air nozzles 240 , may change how the exhaust gas 42 accelerates through the air injector stage 50 . For example, changing the distances 244 , 246 , 248 , and 250 may move the nozzles 240 closer to side walls 96 and 98 , accelerating the exhaust gas near the opposite edges of side wall 102 . In other embodiments, the opposite may occur by decreasing distances 244 , 246 , 248 , and 250 the nozzles 240 may accelerate the exhaust gas 42 flow near the exhaust duct 18 center.
FIG. 7 is a cross-sectional perspective view of the exhaust duct 18 along line 7 - 7 in FIG. 1 , illustrating the air injector stage 52 with air injector nozzles 270 and 280 and air blades 300 and 310 . The embodiment shown in FIG. 7 combines the different air nozzles and air blades from the previous embodiments in FIGS. 2-6 into the air injector stage 52 . Specifically, the air injector stage 52 includes nozzles 270 that are flush with the wall 96 , nozzles 280 that project from the side wall 98 into the duct 17 , air blade 300 that projects from the wall 102 into the duct 17 , and the air blade 310 that is flush with the wall 100 . While FIG. 7 illustrates one possible configuration, many others are possible. For example, some walls may include combinations of air blades and air nozzles that are flush recessed, or projecting relative to the exhaust duct 17 . In still other embodiments, different walls may combine projecting air nozzles 280 with flush nozzles 270 on all the walls 96 , 98 , 100 , and 102 , or an embodiment that combines projecting air blades 300 and flush air blades 310 . Furthermore, the air injector stage 52 may further modify the air nozzles 270 and 280 and air blades 300 and 310 in FIG. 7 using the variables discussed above in FIGS. 2-6 , including changing shapes, angle 312 , sizing, quantity, and spacing.
Technical effects of the invention include the ability to reduce back pressure on a gas turbine system using excess compressed air from the compressor. Specifically, the disclosed embodiments reduce back pressure on a gas turbine engine with air injector stages along an exhaust duct. The air injector stages include air injectors that use the excess compressed air to accelerate the exhaust gases out of the system. In this manner, the system reduces back pressure on the gas turbine engine improving its efficiency.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | In a first embodiment, a system, including an exhaust duct configured to flow an exhaust gas, and an air injection system coupled to the exhaust duct, wherein the air injection system comprises a first air injector configured to inject air into the exhaust duct to assist flow of the exhaust gas through the exhaust duct. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to devices and processes of making and using devices for cell culture. In particular, the present invention relates to devices and processes of making and using devices for growth or maintenance of eukaryotic cells.
BACKGROUND
[0002] Artificial organs, which are devices made entirely of non-biological materials, have greatly advanced health care. Artificial organs and tissue substitutes, including kidney dialysis machines, mechanical respirators, cardiac pacemakers, and mechanical heart pumps have sustained many people with desperate life-threatening diseases. The utility of such artificial organs is reflected in their widespread use.
[0003] Bioartificial organs are artificial organs designed to contain and sustain a viable biological component. Many biological functions are even more complex than simply generating a voltage potential at regular intervals, as occurs in the simplest of pacemakers. Examples include biosynthesis of blood components and catabolic processing of deleterious agents. The liver, endocrine glands, bone marrow, and kidney are prominent in such specialized biochemical functions. Artificial organs without a biological component cannot reproduce the complex biochemical functions executed by these organs.
[0004] The artificial kidney, sometimes termed the kidney dialysis machine, for example, serve admirably as substitutes for their biological analogs. Kidney dialysis machines illustrate both the benefits and shortcomings of purely artificial organs. Kidney dialysis machines effectively remove urea, creatinine, water, and excess salts from the blood, thus partly fulfilling major roles of the natural kidney. Artificial kidneys have postponed deaths of patients in renal failure. However, kidney dialysis machines are insufficiently selective and inappropriately remove biological components, such as steroid hormones, that a functioning natural kidney does not. Consequently, dialysis over an extended period may result in bone loss, clotting irregularities, immunodeficiencies, and sterility. Thus, considering the artificial kidney as a model, the capacity of artificial organs to mimic biologic functions is limited and may result in adverse implications for the patient under treatment.
[0005] Liver failure is classified into several major types, including acute liver failure, chronic liver disease, and multiorgan failure. The main etiologies of liver failure are viral hepatitis and hepatotoxicity induced by drugs and toxins. Advanced liver failure results in encephalopathy and coma, and may be fatal. Treatment focuses on stabilizing the patient until spontaneous recovery of liver function, or until liver transplantation. In the aggregate, the annual mortality attributable to liver failure exceeds 27,000 annually in the United States.
[0006] A patient in hepatic failure, unlike a patient in renal failure, cannot be specifically treated because there is no hepatic equivalent to renal dialysis. Currently, the only available treatment for refractory liver failure is hepatic transplantation. Many patients in hepatic failure do not qualify for transplantation because of concomitant infection, or other organ failure. Because of organ shortages and long waiting lists, even those who qualify for liver transplantation often die while awaiting an allograft. UCLA reported that one quarter of their transplant candidates died before a liver could be obtained. Organs suitable for transplant in the pediatric age group are even more scarce (Busuttil, R. W. et al. Ann Surg 1987, 206, 387).
[0007] The natural liver has four major classes of biochemical functions. First, the liver biosynthesizes a wide range of proteins, including major acellular components of blood, such as serum albumin, alpha-anti-trypsin, alpha-macroglobulin, enzymes, clotting factors, carrier molecules for trace elements, and the apo-lipoproteins. The liver then releases these components to the blood circulation. The liver also maintains appropriate plasma concentrations of amino and fatty acids. Second, the liver has a major role in detoxification reactions. The liver oxidizes or conjugates many harmful external poisons, processes that usually, but not always, diminish the poisonous character of the toxins. The liver also destroys excess hemoglobin, metabolizes the porphyrin molecules of hemoglobin, and recycles the iron component. Third, waste products, such as bilirubin, are conjugated and excreted via the biliary tree. Fourth, the liver synthesizes and secretes the bile salts, which serve as detergents that promote the emulsification and digestion of lipids. The multiplicity and biochemical character of liver function vastly increase the complexity of extracorporeal hepatic support.
[0008] Historically, non-biologic artificial liver substitutes have depended on hemodialysis and hemoperfusion, but have been of very short-term and highly limited benefit (Abe, T. et al., Therapeutic Apheresis 2000, 4:26). In contrast to purely artificial organs, an effective liver replacement must have a biological component. The liver is the most massive organ in the human body, exclusive of distributed organs such as skin, gut, hematopoietic system, and vasculature. Sustaining a large mass of functioning liver cells in vitro presents a variety of hurdles. At least eight major problems to developing a functional bioartificial liver can be described: 1) growing or obtaining appropriate and viable cells; 2) providing for a critical minimum mass of cells; 3) supplying oxygen to the cells; 4) supplying nutrients to the cells, and removing cell waste products efficiently; 5) limiting shear forces and hydrostatic pressures, 6) inducing or sustaining a differentiated cell phenotype with the capacity for biosynthesis and biotransformation of toxins; 7) maintaining sterility; and 8) preventing liver tissue rejection or lysis by complement.
[0009] 1) Growing or obtaining appropriate and viable cells. Liver cells for potential use in bioartificial livers can be established cell lines, primary isolates from human or animal livers, or primordial liver cells however, secretion of tumorigenic factors is negatively affecting FDA approval of BAL designs incorporating cell lines (Xu, A. S. L. et al., 2000 in Lineage Biology and Liver, Lanza, R. P., Langer R., and Vacanti, J. (Ed.), Academic Press, San Diego, pp. 559-597). Cell lines of liver are available, for example HepG2 and C3A, that express many functions of differentiated liver. Cell lines offer the potential of growing sufficient numbers of cells in an extracorporeal mass cell culture system, or bioreactor, for sustaining a patient because the growth of cell lines is not limited by cell senescence, but by nutrient availability. Primary human or animal liver cells can also be obtained in the numbers required for a functional bioartificial liver. However, the use of human liver for cell preparation is limited by its lack of availability, and the use of animal liver for cell preparation suffers from some degree of cellular incompatibility. Acute cellular incompatibility results from the binding of antibodies that recognize foreign cells followed by the binding of proteins of the complement system and lysis of the foreign cells. Longer-term cellular incompatibility mechanisms also exist, but should not present any problems for the use of bioreactors as interim or “bridge” medical products. A possible alternative to initial inoculation with a large mass of differentiated cells is the expansion of liver stem cells that are progenitors of mature liver cells. Recent reports suggest that liver progenitor cells go through multiple cell divisions on the path toward maturation and differentiation (Brill, S. et al., Differentiation 1995, 59, 95; Sigal S. H. et al., Differentiation 1995, 59, 35). Suitable control of the growth and differentiation processes with staged application of appropriate cytokines can permit preparation of a clinically useful quantity of cells.
[0010] 2) Providing for a critical minimum mass of cells. The adult human liver has a mass of about 1400-1600 grams, and features a considerable reserve, or redundant, capacity. It is estimated that human survival can be sustained with about 15-20% of the total liver mass. The figure of 20% of the liver mass corresponds to about 5×10 10 cells (Kasai et al. Artif Organs 1994, 18, 348). Most, if not all, previous bioartificial liver designs suffer from a woefully inadequate cell capacity. That is, such devices are capable of sustaining far fewer than 5×10 10 cells, often orders of magnitude fewer cells. Without the cell mass critical for biosynthesis of plasma components and detoxification reactions, these other designs have little clinical utility.
[0011] 3) Supplying oxygen to the cells. The functional units of most organs such as nephron, acinus, alveoli, microvilli, skin, etc. consists of a capillary bed across which is a physico-chemical gradient. These gradients are controlled by mass transfer effects. Oxygen is the primary nutrient that is limiting in cell cultures (Macdonald, J. M. et al. NMR Biomed 1998, 11, 1; Glacken M. W. et al. Ann NY Acad Sci 1983, 413, 355). ‘Integral’ oxygenation, or aeration inside the bioreactor containing the biological or chemical material of interest, greatly enhances mass transfer of oxygen and carbonic acid. The formation of the latter can be used to control pH.
[0012] Oxygen is generally the limiting nutrient in hollow fiber bioartificial livers (Catapano, G. et al. Int J Art Organs 1996, 19, 61) primarily because hepatocytes are highly aerobic cells which causes problems of oxygen mass transfer. Oxygen has a relatively high diffusion coefficient and its mass transfer from blood in the liver sinusoids to hepatocytes is dominated by diffusion rather than convection (i.e., convection and perfusion are caused by pressure gradients). These effects are because an oxygen molecule is much smaller than other nutrients such as a glucose molecule, or than biosynthetic products such as proteins, and because the hepatocytes generate steep concentration gradients in bioartifical livers. With known rates of oxygen diffusion and oxygen consumption, and reasonable estimates of cell density, the diffusion distance at which oxygen utilization becomes the rate-limiting factor for growth is approximately 200 μm (Macdonald, J. M. et al., 1999, in Cell Encapsulation Technology and Therapeutics, Kuhtreiber, W., Lanza, R. P. and Chick, W. L. (Eds.) Birkhauser Boston, Cambridge, pp. 252-286. In bioartificial livers with serial oxygenation aerated with air, oxygen becomes axially limiting in perfusion media by 25 mm (Macdonald et al., 1999, supra).
[0013] Hepatocytes have a high metabolic rate and require a continuous oxygen supply. The oxygen consumption rate ranges from 0.59 to 0.7 nmole/s/10 6 cells for HepG2 cells (Smith, M. D. et al Int J Artif Organs 1996, 19, 36) and is 0.42 nmole/s/10 6 cells for isolated hepatocytes (Rotem, A. et al. Biotech Bioeng 1992, 40, 1286). Integral oxygenation, that is, continuous supply of oxygen along the path of media supply to the cells, is essential to supplying oxygen to liver cells. Serial oxygenation, which is oxygenation at one or a few places in the fluid line of media supply cannot sustain the mass of liver cells needed for an effective bioartificial liver. A difficulty with serial oxygenation is that the solubility of oxygen in aqueous media unsupplemented with oxygen carriers is so low that any oxygen present is quickly depleted by cell metabolism. In fact, in longitudinal flow along a conventional bioreactor semipermeable membrane, hepatocytes deplete oxygen within 2.5 centimeters along the path and therefore convective oxygen mass transfer via increasing Starling flow is improved. Increasing flow rates through conventional bioreactors can cause fiber breeches and adversely affect hepatocyte function (Callies, R. et al., Bio/Technology 1994 12:75). Thus, bioartificial liver designs that do not provide for adequate oxygen delivery are able to support only a limited number of cells. In addition, the flux of oxygen in a diffusion-limited system constrains cells to grow very near (less than about 0.2 mm) to the supply of oxygen. For example, U.S. Pat. No. 5,622,857 to Goffe discloses a bioreactor with some coaxial and some parallel semi-permeable hollow fibers. The Goffe design allows integral oxygenation but does not constrain the thickness of the cell compartment. The fiber-to-fiber spacing in that design is 3-5 mm so that there is not strict control of the oxygen diffusion distance. Similarly, U.S. Pat. No. 5,183,566 to Darnell et al. discloses a bioreactor with bundles of hollow fibers in parallel. The Darnell et al. design does not permit a multitude of individual multi-coaxial fiber bundles to be built-up with accurate and reproducible diffusion distances, and the design is not easily scaled-up. The Darnell et al. design uses bundles of parallel fibers, again not effectively addressing the issue of oxygen diffusion.
[0014] 4. Supplying nutrients to the cells, and removing cell waste products efficiently. The issue of supplying nutrients such as carbohydrates, lipids, minerals, and vitamins has been successfully solved by several variants of hollow fiber technology, and these features must be successfully incorporated into any viable bioartificial liver or bioartificial organ design. Similarly, the issue of removing metabolic wastes is usually handled by the same system that supplies the nutrients. The consumption rates for glutamate, pyruvate, and glucose are typically in the range of 0.03 to 0.3 nmol/s/10 6 cells, with reasonable assumptions for cell density and growth rate (Cremmer, T. et al. J Cell Physiol 1981, 106, 99; Imamura, T. et al. Anal Biochem 1982, 124, 353; Glacken, M. Dissertation 1987). The diffusion rates of oxygen in tissue are similar to those of pyruvate in water, and higher than those of glucose. As these consumption rates are less than the oxygen consumption rate, oxygen is the limiting nutrient in most conditions.
[0015] 5. Limiting shearforces and hydrostatic pressure. For a given bioreactor there is an optimum balance of convection and diffusion for adequate oxygen mass transfer without creation of severe oxygen gradients. For example, using a nontoxic oxygen range, <0.4 mM (solubility constant is 1.06 mM/atm, for air solubility is 0.2 mM at 37° C.), the convective component of oxygen mass transfer should be increased as cells are increasingly farther than 0.2 mm from supply of oxygen (Macdonald et al., 1999, supra.). Although the partial oxygen tension in the liver sinusoid is about 70 mm Hg near the portal triad dropping to 20 mm Hg near the central vein, which equates to a range of 0.096 to 0.027 mM of free oxygen, the hemoglobin-bound oxygen ranges from 6.26 to 2.91 mM. The velocity of blood flow in the liver sinusoid is about 0.02 cm/s while the oxygen diffusion coefficient is about 4 orders-of-magnitude less, or 2×10 −6 cm 2 /s. However, hepatic function is adversely affected with increasing shear forces, and in vivo hepatocytes are protected by a layer of endothelia and extracellular matrix in the space of Disse. Sufficient shear forces will kill hepatocytes. Others have found that shear forces induce specific cytochrome P450's (Mufti N. A. and Shuler, M. L., Biotechnol. Prog., 1995, 11, 659). A recent study has shown that liver regenerates faster with 90% than with 70% hepatectomy and this was attributed to greater shear forces (Sato, Y. et al., Surg. Today, 1997, 27, 518). However, this faster regeneration could also be due to enhanced oxygen, nutrient, and agonist mass transfer. Therefore, there is some maximum level of shear force that hepatocytes can sustain while still displaying optimal function. This maximum level can be increased if a layer of endothelia protects hepatocytes.
[0016] To increase convection, hydrostatic pressure gradients are increased. Elevated hydrostatic pressures can implode hepatocytes. Therefore, it is important to stay below these pressures. It is possible to cause 100% mortality of isolated rat hepatocytes by generating hydrostatic pressures of greater than 7 psi (>300 mm Hg) for longer than 2 minutes while inoculating these cells into coaxial bioreactor using a syringe.
[0017] 6) Inducing or sustaining a differentiated cell phenotype with the capacity for biosynthesis and biotransformation of toxins. The use of the differentiated phenotype of liver cells is necessary to produce a useful bioartificial liver because the specialized functions of the liver, including biosynthesis of blood components and detoxification of toxins, are associated with the differentiated phenotype. These specialized functions are lost in whole, or in part, as the cells dedifferentiate, which often happens in isolated primary cell culture. In contrast, the form of liver cells capable of rapid growth is the dedifferentiated phenotype, leaving the practitioner to balance two opposing needs (Enat, R. et al. Proc Natl Acad Sci USA, 1984, 81, 1411). Some reports suggest that the phenotype of liver cells may be modulated by the presence of cytokines and extracellular matrix components. In particular, the extracellular matrix components rich in collagen IV and laminin, produced by the Engelbrech-Holm Sarcoma (EHS) cells and available commercially as MATRIGEL™, when used with hormonally defined media induces a differentiated phenotype (Enat, R. et al., supra; Bissell, D. M. Scan J Gasterenterol-Suppl 1988, 151, 1; Brill, S. et al. Proc Soc Exp Biol Med 1993, 204, 261 ).
[0018] 7) Maintaining sterility. The implementation of facile sterilization procedures for bioreactors and associated components is essential for clinical utility of extracorporeal bioartificial organs. Fortunately, the procedures for sterilization are well established, including standard methods both for sterilization of extracorporeal devices and for maintaining asepsis by standard in-line filters.
[0019] 8) Preventing liver tissue rejection or lysis by complement. Rejection of foreign tissue can occur by a rapid process known as complement-mediated lysis that involves binding of circulating antibodies to the foreign cell surface, attachment of the proteins of the complement system, and lysis of the offending cell. The cell-mediated immune system is responsible for delayed rejection reactions. However, the cell-mediated immune system should not play a major role in bioreactor systems that do not permit direct contact of host and donor cells. Foreign body reactions, for example, against the structural components of bioreactors, are also cell-mediated and should therefore not constitute substantial obstacles.
[0020] Examples of current bioreactors used for expansion and/or maintenance of cells include those that make use of hollow fiber bioreactors, flatbed bioreactors, flatbed microchannel bioreactors, and roller bottles.
[0021] Hollow fiber bioreactors incorporate hollow fibers that are extruded hollow tubes and prepared from polypropylene, polysulfone, polyamide, regenerated cellulose, and other extrudable polymers. These hollow fibers do not have adequate permeability to allow long-term survival and functioning of cells in the bioreactor.
[0022] Flatbed bioreactors use impervious, rigid surfaces such as glass or culture plastic as a surface for cells. The mass transfer of nutrients is achieved by flow of the media directly across the cells. These bioreactors are unable to achieve the requisite mass of cells needed for clinical use or for some tissue-specific functions. Moreover, the rigid and impervious surfaces used block requisite three-dimensional shape changes essential for cells to express tissue-specific functions.
[0023] Flatbed microchannel bioreactors use cells sandwiched in extracellular matrix and between two plates of rigid, impervious surfaces such as glass or culture plastic. These bioreactors are incapable of achieving the requisite mass needed for clinically useful bioreactors and are difficult to use for most experimental studies.
[0024] Roller bottles consist of glass or plastic bottles in which cells are expanded and/or maintained on the inner surface of the bottles. The cells are grown as monolayers on the surface of the bottles making the achieving of high density cell populations dependent upon the surface area of the inner surface of the bottles. Also, the cells are blocked in achieving three dimensional shapes requisite for optimal expression of tissue-specific functions.
[0025] It would be desirable to enable the cells to expand to high densities or be inoculated in the bioreactors at high densities to yield very high density, three-dimensional cultures and yet be able to survive long-term (weeks to months theoretically) by providing the supply lines, the hollow fibrous structures, with the needed permeability for mass transfer of nutrients, gases, and wastes. To this end, Applicants disclose herein a use of optimized medical textile products.
[0026] From the first appearance more that 4000 years ago to their present use in products ranging from gowns and wound dressings to arterial and skin grafts, fibers and fabrics have been explored as potential materials for applications in medicine and surgery. This continuing interest has its basis in the unique properties of fibers—which in many respects resemble biological materials—and in their ability to be converted into a wide array of desired end products.
[0027] Medical textile products are based on fabrics of which there are four types: woven, knitted, braided, and nonwoven. The first three of these are made from yarns, whereas the fourth can be generated directly from fibers, or even polymers. There is, therefore, a hierarchy of structure. The performance of the final textile product is affected by the properties of the polymer whose contribution in the final product is modified by the structure at two to four different levels of organization.
[0028] Textile medical products are made from biocompatible polymers. Biocompatibility, or the reactivity of body tissues and fluids when in contact with polymeric structures, is governed both by chemical and physical characteristics of polymers (See for example, Gupta, “Medical Textile Structures: An Overview,” Medical Plastics and Biomaterials, 5 (1): 16-30 (1998) incorporated herein by reference in its entirety). Absorbable materials (e.g. polyglactin, polyglycolic acid, polyglyconate) typically excite greater tissue reaction whereas semiabsorbable materials (e.g. cotton, silk) cause less reaction. Non-absorbable materials (e.g. polyester, nylon, polypropylene, polytetraflouroethylene, polyurethane) tend to be inert and relatively the most biocompatible. Polymers are extruded to make monofilament fibers, which are converted to yarns by twisting or entangling processes that improve strength, abrasion resistance, and handling. Nonwoven fabrics are made directly from fibers or polymers, creating high bulk absorbent and usually isotropic fabrics. These are used in numerous medical applications (wipes, sponges, dressings, gowns) and, with proper polymer base, as biodegradable scaffolds in tissue engineering of liver implants (see for example, Mooney, et al, “Long-term Engraftment of Hepatocytes Transplanted on Biodegradable Polymer Sponges,” J. Biomed. Mater. Re., 37: 413-420 (1997) incorporated herein by reference in its entirety). Weaving, knitting, or braiding of yarns make highly organized anisotropic fabrics that are suited for many implants.
[0029] Fabrics that are woven are usually dimensionally highly stable but less extensible and porous than are the knitted or the braided structures. One disadvantage of wovens is their tendency to unravel at the edges when cut squarely or obliquely for implantation. However, the stitching technique known as a Leno weave—in which two warp threads twist around a weft—can be used that substantially alleviates this fraying or unraveling problem (See for example, Kapadia et al., “Woven Vascular Grafts.” U.S. Pat. No. 4,816,028 (1989) incorporated herein by reference in its entirety). The primary problems with knits are that they are dimensionally unstable and their porosity is difficult to control and engineer. Braiding technology can be used to produce a flat or a cylindrical structure; however, it does not easily lend to producing a stable hollow tube. Some of the current research in the biomedical field is focused on the use of absorbable and elastomeric yarns or fibers into woven materials, and the use of coatings such as albumin (See for example, Mehri, et. al., “Cellular Reactions to Polyester Arterial Prostheses Impregnated with Cross-Linked Albumin: In Vivo studies in Mice,” Biomat. 10(1): 56-58 (1989)), gelatin (Bordenave et al., 1989), and collagen (Frey, et al., “Prosthetic Implants,” U.S. Pat. No. 5,176,708 (1993) each incorporated herein by reference in its respective entirety).
[0030] The ideal artificial vasculature is one that is biocompatible, has the desired porosity and the required mechanical patency (i.e., the ability to resist permanent change in physical size, shape, structure, and properties).
[0031] Specifically, a bioreactor that permits cells to survive and function indefinitely is needed. Preferably this bioreactor enables cells to expand to high densities or be inoculated in the bioreactors at high densities to yield very high density, three-dimensional cultures and yet be able to survive long-term (weeks to months theoretically) by having the needed permeability for mass transfer of nutrients, gases, and wastes. Such a bioreactor is disclosed herein.
SUMMARY OF THE INVENTION
[0032] One aspect of the present invention is to provide varying embodiments of an apparatus which provides efficient oxygen delivery to large masses of cells in a bioreactor cell culture and transfer of beneficial biosynthetic cell products to the patient, and methods of use therefor, comprising multi-coaxial hollow fibrous structures assembled from woven textile fibers with a porosity that is governed by the weave design. Woven textile vasculature may be used to make hollow fibrous structures in hollow fiber bioreactors, as a cell surface for flatbed bioreactors, or in bags for three-dimensional culture systems for expanding and maintaining cells. The woven textile vasculature can be prepared from any fiber or combinations of fiber chemistries such as polyester, cotton (or other forms of cellulose), biodegradable fibers, etc. and with any weave design desired. The weave design and the chemistry of the fibers can be adjusted to provide the requisite permeability of the hollow fibrous structures for engineering of tissues.
[0033] A further aspect of the present invention is to provide an apparatus which permits cells to be contained in a thin annular space adjacent to continuously oxygenated and flowing nutrient medium that provides essential oxygen and nutrients and carries away metabolic products.
[0034] A further aspect of the present invention is to provide an apparatus for the collection of the biosynthetic products of large masses of cells in a bioreactor.
[0035] A further aspect of the present invention is to provide an apparatus to detoxify blood or plasma from a patient unable to remove or inactivate these toxins.
[0036] A further aspect of the present invention is to provide an apparatus to serve as a substitute liver.
[0037] A further aspect of the present invention is to provide varying embodiments of an apparatus which provides efficient oxygen delivery to large masses of cells in a bioreactor cell culture and transfer of beneficial biosynthetic cell products to the patient, and methods of use therefor.
[0038] A further aspect of the present invention is to provide vasculatures in the quality and the quantity ideally suited for the success of bioartifical livers.
[0039] A further aspect of the present invention is to provide bioreactors for use in academic and industrial research on cells.
[0040] A further aspect of the present invention is to provide a means for expansion of cells to high densities for use in biochemical/cell/molecular studies in research or clinical programs (e.g. cell therapies, gene therapies).
[0041] A further aspect of the present invention is to provide protein manufacturing in cells maintained in bioreactors.
[0042] A further aspect of the present invention is to provide organ assist devices (e.g. liver assist devices) to support patients with failing organs.
[0043] A further aspect of the present invention is to provide implantable tissues created ex vivo in woven tubes or woven bags prepared with biodegradable fiber chemistries.
[0044] A further aspect of the present invention is to provide vasculatures in a number of sizes and structures with properties ideally suited for maintaining and expanding cells in bioreactors.
[0045] A further aspect of the present invention is to provide biodegradable vasculatures in which a biodegradable polymeric fiber (such as polylactide) is used along with non-biodegradable material (such as polyester) in the proportion that sets the upper and lower limits of porosity and the transition from one to the other takes place at the desired rate.
[0046] A further aspect of the present invention is to provide elastomeric vasculatures that distend to the required amount in the transverse direction.
[0047] A further aspect of the present invention is to provide such structure for transport of fluid. A further aspect of the present invention is to provide grafts in size and properties suited for by-pass use which are compatible with the transverse elongations of body arteries; e.g. elongations of the level of 20-30%.
[0048] A further aspect of the present invention is to provide these characteristics through the use of elastomeric threads, or threads containing a blend of regular and elastomeric materials, as the weft yarns for construction of vasculatures.
[0049] The bioreactor of the present invention, when used as a bioartificial liver, has a modular design to allow an easy adjustment in liver functional capacity depending on the weight of the patient, whether that patient is child, man, or woman, and on the degree of remaining liver function in the patient. The bioreactor of the present invention further has both plasma and nutrient medium compartments to permit the biotransformation of toxins in the patient plasma and to enhance the effective transfer of biosynthetic products from the bioartificial liver to the patient. When used with liver or other cells, this invention is useful in the preparation of biosynthetic products for patients, in experimental use, and use as a supplemental biotransformation apparatus for detoxification of blood. The toxins in the blood can include, but are in no way limited to, metabolic wastes, products of cell or erythrocyte break-down, overdoses of ethical pharmacologic agents such as acetaminophen, and overdoses of illicit pharmacologic agents. Ease of manufacture of the invention enables cost-effective commercial development.
[0050] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0051] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0052] 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.
[0053] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0054] These together with other aspects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific aspects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] [0055]FIG. 1 illustrates woven vasculatures shown in flat and cylindrical forms.
[0056] [0056]FIG. 2 illustrates two means by which woven cylindrical tubes can be incorporated into the multicoaxial bioreactor, with the air chamber in the inner-most or outer-most compartments.
[0057] [0057]FIG. 3 illustrates the variables used in the implementation of Darcy's law.
[0058] [0058]FIG. 4 illustrates a liver lineage model.
[0059] [0059]FIG. 5 illustrates a multicoaxial bioreactor design.
[0060] [0060]FIG. 6 illustrates porous, biocompatible, biodegradable PLGA microcarriers for cells in bioreactors.
[0061] [0061]FIG. 7 illustrates physical analysis of the liver acinus.
[0062] [0062]FIG. 8 illustrates membrane fouling studies.
[0063] [0063]FIG. 9 illustrates the effect of no hemoglobin on oxygen mass transfer.
[0064] [0064]FIG. 10 illustrates a comparison of conventional with multicoaxial bioreactor.
[0065] [0065]FIG. 11 illustrates a hydrodynamic model.
[0066] [0066]FIG. 12 illustrates the use of MRI to determine axial flow.
[0067] [0067]FIG. 13 illustrates predicted pressure profile and optimum K 1 and K 2 .
[0068] [0068]FIG. 14 illustrates membrane fouling and its adverse effect on mass transfer.
[0069] [0069]FIG. 15 illustrates dead-end and cross flow configurations for the fouling study.
[0070] [0070]FIG. 16 illustrates results of dead-end and cross flow configurations for fouling study.
[0071] [0071]FIG. 17 illustrates results of dead-end and cross flow configurations for fouling study.
[0072] [0072]FIG. 18 illustrates fouling studies of woven vasculature incorporated into multicoaxial bioreactors.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0073] Annular space. The radial distance separating two adjacent vasculatures.
[0074] BAL. Bioartificial liver. Also, specific embodiments of the present invention: the scaled-up multi-coaxial vasculature bioreactor, the tight packed hollow vasculature bioreactor or the serially-linked bioreactor with a complement of liver cells, nutrient medium, and gases.
[0075] Bioreactor module. Coaxially-arranged semipermeable hollow vasculatures. One module forms the core of the multi-coaxial hollow vasculature bioreactor whereas the scaled-up multi-coaxial hollow vasculature bioreactor comprises many modules.
[0076] Biotransformation. The metabolic detoxification of blood or plasma by tissues or cells.
[0077] Fourth compartment. The compartment, if present, in a bioreactor embodiment that is bounded by the outside of the third hollow vasculature and the inside of the fourth, that is, adjacent, hollow vasculature, and is connected to two ports, the fourth compartment inlet port and the fourth compartment outlet port.
[0078] First compartment. The compartment in any of the bioreactor embodiments that is bounded in part by the inside of the first and innermost coaxial hollow vasculature and is connected to two ports, the first compartment inlet port and the first compartment outlet port.
[0079] Integral aeration. Exposure to a gas, typically air or oxygen with carbon dioxide, at almost all points along a flow path. Integral aeration is distinguished from serial aeration, in which a bubbler or gas exchange device is inserted at one point in the fluid circuit.
[0080] Manifold. A part of the bioreactor located at an end of the fibers and intended to physically separate compartments and split flow of fluids.
[0081] Microvasculature or microbore hollow fiber. A semipermeable hollow vasculature of 200 to 500 micrometer o.d.
[0082] Multi-coaxial hollow vasculature bioreactor. The bioreactor comprising three or more coaxially-arranged semi-permeable hollow vasculatures encased by a hollow housing.
[0083] Nutrient medium. The balanced electrolyte solutions enriched with sugars, trace minerals, vitamins, and growth enhancers. Each particular formulation is named by or for the formulator, sometimes with whimsical or non-illuminating designations. Nutrient media include, but are not limited to: RPMI 1640 (Roswell Park Memorial Institute, formulation #1640), Ham's F-12 (the twelfth formulation by Dr. Ham in his F series), DMEM (Dulbecco's modified Eagle's medium), and CMRL-1415 (Connaught Medical Research Laboratory formulation #1415). Nutrient media are routinely enhanced by addition of hormones, minerals, and factors known to those of ordinary skill in the art, including, but in no way limited to, insulin, selenium, transferrin, serum, and plasma.
[0084] One-sided multi-coaxial hollow vasculature bioreactor. The version of the multi-coaxial hollow vasculature bioreactor that has both inlet and outlet ports on the same end plate. This version is particularly adapted to NMR studies and to studies where access to all ports from one side is necessary.
[0085] Outermost compartment. The compartment in any of the bioreactors that is bounded by the outside of the outermost hollow vasculatures and the inside of the housing, and is connected to two ports, the outermost compartment inlet port and the outermost compartment outlet port.
[0086] Scaled-up multi-coaxial hollow vasculature bioreactor. The bioreactor comprising arrays of from about 20 modules to about 400 modules of coaxially-arranged semi-permeable hollow vasculatures, where the entire set of modules is encased by a hollow housing.
[0087] Second compartment. The compartment in a bioreactor embodiment that is bounded by the outside of the first and innermost coaxial hollow vasculature and the inside of the second, that is, adjacent, coaxial hollow vasculature, and is connected to two ports, the second compartment inlet port and the second compartment outlet port. In the one-sided multi-coaxial hollow vasculature bioreactor and in some dead-ended vasculature designs only one port provides access to the second compartment.
[0088] Serially-linked bioreactor. The system comprising a plurality of scaled-up multi-coaxial hollow vasculature bioreactors or of tight-packed hollow vasculature bioreactors, or a combination, in which two or more compartments are connected in a continuous and serial manner. In this context, each scaled-up bioreactor is referred to as a bioreactor subunit.
[0089] Third compartment. The compartment in any of the bioreactor embodiments that is bounded by the outside of the second hollow fiber and the inside of the third, that is, adjacent, coaxial hollow vasculature, and is connected to two ports, the third compartment inlet port and the third compartment outlet port.
[0090] Tight-packed hollow fiber bioreactor. The scaled-up bioreactor comprising arrays of from about 20 modules to about 400 modules of coaxially-arranged semi-permeable hollow vasculatures. Microvasculatures for aeration are arranged parallel and adjacent to the modules and the whole encased by a hollow housing.
[0091] Vasculatures. Vascular tubes made from woven fabric.
Vasculatures
[0092] Ideally, cells should be expanded and maintained in three-dimensional systems such as bioreactors. In a preferred embodiment, the cells behave as closely as is possible, to their behavior in the body. Although existing bioreactor designs have cell compartments in which cells can be three-dimensional, the bioreactor designs are flawed in how they supply nutrients and gases to the cells or how they manage cellular waste exchange or secretion of specialized cell products. The supply lines for the bioreactors make use of small, hollow tubes called hollow fibers that are prepared from a liquid that is pressed through sieves into an environment that yields a solid, hollow tube that can be made porous. The pore sizes are typically 0.1-0.7 microns. The pores in these hollow fibers quickly become clogged with material secreted by the cells when cells are placed in the bioreactor. The clogging results in an inability of the cells to survive and function in the bioreactors for very long. There is a loss of specialized function within 7 days for normal cells and a loss of viability within 21 days for normal cells and within 60 days for even highly malignant cancer cells. The invention disclosed herein permits the cells to survive and function indefinitely in the bioreactors. For a preferred embodiment of a bioreactor, see co-pending application Ser. No. 09/586,981 entitled “Bioreactor Design and Process for Engineering Tissue from Cells, with a priority filing date of Jun. 3, 1999, incorporated herein by reference in its entirety.
[0093] The present invention provides a means to grow healthy liver stem cell based tissues. These tissues can then be used as a bypass or an implant for patients with malfunctioning or failed livers. The use of vascular tubes constructed from fabrics, rather than the fibers obtained from extrusion technologies, provides the means for solving the membrane-fouling problem of Bioartifical Livers. Of the established vascular tubes, woven polyester materials are best because weaves as opposed to knits or braids can have their porosity easily modified and characterized, and polyester has sufficient mechanical patency due to its relatively high integrity and stability to most environments. FIG. 1 illustrates a preferred embodiment of woven vasculatures shown in flat and cylindrical forms. The general methods for the fabrication of such implants are set forth by Gupta et al., “Bio-mechanics of human carotid artery and design of novel hybrid textile compliant vascular grafts,” J. Biomed. Mat. Res. 34:341-349 (1997) and Mizelle et al., “Development of Biomechanically Compliant Arterial Grafts,” Proc. 15 th South. Biomed. Eng. Conf., IEEE, 110-113, (1996), each incorporated herein by reference in its respective entirety). Further, the use of vascular tubes made from woven fabrics that are composed of biodegradable materials or natural polymers results in a controlled increase in porosity and selective cell attachment focal points, respectively. The porosity can be modified by varying the spacing and the structure of the yarns in the weave, and the cylindrical shape and rigidity can be established by heat setting woven materials in the desired configuration under optimum conditions of temperature, pressure and residence time. In a preferred embodiment, the biodegradable material is extruded into fibers of high mechanical integrity and then used as a yarn for weaving into the desired vasculature.
[0094] Thus, bioreactors and cell compartments are set forth which make use of woven textile vasculatures. The woven textile vasculature is used as a hollow fibrous structure in hollow fiber bioreactors, as a cell surface for flatbed bioreactors, or as bags or tubes for three-dimensional culture systems, for use in expansion and maintenance of cells. The woven textile vasculature can be prepared from any fiber or combination of fiber chemistries such as polyester, polyolefin, cellulose, elastomer, biodegradable fibers, etc. and with any weave design desired. The weave design and the chemistry of the fibers can be adjusted to provide the requisite permeability/porosity of the hollow fibrous structures for engineering of tissues.
Bioreactor
[0095] The instant invention includes a modular multi-coaxial bioreactor, having in theory, no limit to the number of coaxial vasculatures. In a preferred embodiment a scaled-up multi-coaxial bioreactor comprises at least two sets of manifolds, at least three hollow vasculature sizes, at least two sets of endcaps, and a housing. This embodiment of the bioreactor contains at least four separated compartments. The modular design is composed of two sets of manifolds, with each pair of manifolds connected to each end of the vasculatures. There is a series of about 20 to about 400 holes coaxially arranged across the sets of manifolds and coaxially aligning the vasculatures. The manifolds optionally include flow distributors so that fluid and gas phase flow rates through the vasculatures are approximately uniform. The vasculature manifold assemblies are attached radially from the largest to the smallest diameter vasculatures, and axially from the smallest to the largest diameter vasculatures. Vasculatures with smaller diameter are inserted into vasculatures of larger diameter and the respective manifolds are sealed together.
[0096] The bioreactors of the current invention advantageously combine ‘integral’ oxygenation with defined diffusion distances, have ports to accommodate potential bile duct formation, and/or are easily scalable. Integral oxygenation permits efficient mass transfer of dissolved gases and control of pH. Defined diffusion distances permit predictable axial and radial physico-chemico-biological parameters such as shear forces, availability of nutrients, and pH. In use with patients, one or more of the at least four compartments can be used for patient blood plasma while another can be used to perfuse cells with integrally oxygenated media. Optionally, two or more bioreactor units are attachable in series so that toxins can perfuse out of plasma radially through the cell mass in one unit and infuse synthetic factors in the next unit. There is the potential for the biliary system to develop using the ports as the bile duct exit ports.
[0097] [0097]FIG. 2 illustrates two exemplary formats wherein woven cylindrical tubes are incorporated into the multicoaxial bioreactor. FIG. 2A illustrates the air chamber in the outermost compartment. FIG. 2B illustrates the air chamber in the inner-most compartment.
[0098] As shown, FIG. 2A illustrates a multi-coaxial fiber unit according to the instant invention comprising a plurality of compartments. Inner vasculature 202 provides intracapillary space or first compartment 204 for the receipt of standard media or plasma. Middle vasculature 206 provides annular space or first middle compartment 208 for the containment of cells such as liver cells. Outer vasculature 210 provides extracapillary space or second middle compartment 212 for the receipt of media. Housing 214 defines the outermost perimeter of the multi-coaxial fiber unit. Space or outermost compartment 216 between housing 214 and outer vasculature 210 allows for the receipt of a gas.
[0099] Similarly, in FIG. 2B inner vasculature 202 provides intracapillary space or first compartment 204 for the receipt of a gas. Middle vasculature 206 provides annular space or first middle compartment 208 for the containment of cells such as liver cells. Outer vasculature 210 provides extracapillary space or second middle compartment 212 for the receipt of media.
[0100] [0100]FIG. 2C illustrates a photographic view of an embodiment of the woven fabric incorporated into a multi-coaxial bioreactor, with air chamber in the outermost chamber, illustrating inner vasculature 202 , middle vasculature 206 , housing 214 , and aeration fiber 218 .
[0101] [0101]FIG. 2D illustrates openings leading to ports to allow for the movement of materials. Innermost port(s) 220 allow for the flow of media or plasma through the bioreactor. First middle port(s) 222 allow for the inoculation of cells into, or flow of cells through, the bioreactor. Second middle port(s) 224 allow for the flow of media through the bioreactor. Lastly, outermost port(s) 226 allow for the flow of gas through the bioreactor. Alternative uses of ports are also envisioned. For example, media can flow through port(s) 226 , cells into, or through, port(s) 224 , media or plasma through 222 , and oxygen or other gases through 220 .
Identification of Optimum Basic Vasculature for BAL Bioreactor
[0102] Property-structure correlation and hydraulic permeability-tissue growth study are used to identify the specifications that provide an ideal stable vasculature for bioartificial liver application(s) and the technological/structural settings that produce such vasculatures on a consistent basis. Several different polyester yarns, differing in linear density and number of filaments are used. Vasculatures of a number of different tightnesses are woven from each yarn. Vasculatures of two different diameters, for use as co-axial bioreactors, are woven. The heat setting conditions that yield the most stable vasculature configuration are identified. The tubes are characterized for porosity, hydrolic permeability, compressional resilience and pore size distribution. Porosity is determined through the use of a structural model relating to the LaPlace equation, which is based on the spacings between the yarns, the diameters of the yarns, and the geometry of the plain woven fabric. Hydrolic permeability is determined experimentally using Darcy's equation. (Darcy's Equation is a formula stating that the flow rate of water through a porous medium is proportional to the hydraulic gradient, and is defined further below.)
[0103] Compressional resilience is determined using an Instron tensiometer, equipped with a compression cell. Pore size distribution is determined using a liquid extrusion device and flat specimens having the same specifications as the tubular vasculatures.
[0104] Darcy's Equation permits one to estimate the correlation between pressure difference and radial flow given the hydraulic permeabilities of the material under consideration. The model assumes incompressible and Newtonian fluid, that the axial pressure gradient is negligible, and that the flow rate across the vasculatures is constant. Deriving this equation for two concentric hollow vasculatures the following relationship is obtained.
Δ P = Q 2 π L [ ln ( r b r a ) K 1 - ln ( r d r c ) K 2 ] ( II )
[0105] [0105]FIG. 3 defines the variables used in the equation. Q is radial flow rate from compartment 302 characterized by a hydrostatic pressure P 1 , through pores in fiber 304 characterized by hydraulic permeability K 1 , through intermediate compartment 306 , then through pores in second fiber 308 characterized by hydraulic permeability K 2 to compartment 310 characterized by hydrostatic pressure P 2 .
[0106] The values obtained relating to these variables and characterizations are correlated to provide a structure-property correlation model. Thus, data from the bioartificial liver bioreactor study disclosed herein provides a model for selecting optimum specifications for producing the vasculature for use in varying applications, without the need for experimental determinations. These applications include but are not limited to bioreactors, organ assist devices, implantable tissues, grafts, and the like.
Development of Next Generation Vasculatures for BAL Bioreactor Application
[0107] Here, biodegradable and transversely compliant vasculatures are developed. The optimum Basic Vasculature for Bioartificial Liver Bioreactor identified as described above, is used. Biodegradable fibers combined with nonbiodegradable fibers are used as warp and weft elements in construction of tubes. (Warp is the set of fibers that run along the length of the material and weft is the set of fibers that are inserted from the side and cover the width. Warp is wound on a beam and run threaded through a loom. Weft is inserted through warp by lifting and lowering alternative warp threads so that there is interlacing.) The rate at which these degrade and the tissue reaction they cause is examined using standard procedures. A polymer is selected and combined with polyester in novel ways for the construction of grafts. The amount of biodegradable fiber used relative to non-biodegradable provides the means for setting the initial and final limits of porosity for the vasculature.
[0108] A second variant is the development of vasculatures with an elastomer combined with polyester for use as weft yarn. The amount and type is varied in order to get different degrees of transverse stretchabilities and, thus, transverse compliances. The level of transverse compliance can be characterized on a specially equipped Instron tensiometer.
Optimization of Hydraulic Permeability and Flow Configuration
[0109] As disclosed herein, in a preferred embodiment, liver progenitors are expanded on biodegradable microcarriers in the space between the two coaxial fibers to generate the entire liver maturation lineage. Thus, the loading density of the progenitors per fiber pair must be minimized to optimize the number of bioartificial livers per human donor. This requires the resolution of two engineering problems. First, the optimum hydraulic permeability of the two coaxial vasculatures sandwiching the cell mass must be determined. Second, the optimum flow configuration to minimize or compensate for membrane fouling and corresponding decrease in hydraulic permeability with cell growth must be determined. In a preferred embodiment, the hydraulic permeability values of the two fibers are similar, such that a peristaltic type of flow configuration can be used to maintain clean nutrient and waste paths.
[0110] [0110]FIG. 4 illustrates a liver lineage model. In a preferred embodiment, progenitors or stem cells feed the lineage of the bioreactor in the same fashion as in the liver acinus. Thus an architecture is provided similar to that used in the liver acinus, wherein progenitors are used to seed the bioreactor and with the correct flow of blood, will result in maturation similar to that which occurs in the liver.
[0111] [0111]FIG. 5 illustrates a multicoaxial bioreactor design. Through the use of this design a preferred flow is achieved.
[0112] [0112]FIG. 6 illustrates porous, biocompatible, biodegradable polylactide glycolic acid (PLGA) microcarriers for cells in bioreactors. In a preferred embodiment, the progenitors referred to in FIG. 4, above, are seeded onto these PLGA microcarriers/beads.
[0113] [0113]FIG. 7 illustrates a physical analysis of the liver acinus, providing an illustration of Darcy's law. Due to the large distance, diffusion alone cannot provide needed oxygen. Thus, mass transfer is dependent on convention and pressure differentials.
[0114] [0114]FIG. 8 illustrates membrane fouling studies. As shown, pores in the polypropylene fibers clog quite rapidly causing an increase in pressure and cell death.
[0115] [0115]FIG. 9 illustrates the effect of no hemoglobin on oxygen mass transfer. This figure illustrates hemoglobin's efficiency in providing oxygen. It also augments the fact that hemoglobin is the preferred oxygen carrier, and that one cannot depend upon diffusion to oxygenate, particularly when the carrier is water. However, due to the velocity used in the preferred embodiment the drop is not as great.
[0116] [0116]FIG. 10 illustrates a comparison of a conventional, with a multicoaxial, bioreactor.
[0117] [0117]FIG. 11 illustrates a hydrodynamic model, providing an application of Darcy's law.
[0118] [0118]FIG. 12 illustrates the use of MRI to determine axial flow.
[0119] [0119]FIG. 13 illustrates predicted pressure profile and optimum K 1 and K 2 . As shown, 100 percent viability is obtained with a pressure of 103 mm Hg. At a pressure of 517 mm Hg the viability reduces to 40 percent. the average pressure in sinusoid is about 5 to 10 mm Hg. While the average sinusoidal blood flow is 0.01 cm/sec.
[0120] [0120]FIG. 14 provides photographic illustrations of membrane fouling and its adverse effect on mass transfer. As stated, membrane fouling causes pressure increase and cell death.
[0121] [0121]FIG. 15 illustrates dead-end and cross flow configurations used for the fouling study.
[0122] [0122]FIG. 16 provides results of dead-end and cross flow configurations for fouling study.
[0123] [0123]FIG. 17 provides photographic results of dead-end and cross flow configurations for fouling study.
[0124] [0124]FIG. 18 provides photographic results of fouling studies of woven vasculature incorporated into multicoaxial bioreactors.
[0125] The bioreactors of the current invention advantageously combine ‘integral’ oxygenation with defined diffusion distances, have ports to accommodate potential bile duct formation, and/or are easily scalable. Integral oxygenation permits efficient mass transfer of dissolved gases and control of pH. Defined diffusion distances permit predictable axial and radial physico-chemico-biological parameters such as shear forces, availability of nutrients, and pH. In use with patients, one or more of the compartments can be used for patient blood plasma while another can be used to perfuse cells with integrally oxygenated media. Optionally, two or more bioreactor units are attachable in series so that toxins can perfuse out of plasma radially through the cell mass in one unit and infuse synthetic factors in the next unit. There is the potential for the biliary system to develop using the ports as the bile duct exit ports.
EXAMPLES
[0126] The following specific examples are provided to better assist the reader in the various aspects of practicing the present invention. As these specific examples are merely illustrative, nothing in the following descriptions should be construed as limiting the invention in any way. Such limitations are, or course, defined solely by the accompanying claims.
1) NMR Analysis of Liver Cell Function in the One-Sided Multi-Coaxial Hollow Fiber Bioreactor
[0127] Sprague-Dawley rats are anesthetized with pentobarbital (50 mg/kg intraperitoneally). The liver is exposed by a ventral midline incision and the portal vein is cannulated for infusion of cell dissociation solutions. The liver cells are dissociated by sequential infusions of ethylene diamine tetraacetic acid (50 mM) and collagenase (1 to 20 mg/ml) in Krebs-Henseleit buffer, pH 7.4. Adequate perfusion of the liver is indicated by uniform blanching of the liver. Isolated cells are collected and introduced into the cell compartment of the one-sided multi-coaxial hollow fiber bioreactor.
[0128] Nuclear magnetic resonance (NMR) is performed using an NMR probe design composed of two Helmholtz coils photo-etched onto flexible copper-coated composite. The two coils, suitably insulated, are wrapped around the bioreactor and oriented orthogonally to each other. The inner coil is tuned to 81 MHz for study of energy metabolism as measured by changes in the spectrum of 31 P. The probe and bioreactor assembly is placed on a centering cradle in the isocenter of the magnet for optimal comparison of spectra. The aerated nutrient medium is supplied to the first compartment inlet port of the bioreactor. Integral aeration is provided by flow of a 95% air with 5% CO2 mix through inlet port 4, associated with the outermost or fourth compartment of the bioreactor. Ham's F-12 nutrient medium is pumped through compartment 3 with a peristaltic pump. The temperature of the reservoir of medium is maintained at 42° C. with a temperature controlled water bath, so as to maintain the bioreactor temperature at 37° C. The NMR signal from γ-31P nucleotide triphosphates and B- 31 P nucleotide diphosphates, other cellular components of energy metabolism, and biosynthesis are analyzed. The NMR signal is monitored as a function of mass transfer dictated by gas flow rate and oxygen percentage, nutrient medium flow rates, and cell loading densities.
2) Oxygen Flux in the Absence of Cells
[0129] Oxygen microelectrodes are connected to a transducer and Workbench™ software, and then calibrated against known standards. The calibrated oxygen microelectrodes are placed at intervals along the fiber length in the second compartment of the multi coaxial hollow fiber bioreactor. A reservoir of plasma is attached to the inlet port of the first compartment, the innermost compartment of the multi-coaxial hollow fiber bioreactor. A reservoir of RPMI 1640 nutrient medium is attached to the inlet port of the third compartment. Peristaltic pumps are arranged in-line to circulate the plasma and nutrient medium. The second compartment is also filled with nutrient medium. The signal from each microelectrode is acquired at ten-second intervals and processed by the software for conversion to oxygen tensions. The gas phase is switched between 95% air with 5% CO 2 and 95% N 2 with 5% CO 2 at selected intervals. Rates of depletion and recovery of oxygen tension are measured at different flow rates to evaluate oxygen flux in the absence and presence of cells.
3) Use as an Extracorporeal Liver Assist Device for Evaluation of Bilirubin
[0130] The Gunn rat model, (the animal model for Crigler Naijar syndrome in humans) is an ideal model for demonstrating the efficacy of the bioreactor as an extracorporeal liver assist device. The Gunn rat has a defect inherited as an autosomal recessive trait in Wistar rats. The defect, present in homozygous recessive animals, is in the gene encoding UDP glucuronosyltransferase, an enzyme necessary for the conjugation and biliary excretion of bilirubin (a breakdown product of hemoglobin in senescent red blood cells). The Gunn rat therefore cannot conjugate and excrete bilirubin and becomes hyperbilirubinemic, having serum bilirubin levels of about 5-20 mg/dL, compared with 1 mg/dL in normal rats.
[0131] A scaled-up multi-coaxial hollow fiber bioreactor is used as an extracorporeal liver assist device with Gunn rats. The livers of heterozygous (phenotypically normal) Gunn rats are perfused and the cells are isolated. The cells are suspended in Dulbecco's Modified Eagle Medium (DMEM) and 10 9 cells are introduced into the second compartment of the bioreactor. Blood from the femoral artery of a Gunn rat (total average blood volume ca. 10 to 12 mL) is perfused through the third compartment of the bioreactor, separated from the liver cell annular space by the wall of the hollow fiber, at a flow rate of about 0.6-0.8 mL/min with the aid of a peristaltic pump. At the same time, DMEM is flowed through the compartment one of the bioreactor at a flow rate of about 0.5 mL/min. Blood flowing out of the bioreactor is returned to the Gunn rat.
[0132] The levels of unconjugated and conjugated bilirubin in blood exiting the bioreactor are determined over the course of six hours using the Sigma Total and Direct Bilirubin assay system according to the instruction supplied by Sigma Chemical Company (Sigma Procedure #522/553).
4) Biosynthetic Hepatocyte Function in a Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor/BAL
[0133] Isolated liver cells are further separated by zonal centrifugation in sucrose density gradients. Density fractions corresponding to parenchymal cells are collected and introduced into the aseptic cell compartment (compartment 2) of the scaled-up multi-coaxial bioreactor.
[0134] The parenchymal cells are maintained by circulating warm Ham's F-12 nutrient medium through compartments 1 and 3, and 95% air with 5% CO 2 through the fourth compartment. The effluent from the first compartment is collected and fractions are analyzed for parameters of biosynthetic liver function. Albumin synthesis is measured by enzyme-linked immunosorbent assay.
5) Biotransformatory Function in a Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor/BAL
[0135] Isolated liver cells are further separated by zonal centrifugation in sucrose density gradients. Density fractions corresponding to Kupffer cells are collected and introduced into the second compartment (cell compartment) of the scaled-up multi-coaxial hollow fiber bioreactor.
[0136] The cells in the bioreactor are maintained by circulating DMEM (without Phenol Red) through the inlet and outlet ports for the first and third compartments and 95% air with 5% CO2 through the ports for the fourth compartment. The cells are permitted to adhere within the compartment, followed by the introduction of free hemoglobin (1-10 mg/ml) into the first compartment. The appearance of hemoglobin and the metabolic products of hemoglobin in the third compartment are monitored with an in-line spectrophotometer.
6) The Serially-Linked Bioreactor with Human Cells for Patient Treatment
[0137] Human hepatoma C3A cells are cultured as described (Mickelson, J. K. et al. Hepatology 1995, 22, 866) and introduced into all the second compartments of the serially-linked bioreactor. Nutrient medium and 95% air with 5% CO 2 are pumped through the third and outermost compartments, respectively, and cell growth is monitored by glucose utilization. When the cells have attained the plateau, or stationary, growth phase, the albumin output is monitored.
[0138] The blood of a patient suffering liver failure is separated into plasma and cells by plasmapheresis and the plasma is pumped into the first compartment of the first bioartificial liver subunit. A portion of the plasma flows radially from the first compartment through the cell compartment to the third compartment to form biotransformed effluent. The plasma exits the first compartment of the first bioartificial liver subunit and flows into the third compartment of the second bioartificial liver subunit. The biotransformed effluent from the third compartment of the first bioartificial liver subunit and flows into the first compartment of the second bioartificial subunit. Radial flow in the first bioartificial liver subunit detoxifies a portion of the plasma and radial flow in the second bioartificial liver subunit contributes biosynthetic products to the plasma to form supplemented plasma. Vital signs, jaundice, and blood level of toxins are monitored at regular intervals. Flow rates of plasma and medium are adjusted to maximize biotransformation of circulating toxins. Survival of the patient is measured.
7) Extracellular Matrix Effects on Differentiation of Hepatocytes in the Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor
[0139] Parenchymal cells are isolated by zonal centrifugation, suspended in reconstituted basement matrix from the Englebreth-Holm-Swarm mouse sarcoma, and introduced into the second compartment (cell compartment) of the scaled-up multi-coaxial bioreactor. The hepatocytes are arrested in a G 0 state by adhesion to the basement matrix, and are maintained in the normal hepatic phenotype.The highly differentiated state is characterized by synthesis of albumin and hepatic transcription factors such as C/EBP−. The parenchymal cells are maintained by circulating warm Ham's F-12 nutrient medium through the first and third compartments, and 95% air with 5% CO 2 through the fourth compartment. The effluent from the first compartment is collected and fractions are analyzed for parameters of biosynthetic liver function. Albumin synthesis is measured by enzyme-linked immunosorbent assay.
8) Growth and Differentiation of Human Hepatocytes in the Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor
[0140] Human parenchymal hepatocytes are isolated by the method of (Block, G. D. et al. J Cell Biol 1996, 132, 1133) and introduced into the second compartment of the scaled-up multi coaxial hollow fiber bioreactor. The parenchymal cells are propagated by exposure to hepatocyte growth factor (HGF/SF), epidermal factor, and transforming growth factor alpha in nutrient medium HGM introduced into the third compartment and air:CO 2 (19:1) introduced into the fourth compartment. The ratio of transcription factor C/EBP to C/EBP is decreased by this process and the cell synthesis of albumin also is decreased. The medium flowing through the third compartment is modified to include transforming growth factor and epidermal growth factor to induce differentiation of the cells and synthesis of albumin, in the formulation described (Sanchez, A. et al. Exp Cell Res 1998, 242, 27).
9) Biosynthesis of Hormones and Factors in the Scaled-Up Multi-Coaxial Hollow Fiber Bioreactor
[0141] Parathyroid glands are obtained aseptically, minced, and treated with collagenase as described (Hornicek, F. L. et al. Bone Miner 1988, 4, 157). The dispersed cells are suspended in CMRL-1415 nutrient medium supplemented with fetal bovine serum and introduced into the second compartment of the scaled-up multi-coaxial bioreactor. A mixture of 95% air with 5% CO 2 is pumped through the fourth port. Warm medium is pumped through the first and third ports and the effluent from the chamber is concentrated by ultrafiltration for collection of parathyroid hormone, parathyroid hypertensive factor, and other cell products. The hormones and factors are purified by immunoprecipitation and chromatography.
10) The Five Compartment Serially-Linked Bioreactor with Human Cells for Patient Treatment
[0142] Human hepatoma C3A cells are grown as in example VI, above, except in the third compartment of a five-compartment serially-linked bioreactor. The innermost compartment (compartment 1) and the outermost compartment (compartment 5) are suffused with the gas mix, 95% air with 5% CO 2 . Nutrient medium is pumped through the second and fourth compartments, respectively, and cell growth is monitored by glucose utilization. When the cells have attained the plateau, or stationary, growth phase, the albumin output is monitored.
[0143] The blood of a patient suffering liver failure is separated into plasma and cells by plasmapheresis and the plasma is pumped through the serially connected second compartments of the bioreactor. Vital signs, jaundice, and blood level of toxins are monitored at regular intervals. Flow rates of plasma and medium are adjusted to maximize biotransformation of circulating toxins. Survival of the patient is measured.
[0144] Various publications have been referred to throughout this application. The disclosures of these publications in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.
[0145] The purpose of the above description and examples is to illustrate some embodiments of the present invention without implying any limitation. It will be apparent to those of skill in the art, in light of this teaching, that various modifications and variations may be made to the composition and methods in the present invention to generate additional embodiments without departing from the spirit or scope of the invention. The specific composition of the various elements of the bioreactor system, for example, should not be construed as a limiting factor. Accordingly, it is to be understood that the drawings and descriptions in this disclosure are proffered to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
[0146] 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. Thus, the invention is properly limited solely by the claims that follow. | A bioreactor for three-dimensional culture of liver cells is disclosed. The device is characterized by the use of textile vasculatures. A model and method for optimizing vasculature parameters is also disclosed. Liver acinar structure and physiological parameters are mimicked by sandwiching cells in the space between the two innermost woven textile hollow fibers, and creating radial flow of media from an outer compartment, through the cell mass compartment, and to an inner compartment. The theoretical optimum hydraulic permeability for the two innermost semi-permeable membranes is determined based on physiological hepatic sinusoidal blood flow and pressures. Experimental studies using a flow rate and pressure monitoring systems in conjunction with phase-contrast velocity-encoded MRI confirm theoretical results. Novel woven vascular tubes with optimum hydraulic permeability are disclosed for culturing hepatocytes in the multi-coaxial bioreactor. | 2 |
This patent application is a continuation of application Ser. No. 08/310,958, filed Sep. 23, 1994, since abandoned, which application was a continuation-in-part of application serial no. 08/091,096 filed Jul. 13, 1993, since abandoned, and entitled FIBER GLASS FIRE RETARDANT NONWOVEN MAT AND METHOD OF PREPARING SAME.
TECHNICAL FIELD
This invention pertains to fire retardant fiber glass nonwoven mats.
BACKGROUND
Fiber glass mat is made in many weights and sizes and can be used for a variety of applications. A general discussion of glass fiber technology is provided in "Fiber Glass" by J. Gilbert Mohr and William P. Row, Van Nostrand, Reinhold Co., New York 1978, which is hereby incorporated by reference. Fiber glass mats of the nonwoven type are generally known.
U.S. Pat. No. 4,145,371 by Tohyama et al discloses a flame-retardant textile fiber consisting of PVA and an amino resin. The amino resin is a condensation product of formaldehyde with melamine and other amino compounds selected from urea, dicyandiamide and benzogranamine. The use of phosphorous additives is suggested to enhance the flame-retardant characteristics of the fiber. The addition of dicyandiamide was found to improve the color fastness of the fiber.
It is known to use relatively large amounts of a phosphorus containing compound to produce a fire retardant condensate as taught by Goulding et al in U.S. Pat. No. 4,159,139. There a melamine-aldehyde is reacted with a relatively large amount of at least one oxyacid of phosphorous in a condensation reaction to form the fire retardant, the inorganic phosphorus compound being added in sufficient amounts that phosphorous is present in the resulting condensation product in the ratio of 0.4-1.7 moles of phosphorus for every mole of melamine.
U.S. Pat. Nos. 4,560,612 and 4,609,709 assigned to Owens-Corning Fiberglas relate to a binder composition containing a urea-formaldehyde resin, a styrene-butadine latex copolymer and a fully methylated melamine-formaldehyde resin. The binder is applied to glass fiber mats used in the production of roofing felts. The utilization of a fully methylated resin provides improved moisture resistance over prior art binders.
U.S. Pat. No. 4,183,832 by Munier et la teaches a method of preparing a melamine formaldehyde resin that has an improved shelf-life and a low free formaldehyde content. The resin is used to increase the tensile strength and suppleness of 100% glass fiber mats.
U.S. Pat. No. 4,960,826 assigned to Borden, Inc. discloses melamine-containing resole, resitol and resite compositions containing at least one phenolic compound, at least one aldehyde compound and at least one free melamine. The compositions are primarily used in applications where hard binders are required, as in engineered, shaped or molded glass fiber containing fabricated parts, e.g. using that invention, C-stage products can be resistant to punking or thermal shock.
In the manufacture of wet laid nonwoven mats containing a large proportion of glass fibers, typically used binders such as urea-formaldehyde resins or polyvinyl acetate, styrene butadiene rubber and acrylic copolymer latexes, will burn. Even polyvinyl chloride resin systems, if not high enough in chloride, will burn and may emit hydrogen chloride and heavy smoke.
It is an object of the present invention to make nonwoven fiber glass fire retardant mats that contain a binder with a very high nitrogen content which increases the fire retardancy of the mat.
It is also an object of the present invention to make fire retardant fiber glass nonwoven mats that do not require or contain additional flame retardants such as phosphates, other than catalytic amounts of phosphorus compounds, ammonium compounds, aluminum compounds or chlorinated compounds whether inorganic or organic.
SUMMARY OF THE INVENTION
Described herein are fiber glass mats and papers comprising a nonwoven glass fiber matrix bonded together with a fire retardant melamine resin binder composition having at least about 27% by weight nitrogen (N) in the dried, but uncured resin and wherein the mat or paper has no more than a catalytic amount of any phosphorus compound present, a catalytic amount being generally less than 1.5 wt percent of the resin, the ratio of resin binder in the mat or paper not exceeding about 0.6 of the N content. Also described is a method of improving the fire retardancy of a nonwoven fiber glass mat comprising the steps of providing an aqueous melamine based resin binder; applying the binder to nonwoven fiber glass mat, wherein the mat has more than about 27% by weight of (N) in the dried, but uncured resin binder and wherein the ratio or percentage of resin in the finished mat or paper does not exceed about 0.6 of the N content of the resin, any phosphorous compounds present do not exceed catalytic amounts which normally are less than about 1.5% by weight of the melamine resin. Further embodiments of the invention include modification of the above mat compositions wherein up to 20% of the melamine based resin is replaced with urea formaldehyde resin binder and mats with binders containing pigments, like carbon black, in amounts up to 25% based on the weight of the resin binder, so long as any phosphorous compounds present do not exceed catalytic amounts as described above.
The preferred mats of the present invention contain 60-90 weight percent of glass fibers, 10-30 weight percent of melamine based binder, and up to 15 weight percent of organic fibers, based on the weight of the finished mat. The preferred nitrogen content of the melamine resin used in the present invention is at least 35 percent with at least 40 percent being better and at least 45 percent being the most preferred for flame resistance, based on the uncured resin after essentially all of the solvents have been removed.
DETAILED DESCRIPTION OF THE INVENTION
Melamine formaldehyde resins are well known resinous materials. The composition of melamine formaldehyde resins and the various reaction mechanisms of the resins have been described in available literature. One reference entitled "Reaction Mechanism Melamine Resins" by Werner J. Blank, JOURNAL OF COATINGS TECHNOLOGY, Vol. 51, n.656, Sept. 1979. pp. 61-70, discusses alkylated amino formaldehyde resins, which is hereby incorporated by reference.
The glass fibers which can be used to make mats can have various fiber diameters and lengths dependent on the strength and other properties desired in the mat as is well known. It is preferred to use glass fibers having diameters in the range of 3 to 20 microns, most preferably 10 to 14 microns. Normally the glass fibers used all have about the same length, such as 0.75±0.08 inch, but fibers of different lengths and diameters can also be used to get different characteristics in a known manner. Fibers up to about 3 inches in length can be used in a wet process for making fiber glass mats. Generally the longer the fiber, the higher the tensile and strengths of the mat, but the poorer the fiber dispersion. A process for making nonwoven fiber glass mats is described in U.S. Pat. No. 4,112,174, which reference is hereby incorporated by reference. Any known method of making nonwoven mats can be used.
The preferred technique for the making of mats of the present invention is forming a dilute aqueous slurry of fibers and depositing the slurry on to a moving screen forming wire to dewater the slurry and form a wet nonwoven fibrous mat, transferring the wet, unbonded mat to a second moving screen running through a binder application saturating station where the melamine resin based binder, usually in aqueous solution, is applied to the mat, removing excess binder, and drying the unbonded, wet mat and curing (polymerizing) the melamine based resin binder bonding the fibers together in the mat. Preferably, the aqueous binder solution is applied using a curtain coater or a dip and squeeze applicator. In the drying and curing oven the mat is subjected to temperatures of 250-450 or 500 degrees F. for periods not exceeding 4 or 5 minutes. Alternative forming methods include the use of well known cylinder forming and "dry laying".
It has been discovered that melamine formaldehyde resins containing at least about 27% by weight nitrogen in the dry, but uncured, resin are resistant to a vertically climbing flame when used as the binder in fibrous glass mats. Such resin binders with such high nitrogen contents do not require conventional flame retardants like antimony trioxide, organic phosphates, phosphorous compounds, aluminum trihydrate, ammonium chloride, chlorinated oils and paraffins, etc. While a minimum of about 27% nitrogen content in the dry, but uncured, melamine formaldehyde resin is critical to the invention, resins having at least 29% perform better, resins having at least 35% are preferred and those with at least 40% are most preferred for flame resistance. These percentages are based on the uncured resin after essentially all of the solvents have been removed.
Fibrous glass papers or mats, or papers and mats containing a mixture of glass fiber and other fibers, when made using the particular kinds of melamine formaldehyde resins, with or without up to 20% urea, described above and when used in critical amounts are not only strong flexible and tough, but are also fire retardant or non-burning. It has been discovered that the nitrogen content in the raw, relatively unpolymerized melamine formaldehyde resin along with the ratio of resin content in the mat divided by this nitrogen content in the dry, but uncured resin is critical to achieving the fire retardancy characteristics in the mat or paper products. The percent of nitrogen in the raw resin is usually achieved by controlling the ratio of formaldehyde to melamine, which can theoretically range from six-to-one down to one-to-one. This provides a corresponding nitrogen content (on a solid resin basis) of approximately 27-70% by weight. These resins are frequently etherified with alkanols, such as one-to-four carbon atoms, preferably methanol or ethanol, to improve water solubility. Ratios of two-to-one to one-to-one (formaldehyde to melamine) resins are historically poor for water solubility. Etherification generally improves solubility in water.
The resins used in the present invention can contain catalytic amounts of a catalyst to speed curing or polymerization at elevated temperatures. However, more than catalytic amounts of most catalysts, such as phosphorus compounds, cannot be used because it would cause premature polymerization of the resin in storage or in the mat process prior to drying which would destroy the fiber bonding capability essential for the resin binder. For this reason, no more than 1.5 weight percent, based on the weight of the resin, of a phosphorus compound, such as a buffered phosphate, can be present in the aqueous resin solutions used in this invention.
The preferred mat compositions of the present invention are described in Table 1 below. The percentages in Table 1 are based on the total weight of the finished mat.
TABLE 1______________________________________Ingredient Weight Percent Preferred Wt. Percent______________________________________Melamine based binder 5-50 10-30Glass fibers 10-95 60-90Organic fibers 0-50 0-15______________________________________
The melamine based binder can also contain up to 25% by weight of the melamine based binder, of a modifier like ethylene vinyl chloride or a PVC latex to make the mat more flexible and to bond in pigments like carbon black in amounts up to about 25%, based on the weight of the resin binder. Also, up to 20% of the melamine based resin binder can be replaced with urea formaldehyde. Within these modification limits the finished mats will retain the good fire retardancy and other properties.
Organic fibers for the aforementioned composition is meant to include natural, thermoplastic, thermoset or miscellaneous fibers. By nature is meant wood, cotton, cellulose derivatives such as rayon or acetate fibers. By thermoplastic is meant polyester, polyamide, olefinic, polyimides, etc. Thermosets may be phenolic, polyester, etc. Carbon fiber is an example of a miscellaneous fiber.
Preferably, the binder is a melamine formaldehyde condensate polymer commercially available. This binder can be used with or without additional additives. Additives such as pigments, defoamers, catalysts, plasticizers and processing aids, within the limitations defined herein, can be used. The melamine formaldehyde polymer may also be "fortified" with nitrogen containing compounds such as urea, melamine, dicyandiamide and guanidine.
After application of the binder to the mat of glass fibers, the mat is then dried and cured to at least a B-stage product. By this is meant that the glass fiber composition has almost all of the water removed from the binder. The B-stage cured mat can be later hot molded into a desired shape, usually after laminating with B-staged fiber glass wool insulation in a known manner, and the resin fully cured to retain the compressed shape. Such mats are useful in molding products such as automotive hoodliners, dash insulators, etc.
Preferably the mat is fully dried and the binder is fully cured. The curing of the glass fiber mat with a binder applied thereto as described herein is generally very quick depending upon the temperature and time treatment. Generally, the temperature ranges from about 300 to about 500 degrees F. with a period of time at that temperature of less than 5 minutes, preferably from about 10 seconds to 2 minutes, and most preferably from about 1 to 10 seconds.
When using the B-staged mat to make a laminate such as automotive headliners or hoodliners, a curing time of less than 90 seconds is preferred. Presently automotive headliners and hoodliners require elevated molding temperatures to have cure cycle times competitive to non-fiber glass products. The inventive composition provides the same cure cycle process time with much lower molding temperatures. For example, a hoodliner made using prior art mats bound with standard thermoset resins will have a cure cycle time of 20 seconds when mold temperatures are 650 degrees F. This high temperature is too high for aluminum molds requiring much more expensive steel molds. When using the B-staged mat of the present invention, mold temperatures can be reduced to 425 degrees F. allowing the use of aluminum tools.
In Example 1 below are described typical products of the present invention. All percentages are by weight unless otherwise stated.
EXAMPLE 1
A. A mat having a basis weight of 6.8 grams per square foot (gsf) containing 18% binder, 4% fine glass fiber with diameters of less than 5 microns, 7% polyester fiber of 3 denier and 0.5 inch length, and 71% of 13 micron glass fiber of 0.75 inch length was made on a wet mat machine The binder was Astromel CR-1, trademark of the Borden Chemical Company. This binder is an aqueous solution of melamine formaldehyde having a solids content of about 80%, a pH of 9.0±0.5 and containing 31-32% nitrogen, based on the weight of the dry, uncured resin. This resin was catalyzed with about 1±0.5% of a buffered phosphate catalyst, usually about 0.5% in a known manner. Other catalysts can be used to accelerate the cure as is well known in the art of making resin binders for bonding fiber glass mats in known wet mat processes. After the mat was formed and the binder solution was applied, the mat was dried and cured at 370 degrees F. in an impingement drier with the mat traveling at about 400-600 feet per minute. The curing time was only a few seconds. The resultant mat did not support a vertical flame in a flame test described in Example 2 below.
B. A 9.0 gsf nonwoven fiber glass mat containing 18% binder and 82% 0.75 inch long 13 micron glass fibers, with the binder being Astromel CR-1, with a pH of about 9 and catalyzed as described in Example 1, was dried and cured by heating briefly to 370 degrees F. The resultant mat does not support a vertical flame.
C. A 13.6 gsf nonwoven fiber glass mat containing 45% binder and 55% 0.5 inch long 10 micron glass fiber was made in a similar manner, but an uncatalyzed Astromel CR-1 binder was used and the bindered mat was dried to a "B" stage (not fully cured) at 300 degrees F. to make a mat that can be remolded at 425 degrees F. to shape the mat and fully cure the binder. The molded and cured mat would not support a vertical flame.
EXAMPLE 2
For this example the composition described in Example 1, B, was made into mats using three different resins and the resultant mats were tested as follows.
______________________________________ Melamine:Formaldehyde % N Flame TestResin Ratio in Resin* Vertical Climb______________________________________Aerotex 3730 1:6 26-27 Failed-climbing flameAerotex MW 1:4 35 Passed-flame snuffs outAerotex MS 1:3 41-42 Passed-will not flame______________________________________ *Determined by Kjeldahl nitrogen.
Aerotex is the trademark of American Cyanamid Company for a family of melamine formaldehyde binders. Mats were made using each of these binders in place of Astromel CR-1 using the same technique used in Example 1, B, and tested in the vertical flame test.
The vertical climb flame test employs a three inch by five inch mat sample. A wide mouth Bunsen burner is placed at the three inch base of the sample approximately 0.5 inch below the sample with a flame height of about 1.5 inch.
The test results shown above show the criticality of the nitrogen content of the binder resin to the flame retardancy. The higher the nitrogen content above 27% in the resin, the greater the ability of the mat to retard flame.
EXAMPLE 3
Further testing of compositions similar to that described in Example 1 (B) above, except for the resin content in the finished mat showed the following:
______________________________________Resin % Resin in Mat Flame Test (Vertical Climb)______________________________________Aerotex 3730 17 Failed (climbing flame)Aerotex 3730 25 Failed (climbing flame)Aerotex MW 21 Passed (flame snuffed out)Aerotex MW 25 Failed (climbing flame)Aerotex MS 19 Passed (wouldn't flame)Aerotex MS 25 Passed (flame snuffed out)______________________________________
This test data shows that the ratio of resin in the mat to the N content in the dry but uncured resin should not exceed about 0.6.
Testing of even high %N containing resins shown diminished smoke generation when burned (either pass the previously described flame test or show less of a flame time when subjected to 700 degrees C., or both). The %N is dictated by the melamine to formaldehyde ratio during the resin manufacturing and further influenced by the amount and type of etherification and pre condensation. Resins having a melamine to formaldehyde ratio from about 1:6 to 1:1 are preferred and a ratio of 1:3 to 1:1 are most preferred.
The following information shows additional fire test results of two mat embodiments of the present invention made with binder resins D and E. Binder resin D is Astromel CR-1, a trademark of Astro Industries, a division of Border, Inc. for a low formaldehyde melamine resin, the binder used in Example 1 above. Resin E is Madurit VMW 3830, trademark of Hoechst AK of Frankfurt, Germany, for a non-plasticized methyl ethered melamine formaldehyde resin having a pH of about 10.
______________________________________ ASTM E662 ASTM E132 NBS Smoke Chamber Flame Time (sec.) &Resin % N Smoke Density Temp. rise during test______________________________________D 40 4.6 106 58° C.E 50 3.9 39 53° C.______________________________________
ASTM 662 detects smoke by the optical density (maximum reached) of smoke generated by vertically burning a specific size sample in a standardized, sealed enclosure. ASTM E132, run in a vertical tube furnace, detects flame time and temperature rise measured in the (750° C.) temperature controlled vertical muffle tube furnace. A specific size sample is observed for flammability/charring/weight loss at this temperature as well as length of time to burn and the subsequent rise in temperature.
EXAMPLE 4
The melamine formaldehyde resins used in the present invention can be fortified with additional high nitrogen containing materials as shown below.
______________________________________Resin & Dicyanamide % Resin in Mat Flame Test - Vertical Climb______________________________________Resin A* 25 Failed - climbing flame90% A + 10% Dicy. 26 Failed - climbing flame70% A + 30% Dicy. 29 Passed - would not flame______________________________________ *Resin was Aerotex 3730
As shown above, a greater increase in nitrogen content by adding Dicyanamide improves the flame test results. The flame test used was the same as described in Examples 1 and 2.
EXAMPLE 5
A preferred embodiment is a mat having a basis weight of about 1.5 lbs/100 sq. ft. made on a continuous wet process machine and having the following composition; 60 wt % 0.75 inch long K filament E glass fiber, 10% sodium borosilicate microfiber (minus 3 micron), 5% carbon black pigment and 5% polyester fiber (1.5 denier by 0.25 inch long) bound together with 20% of a binder made up of 13.5% melamine formaldehyde resin (Astromel CR-1™), about 0.5% amine buffered phosphoric acid catalyst and about 6% PVC latex (BF Goodrich Vycar™, homopolymer PVC). The PVC latex provides good bonding for the carbon black making it a good anti-rub agent, i.e. prevents the carbon black pigment from rubbing off of the mat.
While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. It is not intended herein to mention all of the possible equivalent forms or ramifications of the invention. It is understood that terms used herein are merely descriptive rather than limited, and that various changes obvious to one of ordinary skill in this technology may be made without departing from the spirit or scope of the invention. | Described is a fiber glass mat composition comprising a fiber glass matrix bonded with fire retardant melamine resin binder composition capable of forming a nonwoven mat having at least 27% by weight nitrogen (N) in the dry, bur uncured resin. Also described is a method of making a fire retardant nonwoven fiber glass mat comprising the steps of providing an aqueous melamine based resin binder; applying the binder to fiber glass; and recovering a fire retardant fiber glass mat, wherein the mat has at least 27% by weight N in the dry, but uncured resin wherein the ratio of resin in the mat to N content of the resin does not exceed about 0.6. | 3 |
FIELD OF THE INVENTION
The present invention relates to telecommunications in general, and, more particularly, to telecommunications network security in virtualized environments.
BACKGROUND OF THE INVENTION
Telecommunications network security consists of policies adopted by network administrators to protect the network and the network-accessible resources from unauthorized access. A policy is a combination of rules and services, where the rules define the criteria for access and usage of resources. A “telecommunications network policy rule” is a direction that governs the operation of one or more security devices (implemented in hardware and/or software) in a telecommunications network, such as firewalls, anti-virus software, and others. Exemplary rules include: “do not store executable files on a hard drive”, “block all network traffic to and from port 23 ”, “do not place application A in the same security perimeter with application B”, “do not forward executable files to application A,” etc. Such policy rules are specified by network administrators, and implemented by firewalls, anti-virus programs, and other similar services.
FIG. 1 depicts an example of a telecommunications system as is known in the prior art. Secure Network 110 is an enterprise network. Network 110 is separated from the Internet (i.e. network 130 ) by firewall 120 .
Firewall 120 is software and hardware that is designed to block unauthorized access while permitting authorized communications. It is a device configured to permit, deny, encrypt, and decrypt traffic from network 130 to network 110 . Firewall 120 fulfills its function by examining the traffic between network 130 and network 110 and blocking traffic that violates one or more policy rules. In this example, firewall 120 is configured to prevent telnet traffic between secure network 110 and network 130 .
FIG. 2 depicts the internal organization of secure network 110 . Secure network 110 comprises a low-security perimeter and high-security perimeter. The two perimeters are separated by firewall 220 . Nodes 210 - 1 , 210 - 2 , and 210 - 3 are located in the high security perimeter. Nodes 230 - 1 , 230 - 2 , and 230 - 3 belong to the low-security perimeter.
A node is a physical computer machine that is executing a server. Servers are software applications that provide access to data and other computer resources remotely. An example of a server is a web server which provides access to web page content. As used in this application, the word “server” refers only to software that is executing on a physical computer machine (or node).
A telecommunication network is usually comprised of a plurality of servers which can have varying functions. Some servers can be more prone to become infected with computer viruses than others. For example, a large portion of all computer viruses spread via email, and, consequently, email servers are considered more likely to become a conduit through which computer viruses enter a telecommunications network.
Additionally, some servers are deemed more critical to the utility of a telecommunications network. For example, a server that manages a company's accounting system is much more critical than an email server. The loss of accounting records can be costly and have negative consequences for the company's well-being. Placing such mission-critical servers in different network security perimeters prevents computer viruses from entering the network through vulnerable servers, such as the email server, and spreading to the likes of the accounting server.
Secure network 110 , is an example of a network which separates servers by placing them in different perimeters. As FIG. 2 depicts, nodes 210 - 1 , 210 - 2 , and 210 - 3 form part of a high-security perimeter. And nodes 230 - 1 , 230 - 2 , and 230 - 3 belong to a low-security perimeter. The two perimeters are separated by firewall 220 .
Firewall 220 prevents viruses from propagating to the nodes in the high security perimeter. Just like firewall 120 , firewall 220 is software and hardware that is designed to block unauthorized access while permitting authorized communications. It is a device configured to permit, deny, encrypt, and decrypt network traffic. However, unlike firewall 120 , firewall 220 is configured to implement more stringent network policies than firewall 120 . One such policy rule is “do not allow transfer of executable files.” If a computer virus crosses firewall 120 , the executable file that carries the virus will be blocked from propagating into the high-security perimeter by firewall 220 .
When multiple servers are executed in a physical computer machine, the maintenance of security perimeters becomes complicated. A technique known as virtualization is commonly used to run multiple servers (a.k.a. virtual servers) on the same physical computer machine. When virtualization is used in a network, the boundaries between different security perimeters become blurred and a potential for introducing security vulnerabilities is created.
FIG. 3 depicts the salient components of a node that uses virtualization. The node (i.e. Node 300 ) comprises hardware 310 , virtualization layer 320 , system software 330 , system software 340 , accounting server 332 , and email server 342 .
Hardware 310 is the electronic components that comprise node 310 (e.g. processor, memory, network adapter, etc.).
Virtualization Layer 320 is the main device through which virtualization is achieved. Virtualization layer 320 is a software layer that facilitates the sharing of the resources of hardware 310 by multiple system software instances. In particular, system software 330 and 340 are two different operating system instances that are concurrently executed by node 300 . System software 330 executes an accounting server, and system software 340 executes an email server. The running of each server inside a separate operating system allows node 300 to achieve a degree of separation between the servers. This separation furthers network security and makes using virtualization a better option than running two servers inside the same operating system.
Nevertheless, using server virtualization can introduce security vulnerabilities to a network. As previously noted, it is desirable to keep email servers and accounting servers in separate security perimeters. The reason for the separation is that email servers, in general, are more prone to become infected, while accounting servers, because of their importance, should be kept as secure as possible.
When virtualization is used, as FIG. 3 illustrates, two applications that belong in different security perimeters may wind up executing on the same physical computer machine. Thus, it is possible for a computer virus to enter node 300 through email server 342 , spread into virtualization layer 420 , and infect accounting server 332 from there. In contrast, in the example of FIG. 2 , the nodes do not use virtualization and each server executes on a separate physical computer machine. For this reason, in FIG. 2 , the accounting server is completely separated from the email server, and, therefore, a virus cannot infect the accounting server without crossing a security device, such as firewall 220 , first.
The relevance of the vulnerabilities introduced by virtualization can be understood through the concept of server migration. Server migration is the act of transferring one server from one physical computer machine to another physical computer machine. When a server is migrated, one or more files associated with the server are copied, a new operating system instance is started, and one or more of the copied files are executed within the new operating system instance.
FIG. 4 depicts an example of server migration. FIG. 4 depicts node 410 and node 420 . Node 410 executes concurrently three servers: inventory server 432 , employee information server 442 , and accounting server 452 . Node 420 , in contrast, executes only email server 462 . Each server is executing inside a separate system software instance.
At time=t 0 , node 410 is overwhelmed by having to run three severs, while node 420 is underutilized. For this reason, accounting server 452 is migrated to node 410 .
At time=t 1 , the migration of accounting server 452 is completed and nodes 410 and 420 are executing two servers each. The migration, in this example, involves three salient tasks:
i. copy one or more files associated with accounting server 452 to node 420 , ii. instantiate a new system software instance on node 420 , and iii. launch one or more of the copied files inside the new system software instance.
As a result of the migration, network vulnerability is introduced to node 420 . The vulnerability is rooted in the fact that at time t 1 accounting server 452 and email server 462 are executing on the same physical machine. The vulnerability is of the same type as the one described in the discussion with respect to FIG. 3 . To prevent such vulnerabilities from being created, network administrators must analyze each physical computer machine, and the servers it is running, on a case-by-case basis. The network administrators must exercise special care not to place incompatible servers on the same physical machine.
The exercise of such care is complicated by the number of server migrations which can be performed in a network over the course of a day. Server migration is frequently performed by network administrators. Servers can be migrated when a physical computer machine becomes damaged or when the load on one or more physical computer machines needs to be balanced. In sizable networks, virtual server migration is a routine task that is performed often.
Every time a virtual server is migrated from one physical computer machine to another, the possibility exists that vulnerability will be created because of human error. Therefore, the need exists for a method for increasing the security of the migration of servers that reduces the possibility of human error. Moreover, the need exists for a disciplined approach towards server migration that avoids the case-by-case analysis spoken of above.
SUMMARY OF THE INVENTION
The present invention addresses this need by providing an architecture and method for assessing the security of server migration.
In one embodiment of the present invention, a permission for running a system software instance alongside another system software instance is issued on the basis of a first policy rule concerning the operation of a first software application and a second policy rule concerning the execution of a second software application.
In a second embodiment of the present invention, an association between two network policy rules for individual servers are specified ahead of time (e.g. rule A is incompatible with rule B, etc.). This association is later used to determine whether it is desirable to execute two servers concurrently on the same physical computer machine. For example, and without limitation, if the second embodiment of the present invention is applied to the migration scenario of FIG. 4 , the invention will retrieve a network policy rule associated with the email server and a network policy rule associated with the accounting server. An example of a network policy rule associated with the accounting server is the “do not allow transfer of executable files” rule which is enforced by firewall 220 . Similarly, an example of a network policy rule associated with the email server is the “do not allow telnet traffic” rule that is enforced by firewall 110 . The rules can be retrieved from a database, the firewalls themselves, or other similar source. After the rules are retrieved, the second embodiment of the present invention will locate a third rule that specifies the association between the first two rules. Based on the third rule, the second embodiment of the present invention will render a decision as to whether the email server should be allowed to execute concurrently with the accounting server on the same physical computer machine.
In a third embodiment of the present invention, permission for the concurrent execution of a first and second software applications is issued on the basis of a characteristic of the first software application. A “characteristic” of a software application is an item of information concerning the application. Examples of characteristics are identifier, function, etc. More examples of characteristics are provided in the “Detailed Description” section of this disclosure.
In a fourth embodiment of the present invention, when permission is refused, the system software instance that is used as host computing environment of the migrated software is shut down. In other embodiments, either of the system software instance and the migrated software is denied access to computing resources (e.g. CPU time, network access, etc.) as a consequence of the refusal.
In a fifth embodiment of the present invention, a tentative permission is issued which is contingent upon the implementation of a security policy rule by the physical computer machine to which software is migrated. Upon receipt of the policy rule, the physical computer machine launches a security application, such as an anti-virus program or firewall, and configures the launched application to implement the received rule.
A significant advantage of all embodiments of the present invention is that they increase the security of virtual server migration and provide a systematic way for assessing whether the migration of a server to a particular physical computer machine can become a source of network vulnerability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an example of a telecommunications system as is known in the prior art.
FIG. 2 depicts the internal organization of secure network 110 .
FIG. 3 depicts the salient components of a node that uses virtualization.
FIG. 4 depicts an example of server migration.
FIG. 5 depicts a schematic diagram of the salient components of the illustrative embodiment of the present invention.
FIG. 6 depicts a flowchart of the execution of the salient tasks associated with the operation of the illustrative embodiment of the present invention.
FIG. 7A depicts a flowchart of the execution of task 610 as performed by a first illustrative embodiment of the present invention.
FIG. 7B depicts a flowchart of the execution of task 610 as performed by a second illustrative embodiment of the present invention.
FIG. 7C depicts a flowchart of the execution of task 610 as performed by a third illustrative embodiment of the present invention.
FIG. 8 depicts a flowchart of the execution of the salient subtasks associated with the performance of task 620 .
FIG. 9 depicts a flowchart of the execution of the salient subtasks associated with the performance of task 630 .
FIG. 10 depicts a flowchart of the execution of the salient subtasks associated with the performance of task 640 .
DETAILED DESCRIPTION
FIG. 5 depicts a schematic diagram of the salient components of the illustrative embodiment of the present invention. The illustrative embodiment comprises node 500 and policy decision point (PDP) 510 .
Node 500 is a physical computer machine that executes multiple software applications, wherein each individual application is contained within its own system software instance. In this way, it appears that each application is running on its own dedicated machine. Moreover, because each software application appears to be running on its own dedicated machine, one of the applications can be rebooted without affecting the others, and, also, a failure in one of the applications is less likely to affect the other applications. Node 500 comprises hardware 570 , virtualization layer 550 , security application 560 , policy enforcement point (PEP) 520 , system software 530 , system software 540 , software 532 , and software 542 .
Hardware 570 is the electronic components that comprise node 500 , such as, for example, and without limitation, processor (single-core or multi-core), memory, transceiver, network interface, display, sound interface, permanent storage, video interface, etc. It will be clear to those skilled in the art how to make and use hardware 570 .
Virtualization Layer 550 is a software layer that facilitates the sharing of the resources of hardware 570 by multiple system software images. In accordance with the illustrative embodiment of the present invention, virtualization layer 550 is an OKL4 microkernel, but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which virtualization layer 550 is any other Type 1 hypervisor (e.g. Xen™, VMware ESX Server™, etc.) or any other hosted virtual machine (e.g. QEMU™, VMware Workstation™, etc.).
System software 530 is an instance of the Linux operating system that is running on top of virtualization layer 550 . It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which system software 530 is any type of system software, firmware, or software platform that is capable of executing one or more software applications, such as, for example, and without limitation, Windows™, Android™, Solaris™, etc. It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the size and functionality of system software 530 varies. Those skilled in the art will readily recognize, after reading this disclosure, that alternative embodiments of the present invention can be devised in which system software 530 provides (or contains) only the minimum amount of system services that is necessary for the proper execution of software application 532 .
System software 540 is an instance of the Linux operating system that is running on top of virtualization layer 550 . System software 540 is executing concurrently with system software 530 . It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which System software 540 is any type of system software, firmware, or software platform that is capable of executing one or more software applications, such as, for example, and without limitation, Windows™, Android™, Solaris™, etc. Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the size and functionality of system software 540 varies. Those skilled in the art will readily recognize, after reading this disclosure, that alternative embodiments of the present invention can be devised in which system software 540 provides (or contains) only the minimum amount of system services that is necessary for the proper execution of software application 542 .
Software 532 is an instance of an accounting server application that is running inside the address space of system software 530 . The accounting server manages sensitive information, and, therefore, it needs to be protected by stringent telecommunications network policies. It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which software 532 is any software application capable of executing on node 500 , such as, for example, and without limitation, an FTP server, email server, authentication server, instant messaging server, instant messaging client, email client, etc.
Software 542 is an instance of an email server that is running inside the address space of system software 540 . The email server is not very sensitive with respect to network security, and, therefore, it needs to be protected by less stringent telecommunications network security policies than software 532 . Because software 542 is an email server, it is vulnerable to security breaches by computer viruses. It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which software 542 is any software application capable of executing on node 500 , such as, for example, and without limitation, an FTP server, email server, authentication server, instant messaging server, instant messaging client, email client, etc.
Security application 560 is a software firewall. Security application 560 is responsible for enforcing one more telecommunications network policies for incoming and outgoing traffic from node 500 . In particular, security application 560 is capable of filtering the traffic to system software 540 . It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which security application 560 is any type of security application, such as, for example, and without limitation, an anti-virus program, adware blocker, popup blocker, etc.
Policy enforcement point (PEP) 520 is a software module for enforcing one or more policy decisions that are rendered by policy decision point (PDP) 510 . In accordance with the illustrative embodiment of the present invention, the policy enforcement point (PEP) is configured to block the operation of one or more virtual device drivers which are used by system software 540 . In particular, the policy enforcement point (PEP) is capable of making one more system calls to virtualization layer 550 and instructing it to shut down one or more virtual device drivers. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy enforcement point (PEP) 520 is capable of enforcing the decisions of policy decision point (PDP) 510 in alternative ways, such as, for example, and without limitation, by shutting down system software 540 (which is accomplished by making system calls to virtualization layer 550 ), by blocking one or more networking ports used by system software 540 and the applications running inside it, etc. And still furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy enforcement point (PEP) 520 is capable of enforcing the decisions of policy decision point (PDP) 510 by instructing virtualization layer 520 to abort the loading and starting of system software 540 . The operation of policy enforcement point (PEP) 520 is further described in the discussion with respect to FIG. 4 .
Although, as depicted in FIG. 5 , policy enforcement point (PEP) 520 appears to be part of virtualization layer 550 , it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy enforcement point (PEP) 520 is a separate application executing inside the memory space of virtualization layer 550 . Also, those skilled in the art will readily recognize, after reading this disclosure, that alternative embodiments of the present invention can be devised in which policy decision point (PEP) 520 is executing on another physical computer machine and interacting with virtualization layer 550 through a remote connection (e.g. universal serial bus connection, telecommunications network connection, firewire connection, etc.).
Policy decision point (PDP) 510 is a software module where policy decisions concerning the operation of node 500 are made. In particular, policy decision point 510 is configured to decide whether software 542 should be allowed to execute on the same physical computer machine with software 532 (i.e. whether two virtual servers should be allowed to execute on the same physical computer machine). However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy decision point (PDP) 510 is configured to make a decision about whether system software 540 should be allowed to execute concurrently with system software 530 on the same physical computer machine.
FIG. 6 depicts a flowchart of the execution of the salient tasks associated with the operation of the illustrative embodiment of the present invention. It will be clear to those skilled in the art, after reading this disclosure, how to perform the tasks associated with FIG. 6 in a different order than represented or to perform one or more of the tasks concurrently. Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention that omit one or more of the tasks.
At task 610 , a triggering event concerning the concurrent execution of software 532 and software 542 is detected. Task 610 is further described in the discussion with respect to FIGS. 7A , 7 B, and 7 C.
At task 620 , policy decision point (PDP) 510 analyzes the concurrent execution of software 532 and software 542 . Task 610 is further described in the discussion with respect to FIG. 8 .
At task 630 , policy decision point (PDP) 510 transmits a message indicating the result of the analysis. Task 630 is further described in the discussion with respect to FIG. 9 .
At task 640 , policy enforcement point (PEP) 520 takes action in response to the result of the analysis. Task 640 is further described in the discussion with respect to FIG. 10 .
FIG. 7A depicts a flowchart of the execution of task 610 as performed by a first illustrative embodiment of the present invention.
At task 710 -A, policy enforcement point (PEP) 520 detects the migration of software 542 to node 500 . In accordance with the illustrative embodiment of the present invention, policy enforcement point (PEP) 520 monitors the use of the permanent storage device of node 500 and detects whether a file (e.g. executable file, database file, library file, .dll file, .lib file, etc) associated with software 542 is copied to node 500 's permanent storage. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy enforcement point 520 detects the migration of software 542 in a variety of ways, such as, for example, and without limitation, by receiving a message indicating the pendency of the migration and/or identifying the software to be migrated, by detecting the initiation of a file transfer connection between node 500 and another node, etc. Although, in accordance with the illustrative embodiment of the present invention, the migration is detected by policy enforcement point (PEP) 520 , it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the migration is detected by another software module.
FIG. 7B depicts a flowchart of the execution of task 610 as performed by a second illustrative embodiment of the present invention.
At task 710 -B, policy enforcement point (PEP) 520 detects the launching of system software 540 by virtualization layer 550 . Although, in accordance with the illustrative embodiment of the present invention, the launching is detected by policy enforcement point (PEP) 520 , it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the launching of system software 540 is detected by another software module. It will be clear to those skilled in the art how to detect instantiation of a system software instance by virtualization layer 550 .
FIG. 7C depicts a flowchart of the execution of task 610 as performed by a third illustrative embodiment of the present invention.
At task 710 -C policy enforcement point (PEP) 520 detects the concurrent execution of software 532 and 542 on node 500 . In accordance with the illustrative embodiment of the present invention, policy enforcement point (PEP) 520 monitors the network traffic in and out of node 500 and detects one or more application fingerprints that are present in one or more packets (e.g. low level TCP/IP datagrams or high level packets, such as HTTP packets) that comprise the outgoing traffic. The fingerprinting is used to identify the source application of the packets. When policy enforcement point (PEP) 520 detects that the packets come from multiple sources, that serves as a signal that multiple software applications (e.g. virtual servers, etc.) are executing on node 500 .
In accordance with the illustrative embodiment of the present invention, the measured fingerprint constitutes one or more of the number of bits in packet headers, the specific values of one or more bits in a packet header, the type of encryption used by one or more of the applications, etc. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the fingerprinting is based on any item of data found in one or more packets transmitted by node 500 . Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and alternative embodiments of the present invention in which policy enforcement point (PEP) 520 reads the content of the payload of packets transmitted by software 532 and 542 for information that identifies the packets' source (e.g. navigator objects transmitted by web browsers).
Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the execution of software 542 is detected by monitoring the use of a protocol signaling stack located inside virtualization layer 550 and recognizing that the stack is being called by multiple software applications. And still furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the execution of software 542 is detected by monitoring the utilization of the hardware resources of node 500 (e.g. CPU time, memory usage, etc.) and noticing an increase.
Although, in accordance with the illustrative embodiment of the present invention, the migration is detected by policy enforcement point (PEP) 520 , it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the migration is detected by another software module.
FIG. 8 depicts a flowchart of the execution of the salient subtasks associated with the performance of task 620 . It will be clear to those skilled in the art, after reading this disclosure, how to perform the tasks associated with FIG. 8 in a different order than represented or to perform one or more of the tasks concurrently. Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention that omit one or more of the tasks.
At task 810 , policy decision point (PDP) 510 determines a characteristic of software 532 . In accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 determines an identifier for the software (e.g. a numerical or string identifier serving to distinguish software 532 from other software applications and/or application instances) which policy decision point (PDP) 510 can use to retrieve a policy rule related to the operation of software 532 . In accordance with the illustrative embodiment of the present invention, an indication of the characteristic is transmitted to policy decision point (PDP) 510 by a software module executing on virtualization layer 550 (such as policy enforcement point (PEP) 520 ), but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the identifier is contained in a message received by policy decision point (PDP) 510 from any possible source (e.g. network administrator's computer that transmitted a query to the policy decision point).
It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy decision point (PDP) 510 determines alternative characteristics, such as for example, and without limitation, the function performed by software 532 (e.g. accounting server, file transfer client, Internet chat client, telephony application, anti-virus program, word processor, FTP server, email server, authentication server, etc.), sensitivity of information managed by software 532 , telecommunications protocols used by software 532 (e.g. hypertext transfer protocol (HTTP), file transfer protocol (FTP), session initiation protocol (SIP), etc.), number of simultaneous telecommunications network connections established by software 532 , and so forth.
More specifically, in one alternative embodiment of the present invention, policy decision point (PDP) 510 determines the sensitivity of software 532 with respect to network security. Some software applications manage highly sensitive information, such as bank account numbers, employee social security numbers, etc. This type of software is deemed to require high network security (e.g. multiple firewalls, authorized access only, other stringent network policy rules, etc.). In contrast, other software applications, such as Internet chat clients, manage not so sensitive information, and, consequently, they are subject to more relaxed network policy rules. In accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 retrieves information about the security sensitivity of software 532 from a database. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy decision point (PDP) 510 derives the sensitivity of software 532 with respect to network security from one or more telecommunications network policy rules associated with the software.
At task 820 , policy decision point (PDP) 510 determines a characteristic of software 542 . In accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 determines an identifier for the software (e.g. a numerical or string identifier serving to distinguish software 532 from other software applications and/or application instances) which policy decision point (PDP) 510 can use to retrieve a policy rule related to the operation of software 542 . In accordance with the illustrative embodiment of the present invention, an indication of the characteristic is transmitted to policy decision point (PDP) 510 by a software module executing on virtualization layer 550 (such as policy enforcement point (PEP) 520 ), but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the identifier is contained in a message received by policy decision point (PDP) 510 from any possible source (e.g. network administrator's computer that transmitted a query to the policy decision point).
It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy decision point (PDP) 510 determines alternative characteristics, such as, for example, and without limitation, the function performed by software 542 (e.g. email server, file transfer client, Internet chat client, telephony application, anti-virus program, word processor, FTP server, email server, authentication server, etc.), the sensitivity of information managed by software 542 , telecommunications protocols used by software 542 (e.g. hypertext transfer protocol (HTTP), file transfer protocol (FTP), session initiation protocol (SIP), etc.), number of simultaneous telecommunications network connections established by software 542 , etc.
At task 830 , policy decision point (PDP) 510 determines a telecommunications network policy rule related to the operation of software 532 . In accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 receives the rule over a telecommunications network connection from a database that contains one or more network policy rules, but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the network policy rule is stored in a record residing on the physical computer machine that executes policy decision point (PDP) 510 .
At task 840 , policy decision point (PDP) 510 determines a telecommunications network policy rule related to the operation of software 542 . In accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 receives the rule over a telecommunications network connection from a database that contains one or more network policy rules, but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the network policy rule related to the operation of software 542 is stored in a record residing on the physical computer machine that executes policy decision point (PDP) 510 .
At task 850 , one or more rules for the concurrent execution of software on node 500 are specified. The rules for the concurrent execution of software on the same node take the form of an association between two or more network policy rules and a label that describes whether the two network policy rules are compatible. In accordance with the illustrative embodiment of the present invention, the rules for the concurrent execution of software on the same node are specified manually by a network administrator. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the rules for the concurrent execution of software on the same node are generated automatically.
In accordance with the illustrative embodiment of the present invention, the rules for the concurrent execution of software have the format described in Table 1:
TABLE 1
Rules for the Concurrent Execution of Software on Node 500
Policy Rule Combination
Compatibility
{Policy Rule A}, {Policy Rule B}
Incompatible
{Policy Rule C}, {Policy Rule D}
Compatible
{Policy Rule A}, {Policy Rule B}, {Policy Rule C}
Compatible
The first rule, for the concurrent execution of software, in Table 1 specifies an association between policy rule A and policy rule B and contains the label Incompatible. In particular, the first rule specifies that a permission for the concurrent execution on the same node of a first software which is associated with policy rule A, and second software which is associated with policy rule B should be refused. In accordance with the illustrative embodiment of the present invention, in order for software to be associated with a policy rule, the rule has to be related to the operation of the software. In the example from the “Background” section of this disclosure, the accounting server is subject to the policy rule “do not allow transfer of executable files” which is enforced by firewall 200 . This policy rule is an example of a policy rule related to the operation of a software application. It should also be noted that those skilled in the art will recognize, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the association between software and a network policy rule is determined on account of the rule and the software being related in a database record, or on account of manual input entered by a network administrator.
Furthermore, in accordance with the illustrative embodiment of the present invention, additional rules, for the concurrent execution of software on the same node, are specified that are based on one or more characteristics of software applications. In accordance with the illustrative embodiment of the present invention the rules for the concurrent execution of software on the same node are specified manually by a network administrator. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the rules are generated automatically. In accordance with the illustrative embodiment of the present invention, the rules for the concurrent execution of software on the same node have the format described in Table 2.
TABLE 2
Rules for the Concurrent Execution of Software on Node 500
Characteristic Combination
Compatibility
{Characteristic A}, {Characteristic B}
Incompatible
{Characteristic C}, {Characteristic D}
Compatible
{Characteristic A}, {Characteristic B},
Compatible
{Characteristic C}
The first rule in Table 2 specifies an association between software characteristic A and software characteristic B and contains the label Incompatible. This rule specifies that a permission for the concurrent execution on the same node of a first software which possesses characteristic A, and second software which possesses characteristic B should be refused by policy decision point (PDP) 510 .
It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention that use a variety of rules regarding the concurrent execution of software 532 and software 542 , such as for example, and without limitation, rules that depend on the functions performed by software 532 and 542 , rules that depend on the sensitivity with respect to network security of software 532 and 542 , rules that depend on the telecommunications network protocols used by software 532 and 542 , rules that depend on any characteristic of software 532 and/or 542 , a rule specifying the maximum number of system software instances that are allowed to run on node 500 , etc.
An example of a rule that considers the functions performed by software 532 and 532 is “do not execute instant messaging servers concurrently with inventory management servers.” Instant messaging servers can be very likely to become the conduit for computer viruses (or other malware). Therefore, some network administrator may find it desirable to block those applications from running on the same computer hardware with software that is sensitive with respect to network security.
An example of rule that considers the sensitivity of software 532 and software 542 is “do not run software with high security sensitivity on the same computer hardware as software with low security sensitivity.” Under this rule, for example, email servers cannot be executed concurrently on the same physical computer machine with software that belongs to an employee management system. This rule allows the enforcement of high-security and low-security perimeters, such as those depicted in FIG. 2 .
An example of a rule that considers the telecommunications protocols used by software 532 and 542 is “do not run applications that use the file transfer protocol (FTP) together with applications that use file transfer protocol secure (FTPS). The rationale for this rule is that the use of the file transfer protocol (FTP) application may negate the extended security benefits of file transfer protocol secure (FTPS) and provide a conduit into node 500 for viruses or other malware.
At task 860 , policy decision point (PDP) 510 locates a rule for the concurrent execution of software on node 500 that applies to the situation at hand. In particular, policy decision point (PDP) 510 locates a rule for the concurrent execution of software that covers the combination of the policy rule associated with software 532 and the policy rule associated with software 542 , which were determined at tasks 830 and 840 . After the rule for the concurrent execution of software is located, policy decision point determines whether the combination of policy rules is deemed compatible or incompatible by consulting the label associated with the rule for the concurrent execution of software. If the combination is compatible, policy decision point (PDP) allows the concurrent execution of software 532 and 542 on node 500 . Otherwise, permission for the concurrent execution is denied.
Additionally, in accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 locates a rule that covers the combination of the characteristics determined at tasks 810 and 820 . After the rule is located, policy decision point determines whether the combination of policy rules is deemed compatible or incompatible by consulting the label associated with the rule. If the combination is compatible, policy decision point (PDP) allows the concurrent execution of software 532 and 542 on node 500 . Otherwise, permission for the concurrent execution is denied.
In accordance with the illustrative embodiment of the present invention, an information record with the rules concerning the concurrent execution of software is kept on the physical computer machine that executes policy decision point (PDP) 510 . However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the rules are obtained by policy decision point (PDP) 510 over a telecommunications network connection.
At task 870 , policy decision point (PDP) 510 determines a supplemental telecommunications network policy rule which, when implemented at node 500 , will render software 532 and 542 compatible to execute on the same physical computer machine. More specifically, policy decision point (PDP) searches the rules specified at task 550 for one or more rules in which the combination of policy rules is a superset of the rules determined at tasks 530 and 540 and which comprises the Compatible label. In accordance with the illustrative embodiment of the present invention, the supplemental policy rule(s) is the complement of the set of rules determined at tasks 830 and 840 with respect to the set of rules specified by the combination part of the rule concerning the concurrent execution of software on node 500 .
For example, as Table 1 illustrates, the combination of {Policy Rule A} and {Policy Rule B} is deemed incompatible. Whereas, the combination of {Policy Rule A}, {Policy Rule B} and {Policy Rule C} is deemed compatible. When a situation arises in which software 532 is associated with policy rule A and software 542 is associated with policy rule B, policy decision point will locate the third rule in Table 1 (i.e. {Policy Rule A}, {Policy Rule B} and {Policy Rule C} deemed compatible), and will determine that policy rule C is a supplemental policy rule which when implemented will render software 532 and 542 compatible to execute on the same physical computer machine.
At task 880 , policy decision point (PDP) 510 determines whether node 500 possesses sufficient computing resources to execute both software 532 and software 542 . In accordance with the illustrative embodiment of the present invention, policy decision point (PDP) 510 determines the utilization of one or more of the hardware resources of node 500 (e.g. CPU utilization, bandwidth utilization, memory utilization, etc.) and determines whether node 500 has sufficient computer hardware resources to execute both software 532 and software 542 . In order to make this determination, policy decision point (PDP) 510 obtains an estimate of the resource consumption of software 532 and 542 . In accordance with the illustrative embodiment of the present invention, the estimate is received at policy decision point (PDP) 510 from a remote server, but it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which a record of the resource consumption estimate is kept on the physical computer machine on which the policy decision point is executing. When the cumulative of the consumption of computer hardware resources by software 532 and the estimated consumption of hardware resources by software 542 exceeds the computer hardware resources of node 500 , policy decision point (PDP) 510 determines that the concurrent execution of software 532 and 542 on node 500 is undesirable.
At task 890 , policy decision point (PDP) determines a hardware upgrade for node 500 which would allow it to execute both software 532 and 542 . In accordance with the illustrative embodiment of the present invention, when, at task 870 , policy decision point (PDP) 510 determines that node 500 is short on memory, the policy decision point issues a recommendation to upgrade the amount of memory available to node 500 and prescribes a memory amount by which node 500 needs to be upgraded in order to execute software 532 and 542 concurrently. However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy decision point (PDP) 510 prescribes a different upgrade, such as, for example, and without limitation, processor upgrade, increase of the network bandwidth that is available to node 500 , etc.
FIG. 9 depicts a flowchart of the execution of the salient subtasks associated with the performance of task 630 . It will be clear to those skilled in the art, after reading this disclosure, how to perform the tasks associated with FIG. 9 in a different order than represented or to perform one or more of the tasks concurrently. Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention that omit one or more of the tasks.
At task 910 , policy decision point (PDP) 510 , in a well known fashion, transmits a message indicating whether software 532 can execute concurrently with software 542 . The message indicates the result of the application of the rule(s) for concurrent execution of software at task 860 . It will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the message is based on the application of a rule that pertains directly to system software instances, such as the rule that limits the maximum number of system software instances, which was mentioned above.
At task 920 , policy decision point (PDP) 510 , in a well known fashion, transmits a message indicating whether software 532 can execute concurrently with software 542 . The message indicates the result of the execution of task 860 .
At task 930 , policy decision point 510 , in a well known fashion, transmits the supplemental policy rule.
At task 940 , policy decision point (PDP) 510 , in a well known fashion, transmits a message indicating the recommended hardware upgrade which is determined at task 890 .
FIG. 10 depicts a flowchart of the execution of the salient subtasks associated with the performance of task 640 . It will be clear to those skilled in the art, after reading this disclosure, how to perform the tasks associated with FIG. 10 in a different order than represented or to perform one or more of the tasks concurrently. Furthermore, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention that omit one or more of the tasks.
At task 1010 , policy enforcement point (PEP) 520 receives the message transmitted at task 910 and enforces the decision whether system software 530 can execute concurrently with system software 540 . In accordance with illustrative embodiment of the present invention, policy enforcement point (PEP) 520 enforces the decision by making one more system calls to virtualization layer 550 and instructing it to block one or more virtual device drivers which are used by system software 540 . However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which policy enforcement point (PEP) 520 is capable of enforcing the decisions of policy decision point (PDP) 510 in alternative ways, such as, for example, and without limitation, shutting down system software 540 , by blocking one or more networking ports used by system software 540 and the applications running inside it, etc.
At task 1020 , policy enforcement point (PEP) 520 receives the message transmitted at task 920 and enforces the decision whether software 532 can execute concurrently with software 542 . In accordance with illustrative embodiment of the present invention, policy enforcement point (PEP) 520 enforces the decision by denying computing resources to software 542 . In accordance with the illustrative embodiment of the present invention, policy enforcement point (PEP) 520 blocks the operation of one or more virtual device drivers used by system software 540 . However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the denial of computing resources is accomplished in a different way, such as, for example, and without limitation, by blocking one or more networking ports used by software 542 , by shutting down one or more signaling protocol stacks that are located in virtualization layer 550 , etc.
At task 1030 , policy enforcement point (PEP) 520 , in a well known fashion, causes security application 560 to implement the supplemental policy rule determined at task 860 and launches the security application.
At task 1040 , policy enforcement point (PEP) 520 receives the message transmitted at task 1040 and displays the recommendation on the display screen of node 500 . However, it will be clear to those skilled in the art, after reading this disclosure, how to make and use alternative embodiments of the present invention in which the message is relayed to a computer used by a network administrator who is responsible for hardware upgrades.
It is to be understood that the disclosure teaches just one example of the illustrative embodiment and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims. | A method is provided in which a permission for running a system software instance alongside another system software instance is issued on the basis of a first policy rule concerning the operation of a first software application and a second policy rule concerning the execution of second software application. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims priority from prior Indian Patent Application No. 1009/Del/2004, filed on Oct. 21, 2004, which is based on and claims priority on Indian Provisional Patent Application No. 1009/Del/2004, filed on Jun. 2, 2004, the entire disclosure of each the two-above referenced applications is hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a voltage tolerant input protection circuit, and more particularly to a voltage tolerant protection circuit for input buffer.
BACKGROUND OF THE INVENTION
[0003] The significance of voltage protection circuit for input buffer is discussed with reference to a differential receiver circuit. Herein, the voltage protection circuit is a circuit between the I/O pad of an integrated circuit and a differential receiver, the protection circuit producing a signal that is used as an attenuation free input signal for the differential receiver circuit. For a differential receiver operating on 3.3V technology having common mode input range equal to 0.8V to 2.5V and having differential input sensitivity equal to 200 mV, it is essential that both the inputs of the differential receiver are free of any amplitude attenuation in common mode input range. To make the differential receiver five-volt tolerant, the input voltage must be equal to the supply voltage. Stated differently, the input voltage must exceed and cross the supply voltage.
[0004] Conventionally, NMOS transistors are used in voltage tolerant protection circuits, wherein the gate of the NMOS transistor is connected to the supply voltage. The source is connected to the Pad and the drain is connected to the Input Buffer. If the voltage at Pad is less than or equal to VDD−Vt (NMOS Threshold), the signal at the input buffer follows the Pad voltage without any amplitude attenuation. When Pad voltage is higher than the NMOS threshold then the signal at the input buffer is attenuated at NMOS threshold. For minimum allowed supply voltage, the signal at the input buffer goes beyond NMOS threshold and for large common mode input range the value of NMOS threshold may lie between the common mode input range, thus resulting in signal degradation. Further, delay is introduced on the rising edge of the signal at the input buffer for high frequency operation of the input buffer.
[0005] FIG. 1 illustrates a prior art voltage protection circuit as per US Patent Application Publication No. 2004/0007712 A1, which is hereby incorporated by reference in its entirety. Here, NMOS transistors are used for protection. As per the given circuit, VOUT follows the Pad voltage from 0V to VDD−vt (PMOS threshold), and supply voltage (VDD) is outputted at VOUT whenever input voltage crosses the PMOS threshold. There is static consumption on the supply voltage through transistors 224 & 226 when Pad voltage is less than VDD−vt (PMOS threshold) and it is undesirable to have a direct path between power supply and ground in normal operating condition. When Pad voltage is greater than VDD−vt (PMOS threshold), and 3.3V transistors are used in the protection circuit, there can be electrical stress on PMOS 234 . Electrical stress on the transistors in the protection circuit is undesirable and often results in the output signal attenuation.
[0006] Accordingly what is needed is a method and system to overcome the problems encountered in the prior art voltage protection circuits and to provide a voltage tolerant protection circuit for an input buffer that prevents stress on transistors, minimizes power supply consumption and transfers signals without any change in the amplitude.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved voltage tolerant protection circuit for input buffer. The protection circuit according to the present invention consumes little or zero power on pad in normal operating conditions, and minimum power consumption when pad is operating at a higher voltage. Further, the protection circuit provides an attenuation free signal up to the supply voltage for the input buffer and mitigates stress on the transistors in the protection circuit.
[0008] The present invention provides an improved voltage tolerant protection circuit for input buffer comprising a transmission gate circuit receiving input from the pad. A control signal generator connected between the transmission gate circuit and the input pad provides a control signal for operating the transmission gate circuit. An N-Well generation circuit connected between the pad and the transmission gate circuit, and also connected to the control signal generator generates a bias signal for the transmission gate circuit and the control signal generator.
[0009] The transmission gate circuit comprises a first transistor receiving the control signal from the control signal generator and the bias signal from the N-Well generation circuit to transfer pad voltage from threshold voltage to a supply voltage. A second transistor is connected to the first transistor. The second transistor receives a supply voltage and a ground, as control signals to form a closed path in response to the pad voltage being higher than the supply voltage. A third transistor is connected to the first and second transistors for providing an output equal to supply voltage when the pad voltage crosses the supply voltage. The first transistor is a PMOS transistor and the second and third transistors are NMOS transistors.
[0010] The control signal generator comprises a first PMOS transistor connected to pad. The first PMOS transistor receives control signals from the supply voltage and the N-Well generation block for avoiding power consumption on the input pad. A second NMOS transistor is connected to the first PMOS transistor. The second NMOS transistor receives control signals from the supply voltage and the ground for transferring a voltage potential in response to the pad voltage being less than the supply voltage.
[0011] A third NMOS transistor is connected to the second NMOS transistor. The third NMOS transistor receives control signals for transferring a voltage potential to the source of the second NMOS transistor in response to the pad voltage being less than or equal to PMOS threshold and to form an open circuit path when pad voltage is greater than the PMOS threshold.
[0012] A fourth PMOS transistor is connected to the input pad. The fourth PMOS transistor receives the bias signal and supply voltage for providing a closed path for conduction when pad voltage is greater than the PMOS threshold.
[0013] A fifth NMOS transistor is connected to the fourth PMOS transistor. The fifth PMOS transistor receives control signals from the supply voltage and the ground to provide controlled voltage response when the pad voltage is greater than the supply voltage.
[0014] A sixth NMOS transistor is connected to the fifth NMOS transistor. The sixth NMOS transistor provides a controlled potential at the source of the fifth NMOS transistor.
[0015] A seventh NMOS transistor is connected to the sixth NMOS transistor. The seventh NMOS transistor provides a controlled closed circuit path.
[0016] An eighth NMOS transistor and a ninth NMOS transistor are connected to the sixth NMOS transistor for outputting a NMOS threshold potential in response to the pad voltage being less than or equal to the supply voltage.
[0017] A tenth PMOS transistor and an eleventh NMOS transistor are connected to the sixth and seventh NMOS transistors and to the eighth NMOS transistor. The tenth PMOS transistor and eleventh NMOS transistor both provides a true value (i.e. without change in amplitude) of the supply voltage to the third NMOS transistor.
[0018] The sixth and seventh NMOS transistors are connected in series.
[0019] The drain terminals of the eighth and ninth NMOS transistors are connected to their respective gate terminals, and source of the eighth NMOS transistor is connected to drain of the ninth NMOS transistor.
[0020] The tenth PMOS transistor and the eleventh NMOS transistor are connected to each other to form an inverter circuit.
[0021] The present invention also provides a method for protecting an input buffer circuit comprising:
[0022] transferring a signal from a input pad to the input buffer through a transmission gate circuit;
[0023] providing a control signal to the transmission gate circuit by a control signal generator, the control signal being zero volt in response to a voltage on the input pad being less than or equal to supply voltage, and being of same value as the voltage on input pad when the voltage on the voltage on the input pad is higher than the supply voltage, thereby avoiding electrical stress on the transistors; and
[0024] providing a bias signal for the control signal generator and the transmission gate circuit, the bias signal being equal to supply voltage when the voltage on the pad input is less than the supply voltage and equal to threshold potential in response to the voltage on the pad voltage being greater than supply voltage.
[0025] The foregoing and other features and advantages of the present invention will be apparent from the following more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0027] FIG. 1 is a prior art voltage protection circuit diagram.
[0028] FIG. 2 is the block diagram of a voltage protection circuit for an input buffer in accordance with an embodiment of the present invention.
[0029] FIG. 3 is the circuit diagram of transmission gate of the voltage protection circuit of FIG. 2 , in accordance with an embodiment of the present invention.
[0030] FIG. 4 is the circuit diagram of control signal generation of the voltage protection circuit of FIG. 2 , in accordance an embodiment of the present invention.
[0031] FIG. 5 is the circuit diagram of a conventional NWELL (bias for PMOS transistors) generation block of the voltage protection circuit of FIG. 2 , in accordance with an embodiment of the present invention.
[0032] FIG. 6 is the graph of the DC sweep of the protection circuit in accordance an embodiment of the present invention.
[0033] FIG. 7 is the graph of the transient simulation of the circuit in accordance an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] It should be understood that these embodiments are only examples of the many advantageous uses of the innovative teachings herein. In general, statements made in the specification of the present application do not necessarily limit any of the various claimed inventions. Moreover, some statements may apply to some inventive features but not to others. In general, unless otherwise indicated, singular elements may be in the plural and vice versa with no loss of generality.
[0035] FIG. 2 shows the block diagram of the improved voltage tolerant protection circuit for input buffer, which comprises a Transmission gate ( 11 ), for transferring signal from PAD to the Input Buffer ( 14 ). A Control Signal Generator ( 12 ), to generate control signal PMOSCTRL for the Transmission gate ( 11 ), so as to enable the Transmission gate ( 11 ) to transfer the voltage from PAD to the Input buffer ( 14 ). An NWELL Generator ( 13 ) to provide bias voltage to the Transmission gate ( 11 ) and the Control Signal Generator ( 12 ), for minimizing power dissipation.
[0036] FIG. 3 defines the circuit diagram of the Transmission Gate ( 11 ). Here, PAD is the input signal and VOUT is the output signal of the transmission gate. VOUT is the input signal for the Input buffer. The Transmission gate circuit is required to operate for the following input/output parameters.
[0000] i. When Pad voltage≦VDD, VOUT=Pad voltage
[0000] ii. When Pad voltage>VDD, VOUT≦VDD
[0037] For obtaining the above stated output parameters, the drain of NMOS M 1 is connected to PAD, source is connected to VOUT and gate is connected to the Supply voltage (VDD). As a result of this connection, the voltage VOUT follows the PAD voltage up to the NMOS threshold (VDD−Vtn).
[0038] PMOS M 0 is required to transfer the Pad voltage from NMOS threshold to the supply voltage. To achieve this, the source terminal of transistor M 0 is connected to the Pad, drain terminal is connected to VOUT, and gate of M 0 receives the signal PMOSCTRL from the Control Signal Generator. When the Pad voltage is less than or equal to the supply voltage, the value of PMOSCTRL signal is zero volt and true Pad voltage is transferred to VOUT, through NMOS M 1 and PMOS M 0 . Further, PMOSCTRL signal is equal to Pad voltage when Pad voltage is greater than the supply voltage. Consequently, the PMOS is switched off to avoid the transference of Pad voltage higher than supply voltage. PMOS M 0 receives signal NWELL at its bias from the NWELL generation block. NWELL potential is equal to supply voltage when Pad voltage is less than the supply voltage and NWELL potential is VPAD−Vt (Threshold Voltage) when Pad voltage is higher than the supply voltage. When Pad voltage is higher than the supply voltage, there should not be any risk of consumption from Pad to bulk of transistor PMOS M 0 . Further, when Pad voltage is higher than the supply voltage, PMOS M 0 is switched off and only NMOS M 1 is operational. In this case VDD−Vtn (NMOS Threshold) appears as output voltage on VOUT, which is not the true supply voltage VDD and can thereby cause power consumption at the Input buffer. To overcome these constraints and get true value of supply voltage on VOUT, the drain of NMOS M 24 is connected to VOUT, source is connected to the supply voltage and gate is connected to Pad, the Pad voltage being higher than the supply voltage. Whenever Pad voltage is greater than VDD+Vtn (NMOS Threshold), supply voltage is outputted at VOUT. Size of the transistor NMOS M 24 is such that the voltage VOUT is equal to the supply voltage as soon as the PAD voltage crosses VDD.
[0039] FIG. 4 is a circuit level diagram of the Control Signal Generator of FIG. 2 that receives the input signal from Pad. PMOSCTRL signal is generated from this block as a result. The Control Signal Generator is required to operate for the following input/output parameters.
i. PMOSCTRL=0, when Pad voltage is less than or equal to VDD+Vt (PMOS Threshold). ii. PMOSCTRL=Pad Voltage, when Pad voltage is higher than VDD+Vt (PMOS Threshold), here the PMOSCTRL signal follows the Pad voltage.
[0042] For obtaining the above stated parameters, the source terminal of PMOS M 9 is connected to PAD, drain receives the PMOSCTRL signal, gate is connected to the supply voltage (VDD) and bias is connected to signal NWELL, to avoid power dissipation at the bulk of PMOS M 9 .
[0043] Drain of NMOS M 10 is connected to PMOSCTRL, source of NMOS M 10 is connected to the drain of NMOS M 11 and gate of NMOS M 10 is connected to VDD. As a result, stress on M 10 and M 11 is prevented when PMOSCTRL follows the Pad voltage, and zero volt signal is transferred when Pad voltage is less than VDD. Thus, the drain of M 11 does not exceed NMOS Threshold and drain to source voltage of transistor M 10 is VPad−VDD, so that the transistors are not stressed up to the Pad voltage.
[0044] Source of NMOS M 11 is connected to ground GND, drain of NMOS M 11 is connected to source of NMOS M 10 and gate is connected to the signal NMOSOFF. The value of NMOSOFF signal is equal to supply voltage when Pad voltage is less than or equal to the supply voltage and it is equal to zero when Pad voltage is greater than the supply voltage.
[0045] As per the above description of M 9 , M 11 and M 11 , the three transistors operate for the following input/output parameters:
i. When PAD voltage is less than or equal to VDD+Vt (PMOS Threshold), then the value of NMOSOFF is VDD so that NMOS M 11 transfers zero volt to the source of M 10 . As gate of NMOS M 10 is connected to VDD, it transfers zero volt to PMOSCTRL. As a result the gate to source voltage of PMOS M 9 is positive, hence PMOS M 9 is switched off, thereby outputting a zero potential at PMOSCTRL, ii. When PAD voltage is greater than VDD+Vt (PMOS Threshold), a zero value of voltage is outputted at NMOSOFF, therefore the gate to source voltage of NMOS M 11 is zero, thus resulting in a switched off NMOS M 11 . As a result the gate to source voltage of PMOS M 9 is negative and the Pad voltage is transferred to PMOSCTRL, thus PMOSCTRL follows the Pad voltage.
[0048] It is desirable to have the value of NMOSOFF signal equal to VDD when Pad voltage is less than or equal to the supply voltage, and equal to zero when Pad voltage is greater than VDD.
[0049] To achieve the above stated objective, PMOS M 15 & M 16 , NMOS M 19 , M 20 , M 21 , M 22 , M 23 & M 25 are used. Source of PMOS M 15 is connected to PAD, gate of PMOS M 15 is connected to VDD and drain of PMOS M 15 is connected to drain of NMOS M 19 . PMOS M 15 is on when pad voltage is greater than VDD+Vt (PMOS Threshold). Width of PMOS M 15 should be kept high to transfer Pad voltage at the drain of PMOS M 15 as soon as pad voltage crosses VDD.
[0050] Gate of NMOS M 19 is connected to VDD, source of NMOS M 19 is connected to the drain of NMOS M 20 , NMOS M 21 and to the gate of PMOS M 16 and NMOS M 23 . NMOS M 19 is used to avoid any stress on MOS M 16 , M 20 , M 21 , M 22 , M 23 & M 25 . In any case source of NMOS M 19 does not exceed VDD−Vt (NMOS Threshold).
[0051] NMOS M 20 and M 25 are connected in series. Drain of NMOS M 20 is connected to source of M 19 , source of NMOS M 25 is connected to ground GND and gates of both NMOS M 20 & M 25 are connected to signal NMOSOFF. NMOS M 20 & M 25 should be long channel transistors for good switching at the drain of NMOS M 20 . When Pad voltage is higher than VDD, gates of M 16 & M 23 should be close to VDD−Vt (NMOS Threshold), thus the current through these M 20 and M 25 should be very less.
[0052] Drain of NMOS M 21 and M 22 are connected to their gate, wherein both the transistors operate like diodes. Source of NMOS M 21 is connected to drain of NMOS M 22 , source of NMOS M 22 is connected to ground GND. NMOS M 21 and M 22 are used to provide 2*Vt (NMOS Threshold) to the gate of M 16 and M 23 , when Pad voltage is less than or equal to VDD. NMOS M 21 & M 22 are long channel transistors for reducing power dissipation on Pad, the Pad voltage being greater than VDD.
[0053] PMOS M 16 and NMOS M 23 are connected together to form an inverter. Switching threshold for this inverter should be greater than 2*Vt (NMOS Threshold) and less than VDD−Vt (NMOS Threshold) for obtaining the desired value of NMOSOFF.
[0054] As per the above description of M 15 , M 16 , M 20 , M 21 , M 22 , M 23 & M 25 , the circuit operates for the following input/output parameters.
[0055] When Pad voltage is less than or equal to VDD+Vt (PMOS Threshold), Vgs (Gate to source voltage) of PMOS M 15 is positive, consequently M 15 is switched off. A potential 2*Vt (NMOS Threshold) is established at the gate of M 16 and M 23 , due to NMOS M 21 & M 22 . The switching threshold of the inverter formed by M 16 and M 23 causes NMOSOFF approach towards VDD, thereby causing NMOS M 20 & M 25 to be switched on, thus the potential at the gates of M 16 and M 23 is zero volts. Thereby, NMOSOFF approaches true value of VDD.
[0056] When PAD voltage is greater than VDD+Vt (PMOS Threshold). Vgs of PMOS M 15 is negative so the PMOS M 15 is switched on. As gate of NMOS M 19 is connected to VDD, gate of M 16 & M 23 achieve a voltage level of VDD−Vt (NMOS Threshold). As a result of the switching threshold of the inverter formed by M 16 and M 23 , NMOSOFF become ZERO and NMOS M 20 & M 25 are switched off.
[0057] FIG. 5 illustrates the circuit diagram of a conventional NWELL generator. PAD is the input signal for the NWELL generator and it generates bias signals for PMOS transistors in the protection circuit.
[0058] As described earlier, bias voltage for each PMOS transistors in the protection circuit is desirable at VDD when Pad voltage is less than VDD and at VPAD−Vt (Threshold voltage) when Pad voltage is greater than VDD.
[0059] To achieve this, the source of PMOS M 2 is connected to VDD, drain & bulk of PMOS M 2 is connected to NWELL, and gate of PMOS M 2 is connected to PAD. Source of PMOS M 4 is connected to PAD, gate of PMOS M 4 is connected to VDD, bulk of PMOS M 4 is connected to NWELL and drain of PMOS M 4 is connected to gate of PMOS M 3 and to the drain of NMOS M 12 . Source of PMOS M 3 is connected to VDD, drain & bulk of PMOS M 3 is connected to NWELL. Gate of NMOS M 12 is connected to VDD, source is connected to drain and gate of NMOS M 14 . This NMOS is used to avoid stress on M 14 and M 5 . NMOS M 14 and M 5 are drain-gate connected transistors for providing 2*Vt (NMOS Threshold) on the gate of PMOS M 3 when Pad voltage is less than VDD+Vt (PMOS Threshold).
[0060] As per the above stated description, the transistors M 2 , M 3 , M 4 , M 5 , M 12 & M 14 , operate to perform the following functions:
[0061] When Pad voltage is less than or equal to VDD+Vt (PMOS Threshold), Vgs of PMOS M 4 is greater than PMOS threshold, thus PMOS M 4 is switched off. Due to drain gate configuration of NMOS M 14 and M 5 , gate of M 3 is at 2*Vt (NMOS Threshold). As a result the gate voltage (Vg) of PMOS M 3 is less than the threshold voltage, hence VDD is outputted at NWELL. For Pad voltage range 0 to VDD−Vt (PMOS Threshold) PMOS M 2 is switched on.
[0062] When Pad voltage is greater than VDD+Vt (PMOS Threshold), Vgs of PMOS M 4 is less than PMOS threshold, thus PMOS M 4 is switched on and gate of PMOS M 3 and M 2 are at same potential as on PAD, thereby resulting in switching off PMOS M 2 and M 3 . As source of PMOS M 4 is connected to PAD and bulk is connected to NWELL, there is one diode formed between source and bulk. If source voltage is higher the bulk voltage plus threshold voltage, diode conducts and NWELL become VPAD−Vt (Threshold voltage).
[0063] FIG. 6 shows the effect of using protection circuit for the Input buffer in dc-sweep. Here, X-Axis of this graph is the PAD voltage while the Y-Axis is the voltage to the Input Buffer. The protection circuit is simulated for three supply voltage levels 3.0V, 3.3V and 3.6V. As shown in the figure, the PAD voltage is varied from 0V to 5.6 Volt. VOUT follows the PAD voltage up to VDD+Vt (PMOS Threshold, ˜0.35V in this simulation), and the value of VOUT is either VDD−Vt (NMOS threshold) or VDD. Simulation results show that the Input buffer is protected from the higher PAD voltage and there can be full swing from 0V to supply voltage (VDD) at VOUT. Thus, it is concluded from the simulation results that attenuation free signal is obtained for the Input buffer.
[0064] FIG. 7 shows the transient simulation results. Here, the circuit is simulated for the supply voltage levels of 3.0V, 3.3V and 3.6V. Pulse of amplitude 5.6V is applied on the PAD for generating a pulse of amplitude equal to supply voltage (VDD) at VOUT, thus providing the required voltage level to the Input Buffer.
[0065] Although a specific embodiment of the invention has been disclosed, it will be understood by those having skill in the art that changes can be made to this specific embodiment without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiment, and it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention. | An improved voltage tolerant protection circuit for input buffer comprising a transmission gate circuit receiving input from the pad for passing the input signal to the input of the input buffer, a control signal generator electrically coupled between the transmission gate circuit and the pad to provide a control signal for operating the transmission gate circuit, and an N-Well generation circuit electrically coupled between the pad and the transmission gate circuit, and also electrically coupled to the control signal generator for generating a bias signal for the transmission gate circuit and the control signal generator. Thus, the present invention provides a voltage tolerant protection circuit that prevents electrical stress on transistors, minimizes power supply consumption and transfers signals without any change in amplitude. | 7 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to voltage regulators. More particularly, the inventions described herein relate to systems and methods for interconnecting voltage regulators to provide simple current sharing techniques and improved regulation characteristics.
[0002] Voltage regulators are found in virtually every device that requires electricity. The purpose of a voltage regulator circuit is to control and regulate voltage from a power source to a load, typically through certain conditioning and regulation circuitry. A typical application of voltage regulator circuitry is to convert AC power, provided by a power utility, to a regulated DC voltage suitable for use with consumer electronics. Such power supplies are controlled by a voltage regulator. Although voltage regulators are implemented as stand alone systems, often they are constructed as integrated circuits (ICs) and used in various applications including communication and computing systems.
[0003] Two or more voltage regulators may be connected together to provide greater output current. Factors favoring the parallel of connection voltage regulators include the need to dissipate heat over a wider area as well as increase output current. In some instances, many voltage regulators may be connected together to provide additional voltage to a load. In other instances, the voltage regulators may be connected in parallel to provide additional load current. In such instances, the connected voltage regulators are typically configured in an attempt to share current to the load. This may be done in order to promote load balancing and/or to maintain system operation within a desired peak temperature range.
[0004] As manufactured, voltage regulators experience wide variation in output voltage, thereby making current matching between directly paralleled voltage regulators relatively difficult to achieve.
[0005] The portion of load current supplied by each parallel connected voltage regulator is often dependent on the difference in output voltage and output impedance of the respective voltage regulators. Thus, when voltage regulators are connected in parallel, the regulator having the higher output voltage typically supplies more current than the supply with a lower output voltage. As a result, the supply with the higher output voltage may provide most or all of the current to the load. Moreover, the regulator providing the highest output voltage may limit in overload before the other regulators begin to supply current. This unbalanced condition is further exacerbated if the regulator with the higher output voltage also has the lower output impedance of the two (or more) supplies.
[0006] The unequal sharing of load current by paralleled voltage regulators may degrade both the performance and reliability of a power system. This problem is of particular concern for surface mounted voltage regulators due to the inherent limitation of power dissipation when mounted on a circuit board. In certain situations, the additional thermal stress resulting from such severe current imbalances may reduce component lifetime in the sourcing supply by 50% or more.
[0007] Various techniques have been used to balance current among parallel connected voltage regulators. One known current sharing technique involves the use of a “share bus” configuration in which output current information is shared among the parallel connected regulators to regulate current. In such systems, a current sense resistor is used to develop a voltage which represents the output current of the parallel connected voltage regulators. This voltage is reproduced on the share bus and monitored by the voltage regulators to determine how much current to provide. Because the power supplies are providing current based on both an internal error voltage (for individual supply regulation) and the voltage on the share bus (for group regulation), current is supplied approximately equally. One drawback with this arrangement, however, is the need for complicated controller circuitry and specialized interconnections among the voltage regulators.
[0008] Accordingly, it would be desirable to provide circuits and methods for the efficient sharing of current among paralleled voltage regulators that does not degrade voltage regulation.
[0009] Moreover, it would be desirable to provide circuits and methods for heat dissipation in parallel coupled voltage regulators that result in improved current sharing.
SUMMARY OF THE INVENTION
[0010] Circuits and methods for paralleling voltage regulators are provided which efficiently share current among paralleled voltage regulators and that does not degrade voltage regulation. The parallel coupled voltage regulators of the present invention enjoy improved heat dissipation and current sharing over a broad operating range.
[0011] In one embodiment, a method of coupling two or more voltage regulators in parallel to provide a combined output current is provided, including providing a first voltage regulator that generates a substantially constant voltage, the first voltage regulator having a power output stage; the first voltage regulator output stage having a control input and an output, a second voltage regulator that generates a substantially constant voltage, the second voltage regulator having a power output stage; the second voltage regulator output stage having a control input and an output, coupling the control input of the first voltage regulator output stage to the control input of the second voltage regulator output stage such that the voltage at an output of the first voltage regulator and the second voltage regulator is substantially equal; and coupling the output of the first voltage regulator to the output of the second voltage regulator in parallel such that current produced is substantially equal to the sum of current produced by the first voltage regulator and the second voltage regulator.
[0012] In certain embodiments, the invention may further include minimizing the voltage difference between the control input and the output of the first regulator output stage. Ballast resistors having small resistance values may be used in some embodiments to further improve the precision of output current without sacrificing load regulation. Other aspects of the invention include effective heat dissipation which minimizes hot spots and the need for separately mounted voltage regulators and heat sinks in surface mounted circuit board applications.
[0013] In other embodiments, a voltage regulator suitable for implementation on an integrated circuit is provided that supplies a substantially constant output voltage and is suitable for coupling to one or more voltage regulators in parallel to provide a combined output current, the voltage regulator circuit comprising, a current reference circuit for providing a substantially constant output current, a set impedance coupled to the current reference circuit for generating a substantially constant set voltage from the substantially constant output current, an amplifier circuit coupled to the current reference circuit and the set impedance that generates a substantially constant output voltage based on the set voltage, and a ballast impedance coupled to the output of the amplifier circuit for establishing an output impedance of the voltage regulator circuit. In such embodiments, the load regulation of the voltage regulator may be substantially independent of output voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0015] FIG. 1 is a diagram of one embodiment of parallel connected voltage regulators in accordance with the principles of the present invention; and
[0016] FIG. 2 is a schematic diagram of another embodiment of parallel connected voltage regulators constructed in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] A diagram of one embodiment of two parallel connected voltage regulators constructed in accordance with the principles of present invention is shown in FIG. 1 . As shown, system 100 generally includes voltage regulator circuits 110 and 120 . Voltage regulator circuit 110 may generally include a voltage reference circuit 111 and a power output stage driven by resistor 112 and operational amplifier 113 . Similarly, voltage regulator circuit 120 may generally include a voltage reference circuit 121 and a power output stage driven by resistor 122 and operational amplifier 123 . For simplicity, only two voltage regulators are shown in FIG. 1 . However, additional voltage regulators may be added as shown, if desired. This may be done, for example, to further improve the aggregate current sourcing capability of system 100 .
[0018] In operation, voltage reference circuits 111 and 121 may provide a predetermined voltage through resistors 112 and 122 to the non-inverting input of amplifiers 113 and 123 respectively, which are preferably configured as voltage followers (i.e., provide a current gain with unity voltage). This causes amplifiers 113 and 123 to generate an output with voltages substantially equal to their input. Each output signal may be passed through ballast resistors 114 and 124 to generate a composite output V OUT , which is a combination of the two outputs. The ballast resistors help establish a maximum current imbalance between voltage regulators 110 and 120 at full output and help minimize overall current imbalance of system 100 .
[0019] As shown in FIG. 1 , because the non-inverting inputs of amplifiers 113 and 123 are coupled together, their respective outputs are substantially equal in voltage. Each non-inverting input may be considered a control input of regulators 110 and 120 . If ballast resistors 114 and 124 are configured to have substantially the same value, then the-output current of each regulator is substantially the same as well. Thus, for example, if voltage regulators 110 and 120 are each configured to provide a 5 volt output at 1 amp (5 watts), the total output of system 100 would be 5 volts (same voltage) but at 2 amps (10 watts).
[0020] In some embodiments, an external voltage regulator circuit (not shown) may be coupled to the control input of regulator 110 and/or 120 which may be used to establish the output voltage of the paralleled regulators. This allows regulators 110 and 120 to be programmed by sources other than reference circuits 111 and 121 . In this case, the voltage follower circuits in each regulator continue to provide the output voltage and shared current as described herein, but based on the value established by the external source. In such embodiments, reference circuits 110 and/or 120 may be turned OFF or disconnected from the voltage follower circuits. Moreover, voltage references 111 and/or 121 may be programmable, so that a manufacturer or end user and set the desired output voltage of the paralleled regulators.
[0021] Small mismatches in the output voltages are impressed across the ballast resistors. If the voltage followers are precise, with low offset between input and output, ballast resistors with very low impedance can be used. In general, the lower the value of the ballast resistor, the less degradation in load regulation. Such ballast resistors can be made of a short piece of printed circuit board trace. Generally speaking, the value of the ballast resistors is a function of the precision of the voltage follower circuits. The greater the precision of the voltage followers, the lower the value of the ballast resistors.
[0022] In the example above, each voltage regulator provides substantially the same current to a load connected to V OUT (not shown) and thus provides an effective current sharing architecture. Another benefit of this general configuration is that it uses commonly available components and eliminates the need to generate system based signals for output current regulation, greatly simplifying the regulation circuitry.
[0023] For example, in integrated circuits, very accurate implementations of the voltage follower circuitry described above may be obtained, allowing, in some instances, the potential difference between amplifiers 113 and 123 to be as low as one to two millivolts of their input. In some embodiments, the offset associated with the voltage followers may be minimized by trimming components during the manufacturing process.
[0024] Because the output voltages of each regulator are substantially equal, the value of ballast resistors 114 and 124 may be very low, desirably reducing or eliminating any load regulation loss associated with the resistive ballasting such that the performance of the supplies remain substantially unaffected. In some embodiments, load regulation loss may be in 5-10 millivolt range, which is well within the 1% load regulation requirement commonly specified for voltage regulators. Such low value ballasting resistors may be obtained from less than an inch of copper PC board used to connect the supplies and may have a resistance in the order of about 10 milliohms. Other suitable resistances may be specified by a manufacturer of specific embodiments of the devices described herein.
[0025] In addition to providing increased output current, the present invention also provides a means for dissipating heat over a larger area during circuit operation. For example, when a voltage regulator such as regulator 110 is surface mounted on a circuit board, the amount of heat that can be dissipated by that regulator is limited due to various physical constraints, which in turn limits the maximum output current of the regulator. By connecting regulators 110 and 120 in parallel, the heat generated is spread out across a wider area, providing better dissipation and thus better cooling, which allows the two regulators to provide their rated current without running into their thermal limit.
[0026] Furthermore, this reduces the number and intensity of “hot spots” on a circuit board, lowers overall peak temperatures and reduces the need for separately mounted voltage regulators with large heat sinks. As a result, multiple voltage regulators may be mounted on the same or closely spaced circuit boards to achieve a desired output current without restriction due to elevated operating temperatures.
[0027] Referring now to FIG. 2 , another embodiment 200 constructed in accordance with the principles of the present invention is shown. Circuit 200 is similar in many respects to the circuit described in FIG. 1 and generally includes components and functional blocks which have been numbered similarly to denote similar functionality and general correspondence. For example, circuit 200 includes voltage regulator circuits 210 and 220 (voltage regulators 110 and 120 in FIG. 1 ), amplifier circuits 213 and 223 (amplifier circuits 113 and 123 respectively in FIG. 1 ), and ballast resistors 214 and 224 (ballast resistors 114 and 124 in FIG. 1 ).
[0028] As shown, system 200 may operate in substantially the same way as system 100 , with the exception of reference circuits 211 and 221 . Rather than operate as voltage-based circuits as described in FIG. 1 , reference circuits 211 and 221 are configured to provide a substantially constant reference current, with the output voltage of each regulator being set by a resistor to ground. As shown, set resistors 212 and 222 establish a voltage V SET which is provided to the non-inverting input of amplifiers 213 and 223 . Once this set voltage is established, circuit 200 may operate similarly to circuit 100 described above. One benefit of using current references is voltage dividers are not required, which provides improved load regulation. Moreover, in such embodiments, load regulation is independent of output voltage. Furthermore, ballast resistors do not need to be scaled to output voltages.
[0029] As in circuit 100 , the value of ballast resistors 214 and 224 may be very low, and achieve the same load regulation benefits described in connection with the circuit of FIG. 1 . Moreover, voltage regulators 210 and 220 with different current sourcing capabilities may be coupled in parallel as shown with ballast resistances 214 and 224 scaled between the voltage regulators to ensure current sharing in the ratio of available current. For example, if the current sourcing capability of voltage regulator 210 is five times greater than that of supply 220 , ballast resistors 224 and 214 may be configured in a five to one ratio to allow current to be drawn proportionately from each supply and ensure that system 200 provides a maximum output current.
[0030] In some embodiments, resistors 212 and 222 may be external and adjustable to set the output voltage of circuit 200 . In other embodiments, only one resistor may be used to set the voltage value for multiple regulators (not shown). Such a resistor may be internal or external and fixed or adjustable. In the case where multiple set resistors are used for multiple supplies, the value of the set resistors may need to be selected in view of the resulting parallel combination in order to achieve the desired resistance and thus the desired output voltage.
[0031] In certain other embodiments, e.g., such as those used for integrated circuits, it may be desirable to employ voltage follower circuits that have a negative temperature coefficient (i.e., a voltage follower circuit whose output voltage decreases after the temperature exceeds a certain point or decreases with temperature). In such embodiments, the negative temperature coefficient itself may be used as a ballasting mechanism (e.g., with or without the use of ballasting resistors).
[0032] For example, in operation, assume regulators 210 and 220 are configured such that they both have substantially the same negative temperature coefficient. If one of these supplies begins to source more current than the other, or provides current above that specified in a predetermined ratio, that supply will begin to rise in temperature. The built in temperature coefficient of that regulator will provide temperature regulation, which reacts to the temperature increase (i.e., unequal temperature rise) and causes its output voltage to correspondingly decrease. This, in turn, causes the current to adjust as well (based on the thermal resistance characteristics and temperature of the regulators). As a result, the output current of the supplies return to a state where the output current is balanced to a certain degree (e.g., based on how closely certain factors are matched such as temperature coefficient, heat sinking capability, ambient temperature, etc.).
[0033] In such embodiments, current sharing based on temperature regulation does not require the use of ballast resistors (e.g., resistors 114 , 124 , 214 and 224 ). However, small impedances may be used if desired to achieve further output precision. Moreover, in some embodiments, heat sinking by itself may be used as a means of establishing current ratios between supplies. For example, if two (or more) supplies capable of producing substantially the same or similar current, with substantially the same negative temperature coefficient are provided with different heat sinks, the supply with the lesser heat sinking capability may provide proportionally less current based on its temperature limits. Thus, if an operating temperature range is known, various paralleled voltage regulators can be provided with heat sinks that will allow them to provide current in a desired ratio based on their respective heat dissipation characteristics.
[0034] Similarly, in some embodiments, the temperature regulation itself may be used as a means of establishing current ratios between supplies. For example, if two (or more) regulators capable of producing substantially the same or similar current are provided with different negative temperature coefficients, the regulator with the more negative temperature coefficient may provide proportionally less current based its temperature limits.
[0035] Moreover, it will be apparent from the foregoing that both heat sinking and temperature coefficient factors may be combined to establish current sharing parameters between voltage regulators, e.g., supplies with less negative temperature coefficients having more heat sinking capability may be coupled with supplies having more negative temperature coefficients and less heat sinking capability, the former providing proportionally more current than the latter, etc. Such implementations may optionally include ballast resistors, if desired to further improve precision. Other configurations are possible as well.
[0036] It will be understood that the systems and methods described herein have broad based applicability and may be employed in multiple different contexts. For example, the systems described above may be used in “box” type power supplies such as those commercially produced by Lambda Corporation, Kerco, or Agilent, or in integrated circuit type voltage regulators such as those produced by Linear Technology Corporation of Milpitas Calif., the assignee of this patent application. Accordingly, commonly available circuitry referred to above may include external circuitry commonly available in a box implementation such as easily added components on a circuit board, or, in an IC implementation, may include amplifiers or such components which may be added during design at little or no additional expense.
[0037] Moreover, voltage reference circuits 111 and 121 may include any circuitry suitable for supplying a substantially constant predetermined voltage through a resistor, and may include any suitable configuration of switching or linear based regulator or other conventional reference circuitry. Similarly, current reference circuits 211 and 212 may include any circuitry suitable for supplying a substantially constant predetermined current, and may include any suitable configuration of switching or linear based regulator or other conventional reference circuitry. Such reference circuits may include the reference circuits described in co-pending U.S. patent application entitled Bandgap Voltage and Current Reference Ser. No. 11/731,279 filed Mar. 30, 2007 assigned to the assignee of this patent application, which is hereby incorporated by reference in its entirety.
[0038] Further, although ballast resistors 114 , 124 , 214 and 224 are shown as external to voltage regulators 110 , 120 , 210 and 220 such resistors may, in some embodiments, be internally based. In some embodiments, bonding wires commonly found in an integrated circuit package can also be used as ballast. Also, the regulation itself may act as a ballast. Furthermore, the voltage follower circuitry described herein may be constructed using any suitable topology known in the art. Although such circuits are described herein with a unity voltage gain it will be understood that gains other than unity may be used if desired. At gains above unity, less precise matching is typical and accurate sharing is more difficult. Certain older voltage regulators may operate with a 1-3% error in their output, an may operate above unity gain. Such regulators have difficultly being coupled in parallel as described herein and may rely on large ballast resistors which degrade load regulation. Moreover, in some embodiments, where amplifiers are running at or near their power or ground rails, offset voltages may be employed if desired to prevent or insure cutoff.
[0039] Although preferred embodiments of the present invention have been disclosed with various circuits connected to other circuits, persons skilled in the art will appreciate that it may not be necessary for such connections to be direct and additional circuits may be interconnected between the shown connected circuits without departing from the spirit of the invention as shown. Persons skilled in the art also will appreciate that the present invention can be practiced by other than the specifically described embodiments. The described embodiments are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow. | Circuits and methods for paralleling voltage regulators are provided. Improved current sharing and regulation characteristics are obtained by coupling control terminals of the voltage regulators together which results in precise output voltages and proportional current production. Distributing current generation among multiple paralleled voltage regulators improves heat dissipation and thereby reduces the likelihood that the current produced by the voltage regulators will be temperature limited. | 8 |
BACKGROUND OF THE INVENTION
This invention concerns dehumidifiers for use especially in connection with bathrooms and the like. It is well known that when an individual is taking a shower, a great deal of water vapor accumulates and condenses on the various surfaces of the bathroom. Most bathrooms have exhaust fans for removing the undesirable humid air; but, exhaust fans simply exhaust moist air from the room and replace it with air from an adjacent room. Since bathroom doors are customarily closed, it is inefficient and difficult for an exhaust fan to pull air from an adjacent room. If the door is left open, the exhaust fan might become effective but air from an adjacent room is typically undesirably cold.
Besides exhaust fans, dehumidification is accomplished by the use of a dehumidifier or refrigeration system wherein the evaporator acts as a cold surface on which moisture condenses and the condenser acts as a heat exchanger to rewarm the air before it passes back into the room. Such dehumidifiers are typically too large to fit conveniently in a typical bathroom.
SUMMARY OF THE INVENTION
By this invention, dehumidification in a bathroom is accomplished when air from an adjacent room enters the device and is selectively directed into contact with a heat exchanger and then forced into the bathroom by fan means.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic representation of a dehumidifying system according to this invention;
FIG. 2 is a top plan view showing the interior of the dehumidifier;
FIG. 3 is a side elevational view showing the interior of the dehumidifier; and
FIG. 4 is a perspective view showing the dehumidifier in accordance with this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, with particular reference to FIG. 1, the numeral 1 designates a conventional shower head. Hot water is supplied initially through pipe 2 whereby it enters dehumidifier 3 and then exits dehumidifier 3 through pipe 4 whereby it is directed to shower head 1 . The flow of hot water is controlled by means of valve 5 as is well known. Cold water is supplied directly to shower head 1 by means of pipe 6 and is controlled by valve 7 also as is well known.
With the door to bathroom B shut and the bathroom thereby effectively sealed off from adjacent rooms, air from adjacent room A enters duct 8 through inlet 9 . Air from adjacent room A then enters inlet plenum 10 by which it is directed to dehumidifier 3 . More specifically and as best shown in FIG. 2, dehumidifier 3 comprises a heat exchanger in the form of hot water coil 11 which is heated by means of hot water entering through pipe 2 and then exiting through pipe 4 . Air from adjacent room A is pulled through duct 8 and through hot water coil 11 by means of fan 12 which then directs the heated air through duct 13 and out through outlet grill 14 into bathroom B. To simplify the device, duct 13 can be eliminated with the air from dehumidifier 3 forced directly to bathroom B. Of course, dehumidifier 3 could comprise an electric heater thereby eliminating the need for the hot water connection.
According to one feature of this invention, the device is provided with heating damper 15 and bypass damper 16 . Dampers 15 and 16 are either manually or thermostatically operable, as is well known, to provide the optimum temperature of the air flowing from adjacent room A. As is shown in FIG. 2, bypass damper 16 is in its fully closed position and heating damper 15 is fully open. By this means, all the air entering inlet plenum 10 is directed through hot water coil 11 and into fan section 17 whereby it is forced by means of fan 12 ultimately into bathroom B.
Of course, if heating damper 15 is closed and bypass damper 16 is fully open, none of the air entering inlet plenum 10 will be heated and room temperature air from adjacent room A will be forced into bathroom B. By setting damper 15 and 16 to intermediate positions, air temperature is achieved as desired between being fully heated and at room temperature.
According to another feature of this invention, the device is provided with sensor 18 which acts to sense movement of hot water through pipe 2 which in turn causes the simultaneous activation of fan 12 and exhaust fan 19 in a conventional manner. Of course, besides a waterflow switch, the device can be controlled by any well known means such as a humidistat, temperature sensor and the like. Also the device can be activated by means of a direct electrical connection to exhaust fan 19 .
Therefore, by this invention, dehumidification is provided by utilizing room temperature air from an adjacent room and, if desired, heating it by means of hot water coil 11 . As humid air is exhausted out of the bathroom by means of exhaust fan 19 , the bathroom air is replaced with dry air from an adjacent room. The user is able to conveniently control the desired temperature of the air in the bathroom by the variable activation or deactivation of respective dampers 15 and 16 .
Although the drawings show this invention for use primarily in connection with a bathroom environment, it is readily apparent that this invention is well suited for other environments where hot water is present such as kitchens, laundry rooms and the like. | A dehumidifier comprising hot and cold water supply pipes interconnected to a showerhead in a bathroom, a hot heat exchanger interconnected to the hot water supply pipe, fan means to pull air from an adjacent room across the hot air exchanger and into the bathroom, and an exhaust fan to remove air from the bathroom | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. provisional application Ser. No. 60/933,803, filed Jun. 8, 2007.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to a canopy system, and, more particularly, a canopy system which provides mechanical alignment and registration of the canopy modules when grouped together.
[0003] Exposed structure types of spaces which utilize suspended ceiling islands or ceiling canopies are in increasing demand. Such systems provide architects and designers with the ability to create unique and dramatic visual effects not available with continuous, wall-to-wall ceiling systems.
[0004] For aesthetic purposes, it is desirable for the ceiling canopies to have clean, finished edges free of any exposed, unsightly edge detail or fastening means. One solution for providing this desired edge detail is shown and described in U.S. Patent Application Publication No. 2007/0033902, entitled “Suspension Systems” (hereinafter “the 2007/0033902 application”).
[0005] Canopy systems have unique code requirements which dictate the placement of the individual canopies relative one another. For example, in areas which experience seismic activity, each independently hung canopy, when hung in the ceiling space, must be spaced 18 inches apart from one another, as well as 18 inches apart from any other building component.
[0006] Additionally, irrespective of the level of seismic activity, there are additional installation concerns, including concerns regarding alignment and registration of canopies when grouped together in the ceiling space. Alignment and registration are currently achieved through careful installation which is time consuming, which, in turn, adds cost to the system. Another concern with current canopy systems is that they currently require several attachment points to the overhead building structure. Reduction in the number of hanging points will reduce installation time and cost as well as eliminate points of electrical and mechanical interference.
[0007] Thus, the present invention is directed to a system that meets the seismic code requirements and provides a means to mechanically align and register the individual canopies with one another. Also provided is a system having a minimum number of attachment points to the overhead building structure.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to an improved canopy system. The system includes a grouping frame and at least one canopy module. The grouping frame includes at least two intersecting struts. The canopy module includes a panel and suspension hardware. The suspension hardware includes at least one suspension bar which is attached to the back surface of the panel at an in-board location. Each of the intersecting struts has a hook member attached thereto. Each hook member rests on, and is supported by, a strut.
[0009] When installed, the canopy module is locked to the grouping frame in both its longitudinal and cross axes. Additionally, the grouping frame and the attachment hardware of the canopy module works in combination to mechanically register and align two or more canopy modules relative one another.
[0010] The improved canopy system provides: downward accessibility; a rigid suspension system that complies with seismic codes; a mechanism for multiple individual canopies to act as one and be installed in close proximity; ease in installation in terms of panel spacing and alignment; and a reduction in the number of attachment points to the overhead building structure by 25-50%.
[0011] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view illustrating an example embodiment of the canopy system of the invention.
[0013] FIG. 2 is an exploded perspective view of a canopy module from FIG. 1 .
[0014] FIG. 3 a is a perspective view of the hook shown in FIGS. 1 and 2 .
[0015] FIG. 3 b is a perspective view of the suspension bar shown in FIGS. 1 and 2 .
[0016] FIG. 3 c is a perspective view of the suspension bar connector shown in FIGS. 1 and 2 .
[0017] FIGS. 4 a through 4 d are perspective views showing the progressive steps in installing a canopy module in the system.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Referring now in greater detail to the figures, wherein like numerals refer to like parts throughout the drawings.
[0019] FIGS. 1 and 2 illustrate the general structural arrangement of an example embodiment of the canopy system of the invention. The canopy system 10 includes a grouping frame 12 and one or more canopy modules 14 . The grouping frame 12 has at least two intersecting struts 16 which are attached to one another and are supported by the overhead building structure (not shown) by a hanging device, such as the suspension cables 17 shown in FIG. 1 .
[0020] As best seen on FIG. 2 , the canopy module 14 has a panel 18 , such as a fibrous acoustical panel or wood panel, which has a top surface 20 , a bottom surface 22 and an edge 24 extending therebetween. The panel 18 includes a routed in-board channel 26 which extends from the top surface 20 in a direction toward the bottom surface 22 . For purposes of this description, the term “in-board channel” refers to a channel that does not extend to an edge of the panel. This in-board feature substantially preserves the integrity of the panel and provides freedom of the edges. In other words, the edge configuration is not dictated by the support structure. Also, since the channel 26 does not extend to the edge of the panel 18 , no further edge detail, such as a trim element, is required to finish the edge of the panel 18 .
[0021] The canopy module 14 also includes suspension hardware, the components of which are best seen in FIGS. 2 and 3 a - 3 c . The suspension hardware includes one or more longitudinally extending suspension bars 32 (See FIG. 3 b ). In the preferred configuration shown throughout the drawings, more than one suspension bar 32 is utilized. Here, the individual suspension bars 32 are mechanically attached to one another in the channel 26 to form an inter-locking continuous suspension bar. For example, the suspension bars can be attached via corner splices 40 (See FIG. 3 c ). When assembled to the panel, the suspension bars 32 provide rigid support for the panel in both the longitudinal and cross directional axes of the panel. Various types of suspension bars 32 can be utilized, including the extruded H-bar shown throughout the Figures and the conventional inverted-T grid members illustrated in the 2007/0033902 application.
[0022] The suspension hardware also includes a plurality of hook members 42 which are fixedly attached to the longitudinally extending suspension bars 32 and extend therefrom in a direction generally perpendicular thereto. As best shown in FIG. 3 a , the hook members 42 include a hook portion 43 at one end and an attachment flange 45 at the opposite end. The example hook members shown in the drawings are of general J shape and are preferably attached to the suspension bars 32 via the attachment flange 45 at an interior position of a respective suspension bar 32 . Preferably, for a more fixed attachment, the hook portion 43 includes detailing which conforms to the shape of the intersecting struts 16 so that the hook member 42 will fit over and around, and ultimately rest upon, the intersecting struts 16 . For example, the hook members are shown to be attached at the center of the suspension bar so that they will be attachable to the intersecting struts of the grouping frame as described in greater detail below.
[0023] The panel module 14 is installed on the grouping frame 12 by resting the hook members 42 over the struts 16 of the grouping frame 12 . For ease of installation, the hook portion of the hook members all face the same direction, i.e. they each face in either the clockwise or counterclockwise direction. For illustration purposes, each hook portion of the hook members shown throughout the drawings face the counterclockwise direction.
[0024] The progressive steps of attaching the canopy modules 14 onto the grouping frame are now described in greater detail with respect to FIGS. 4 a - 4 d . As illustrated, the canopy modules 14 are downward accessible, i.e. the modules 14 are inserted up onto the grouping frame from a position below the grouping frame (as shown in FIG. 4 a ). As shown in FIG. 4 b , the module is lifted upwardly until the hook portions 43 of all the hook members 42 are positioned above the intersecting struts 16 . As shown in FIG. 4 c , the module 14 is then rotated in a counterclockwise direction, i.e. the same direction in which the hook members are facing, until the hook portion of the hook members are positioned over the struts of the grouping frame. The struts 16 essentially act as a stop for movement of the canopy module in the counterclockwise direction. As shown in FIG. 4 d , the module 14 is then allowed to drop down until the hook portion of the hook members engage, and rest upon, the intersecting struts 16 .
[0025] The grouping frame 12 , therefore, works in combination with the hook members 42 of the canopy module 14 to permit the modules to be easily locked onto the grouping frame in both the longitudinal and cross axes. Additionally, due to the installation procedure afforded by the components of the canopy modules, the modules can be installed on the grouping frame in close proximity to one another. Also, by attaching the modules to a grouping frame, the modules are indirectly attached to one another and are easily aligned and registered relative one another.
[0026] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A canopy system for use in the interior building environment. The canopy system of the invention meets seismic code requirements and includes a means for mechanically aligning and registering canopy modules relative one another. The system requires a minimum number of attachment points to the overhead building structure. | 4 |
[0001] This patent application is a continuation of U.S. patent application Ser. No. 13/735,496, which was filed on Jan. 7, 2013 and issues as U.S. Pat. No. 8,799,090 on Aug. 5, 2014, which is a continuation of U.S. patent application Ser. No. 12/725,780, which was filed on Mar. 17, 2010 and issued on Jan. 8, 2013 as U.S. Pat. No. 8,352,313, which was a continuation of U.S. Pat. No. 7,711,601, which was filed on Jul. 11, 2001. The entireties of those applications are expressly incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to the field of automated payment facilities, such as exit facilities for parking garage or parking lot applications.
[0003] Exit facilities for parking lots and parking garages are well known. In the typical exit facility, an exit gate bars egress from the parking area until payment has been registered. In a typical parking facility, a live attendant sits within a tollbooth at the exit. The attendant calculates the value of parking, receives payment and activates the gate to permit a vehicle to pass.
[0004] In recent years, automation has reached the exit facility for parking lots and parking garages. In the automated system, a vehicle operator pays the cost of a parking validation ticket at a remote site. The ticket itself is encoded to indicate that payment has been received. The vehicle operator then proceeds to the exit facility where the validated ticket is read and registered. When the appropriate payment signal is sensed by the exit equipment, the gate opens allowing egress. One difficulty in facilities of this type is that the payment feature is isolated from the exit facility. In a typical situation, live attendants occupy adjacent booths to take payment in the likely event that the commuter fails to validate his/her parking ticket prior to exit. Thus, while this type of automated facility obtains some of the benefits of the automation, it still does not completely satisfy or achieve the objective of a fully automated system. In fact, in a typical installation, more vehicles pass through the operator attendant booths than the fully automated booth.
[0005] One decided advantage of the live parking attendant is the capability of human interaction. Even in these days of automation, many individuals still prefer the human touch, particular when one is paying money. The fully automated systems do not have the capability of providing any human interaction, which often makes these types of systems undesirable in spite of the conveniences that they may otherwise present.
[0006] There remains a need for an automated payment facility that combines the benefits of the human attendant with the benefits of the automated system.
SUMMARY
[0007] In order to address these needs, the present invention contemplates an automated payment facility that permits human interaction with the walk-up or drive-up customer. In one embodiment, a central monitoring station is linked to a number of remote facilities, such as exit facilities at parking lots or garages. Each exit facility includes means for assessing and receiving a payment amount. For an exit facility in connection with a parking lot, this means includes means for assessing a payment amount that can comprise a ticket reader, a processor for calculating a time duration and associated fee, and a display for displaying the fee amount to the customer. The overall means can also include means for receiving the payment amount, which can further comprise a credit/debit card reader and/or cash acceptor, in addition to software within the processor capable of processing the payment. All of these components can be of known design and can all operate to control an exit gate mechanism as is known in the art.
[0008] The present invention contemplates the novel addition of means for providing two-way video and audio communication with the central monitoring facility remote from each payment terminal. In the preferred embodiment, this means comprises a digital video camera, a monitor or video display and an audio speaker and microphone element at both the payment terminal and the central monitoring facility. The communication means can be continuously activated, automatically activated when a customer approaches or access the exit terminal, or on issuance of a help request by the customer through the exit terminal. When activated, the communication means provides for two-way human-to-human interaction between the customer and a remote live attendant.
[0009] In one aspect of the invention, this two-way communication feature can allow the customer to speak directly to a live attendant to at least verbally address problems that may have been encountered at the facility. The communication feature can also be used as a security or emergency call capability. In a preferred embodiment, the remote attendant can access the processor of the remote payment terminal to perform a variety of functions. For instance, the attendant can troubleshoot components of the exit facility, determine a proper payment amount, or process payment of the requisite fee. The terminal processor can also be remotely accessed by the central attendant to directly activate the exit facility, such as by raising the exit gate to allow the customer to exit.
[0010] The two-way communication feature allows the customer to remain in contact with the remote attendant until the particular transaction is complete. In addition, the feature allows a central monitoring station to be linked to a plurality of remote terminals, such as parking payment and exit facilities. The central monitoring station can include a P/C that is linked to each remote terminal in a variety of ways. Preferably, the link is established through an ethernet or the internet, or through a direct communication line, including a land-line or a satellite link.
[0011] The P/C allows the remote attendant to access any of the linked payment terminals, either in response to a signal from the terminal itself or at the attendant's own behest. Thus, a single attendant can be available to communicate with several payment terminals, in lieu of the prior approach of manning a payment booth at each facility. A bank of P/C's and associated attendants can work from the central monitoring station to communicate with dozens of remote facilities, providing the human touch to each facility regardless of the location of the central station and the remote facilities.
[0012] It is one important object of the present invention to provide human interaction at a remote terminal, such as a payment terminal at a parking facility. Another object is to maintain this direct human interaction with a large number of remote terminals, while minimizing the manpower requirements for providing this service.
[0013] One clear benefit achieved by the present invention is that a customer at a remote facility can readily reach a human to help address problems occurring at the facility. Another benefit is that a remote attendant at a central station can monitor and control the remote facility as required.
[0014] These and other objects and benefits will become apparent upon consideration of the following written description and accompanying figures.
DESCRIPTION OF THE FIGURES
[0015] FIG. 1 is a side diagrammatic representation of an exit facility in accordance with one embodiment of the present invention.
[0016] FIG. 2 is a block diagram of the components of the exit facility shown in FIG. 1 .
[0017] FIG. 3 is a block diagram of the components of a universally monitored and administered array of exit facilities.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. The inventions includes any alterations and further modifications in the illustrated devices and described methods and further applications of the principles of the invention which would normally occur to one skilled in the art to which the invention relates.
[0019] The present invention contemplates integrating video conferencing capabilities with an automated payment terminal. The following description of the preferred embodiment envisions use of the invention as part of a parking facility. However, it should be understood that other applications of the inventive concepts disclosed herein are contemplated beyond the illustrated embodiment.
[0020] In accordance with a preferred embodiment of the invention, an exit facility 10 , for a parking garage for example, includes a gate mechanism 11 that restricts egress from the parking structure. A payment terminal 20 is provided that controls the operation of the gate mechanism 11 . The payment terminal 20 can remain generally dormant until a vehicle arrives at the exit facility 10 . In other words, the electrically powered components of the terminal 20 can be retained in a standby condition or a reduced power condition until the terminal 20 is fully activated. This activation can occur by a pressure switch adjacent the terminal 20 , a sensing eye, or by operator interaction with the terminal itself.
[0021] In one feature of the preferred embodiment, the payment terminal 20 includes a series of sequential instruction displays 22 , 23 and 24 . Preferably, each display is back-lighted or illuminated to be readily visible by the driver. In additions most preferably each of the displays 22 - 24 is illuminated in sequence to indicate the next step to be performed in the payment process.
[0022] In the instance in which the payment terminal 20 is activated by the presence of the vehicle, the first display 22 can be illuminated to identify the location in which the vehicle operator inserts the parking ticket. Specifically, the ticket is inserted into a ticket reader 28 . The ticket can be of any conventional type, such as hollerith, scan-stripped or bar-coded, and the reader can be of a known type capable of reading the particular ticket. The payment terminal 20 includes a microprocessor 65 (see FIG. 2 ) that registers the ticket inserted into the reader 28 and determines the duration at the parking facility and the required fee. It also is envisioned that the ticket reader 28 and the associated software can identify prepaid tickets, user passes, discount cards and other indicia on the ticket to identify a particular payment regime. In some instances, such as in the case of a parking pass, the central processor 65 can be configured to identify the ticket inserted into the reader 28 as providing automatic egress, in which instance, the processor 65 provides a instruction on the gate signal line 68 to raise the gate mechanism 11 .
[0023] However, in the typical instance, the processor 65 will undertake a calculation to determine the requisite fee. At that point, the display 22 is turned off, and the next display 23 is illuminated. This display identifies the location for payment by the vehicle operator. The required payment amount is shown in the fee display 30 , which is again controlled by the central processor 65 in a known manner In accordance with the most preferred embodiment, two general payment approaches are permitted. In the first, a credit card reader 32 can scan a credit card, debit card, prepaid value card or a validation coupon (such as a validated parking ticket). In the second, a cash acceptor 33 accepts conventional bills. A coin acceptance unit can also be incorporated as a payment vehicle. In the event that a credit or debit card is inserted into the reader 32 , the central processor 65 can activate known software which performs the necessary credit check to evaluate the validity and credit worthiness of the card to determine whether payment can be accepted through this means. If the card is “rejected”, the reader 32 operates to eject the card. The fee display 30 can be altered to provide an additional display indicating that the credit card payment method has been rejected, thereby requiring a cash payment.
[0024] Once an appropriate amount of cash payment has been inserted into the cash acceptor 33 , or an appropriate credit card 32 has been evaluated by the reader 32 , the display 23 is de-energized, and the next display 24 is illuminated. This display identifies the location of the receipt printer 35 in which a paper receipt is produced for the vehicle driver. In addition, if cash is provided at the acceptor 33 , the central processor 65 determines whether the inserted cash exceeds the requisite payment amount. In this instance, appropriate change is dispensed through the change dispenser 36 .
[0025] As thus far described the payment terminal 20 parallels many known “pay on foot” stations, or fully automated payment stations. In accordance with an important feature of the present invention, the payment terminal 20 includes what amounts to a video conferencing capability. Specifically, the terminal 20 includes a digital video camera 40 , a monitor or video display 42 and communication speakers/microphones 43 and 44 . As described in more detail herein, the payment terminal 20 is remotely connected to a workstation occupied by a human A video camera transmits an image of the attendant to the payment terminal 20 for display on the monitor 42 . Likewise, two-way communication between the attendant and the driver is facilitated by the speakers/microphones 43 and 44 . The video camera 40 transmits an image of the person at the payment terminal to provide the live attendant with commensurate human interaction.
[0026] In one embodiment, the video and audio interaction features of the payment terminal 20 are constantly activated, or at a minimum activated when the payment terminal 20 is activated. Alternatively, the video conferencing capabilities can be accessed through the help button 38 . The terminal 20 can include an easily and clearly identified help button 38 that can be depressed to send a signal from the payment terminal 20 to the remote monitoring station. Depressing the help button 38 can automatically activate the video conferencing equipment, namely, the camera 40 , the display 42 and the speaker/microphones 43 , 44 . Alternatively, the attendant can remotely energize the video conferencing equipment, once from the payment terminal 20 .
[0027] When the video conferencing component of the payment terminal 20 is activated, the consumer, such as a vehicle driver, can directly interact with the remote-based attendant. At this point, the driver can identify specific problems that are being encountered, such as the ticket reader 28 is failing to read the parking ticket, the cash acceptor 33 is not accepting the cash, the credit card reader is rejecting the credit/debit card, no receipt has been generated, or no change has been received. Moreover, and perhaps most importantly, the activation of the video conferencing can be used as a safety or alert feature.
[0028] The attendant can have a varying range of control over the components of the payment terminal and can remotely access the central processor 65 of the payment terminal 20 . For instance, the remote attendant can execute a diagnostic routine that determines whether any of the electronic or mechanical components of the terminal has malfunctioned. The live attendant can help resolve credit/debit card issues. In case of a failure of the ticket reader, the attendant can verbally receive the length of time that the vehicle has been parked directly from the vehicle operator (of course, relying upon the “honor system” in this regard). The remote attendant can remotely calculate the appropriate fee and can activate the fee display and associated software within the central processor 65 . Finally, but not exclusively, the remote operator can initiate a signal on the gate signal line 68 to open the gate mechanism 11 depending upon the outcome of the video conferencing.
[0029] In order to accomplish this human interaction through video conferencing the payment terminal 20 includes a remote processor unit 50 . The remote processor 50 is preferably a pc-based system with some limited computing power and limited memory. Most significantly, the remote processing unit 50 is provided with some means for communicating with a remote-based attendant.
[0030] In the preferred embodiment, the remote processor unit 50 includes an input control module 54 that communicates with the ticket reader 28 , credit card reader 32 and cash acceptor 33 . The input control module 54 can provide two-way communication with each of the various readers to receive digital signals indicative of data contained on the ticket and send control signals to the reader/acceptor electronics. The input control model 54 can communicate with a fee calculation module 56 which can calculate the appropriate parking fee based on validation of the parking ticket through the reader 28 , and then ultimately determine whether the fee has been paid. The fee calculation module 56 can also determine whether the fee has been overpaid by payment through the cash acceptor 33 and determine the amount of change to be dispensed through the change dispenser 36 . The fee calculation module 56 communicates with the central processor 65 , which can then appropriately control other components of the terminal 20 .
[0031] The remote processor unit 50 also includes a display control module 58 , which is connected to the sequential displays 22 - 24 . The display control module 58 can include a switching network to turn on and off the illumination for each of the displays, based upon signals received from the central processor 65 .
[0032] A communication control module 60 is provided to accomplish the video conferencing features. This module is connected to the video camera 40 , the monitor/video display 42 and the speaker/microphones 43 , 44 . The display control module 58 also communicates with and is controlled by the central processor 65 to transmit and receive audio and video signals.
[0033] The remote processor unit 50 also includes an output control module 62 that controls the display on the fee display 30 , the generation of a receipt through the receipt printer 35 , and the discharge of change through change dispenser 36 . Again, the output control module 62 is controlled by signals from the central processor 65 . Moreover, the central processor 65 provides a signal on gate signal line 68 to the gate mechanism in 11 instructing the mechanism to raise or lower as a function of the activity occurring at the payment terminal 20 .
[0034] It is understood that each of the basic modules can be readily implemented in hardware, electronics and software or a combination thereof, which is all within the skill of the ordinary artisan in this field. Preferably, as indicated above, the remote processor unit 50 is a personal computer, which can then include a number of software routines to perform the various modular functions. In addition, the processor unit 50 can include a memory 66 associated with the central processor 65 . This memory can be continuously accessed by the central processor 65 to obtain pricing information. In addition, the memory 66 can store information from each payment transaction. This data can then be downloaded through the payment terminal 20 , or more preferably periodically transmitted to a remote monitoring station for evaluation. The data stored within the memory and/or transmitted to the central monitoring station can include the number of vehicles passing through the exit facility 10 , the average stay of a particular vehicle in the facility, the number of malfunctions or errors occurring, and other information indicative of the performance of the payment terminal 20 .
[0035] In order to effect the communication from the payment terminal 20 to a remote monitoring facility 75 , the remote processor 50 also includes a communication module 70 that can provide immediate and direct communication through a data link 71 , as depicted in FIG. 3 . In one embodiment, the communication module can be a hard-wired link to a remote location. For instance, in a building that includes a parking facility, the remote monitoring personnel can be the building attendant.
[0036] However, most preferably, the datalink 71 is accomplished through an internet or ethernet connection. In this instance, the communication module 70 can include a modem capable of making a remote 75 or dial-up connection. Thus, a remote or central monitoring station can be located virtually any place in the world and still provide the video conferencing and human interaction features of the present invention. Referring to FIG. 3 , a number of communication modules 70.sub.a-70.sub.zz, corresponding to a like member of widely dispersed payment terminals, are shown linked to a central monitoring station 75 . The monitoring station includes its own communication module 77 that can administer the flow of data from each of the independent and remote payment terminals to and from remote station. For instance, the module 77 can include a communication modem and software to avoid conflicts and data crashing.
[0037] The central monitoring station 75 can include a personal computer 79 with a video display, a video camera 80 , and a speaker/microphone system 81 , all similar to the like components found on the payment terminal 20 . Thus, the video camera transmits an image of the human attendant at the remote monitoring station 75 , while the speaker/microphone accomplishes two-way communication. The remote attendant can perform the various monitoring and communication functions described above through the PC 79 .
[0038] In a most preferred embodiment, the PC 79 includes software that permits multiple displays on the pc monitor as audio/video data is received from individual ones of the payment terminals 20 . Alternatively, the display seen by the remote attendant can be scrolled from payment terminal to payment terminal Of course, if the attendant were working with a driver at one payment terminal, request from help from another payment terminal would ordinarily be delayed. Most preferably, the central monitoring station can include a number attendants, each jointly monitoring all of the remote payment terminals affiliated with that monitoring station the instance where multiple help requests are incoming to the monitoring station 75 , the requests can be conveyed to successively available attendants.
[0039] The local monitoring/video display 42 at the payment terminal 20 can receive and display other images when not being used to communicate with the remote station. For instance, the monitor can display advertisements, or describe events occurring in the city, provide weather or traffic information, or virtually any kind of information that is desired. The same ethernet or internet link can be used to provide a wide range of video display when the attendant is busy or when an attendant is not required.
[0040] In the preferred illustrated embodiment, the inventive payment facility finds great utility in connection with a vehicle parking facility. The same inventive concepts can be used with “pay-on-foot” stations, street-side parking meters, entry facilities such as for a building, museum, exhibit or concert, and the like. The video conferencing capability not only adds a human touch, it also provides access to a decision-marker who can field questions and provide immediate solutions.
[0041] In the most preferred embodiment, the payment facilities are linked to the central monitoring facility using an internet-type connection. Each payment facility, or at a minimum each video camera, can be ip addressable. Similar technology is incorporated into videoware provided by cuseeme networks, inc., which videoware could be readily adapted for use with the present inventive system.
[0042] Each payment facility can include its own payment processing capability, as described above. An independent dial-up type connection can be provided as is known in the art. Alternatively, credit/debit card payments can be processed through the central facility.
[0043] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It should be understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. | A central monitoring station is linked to a plurality of remote terminals, such as payment terminals at a plurality of parking facilities. A two-way communication system enables communication between a customer who is remote from the central monitoring station and an attendant at the central monitoring station. The communication system may also allow the attendant to manipulate each remote terminal to collect data or troubleshoot or override the function of the terminal. | 6 |
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for providing responses to requests of a client, and particularly to a method and apparatus for providing responses to requests of a client that is in an off-line state.
BACKGROUND OF THE INVENTION
The nineties of the 20th century featured a tremendous social technology revolution which by the collaboration of the data processing industry with the consumer electronics industry. Like all other revolutions, it has had a prominent effect on the technology development trend, especially accelerating the development of those technologies which have been in a fledgling state. One main field among these technologies is the transmission of Internet relevant documents, media and applications. The combination of the consumer electronics industry with the data processing industry has greatly prompted demands on versatile communication transmission methods. From being a loose-coupled computer network used for transmitting science and government data, the Internet has entered a strikingly developing era after over ten years of silent existence. With such development, business and consumers can access all the documents, media and programs directly.
The Internet is an open and worldwide computer network which includes lots of connected subnets. It has been developed from the previous American ARPAnet. Now, it mainly uses TCP/IP as the communication protocol. TCP/IP is an acronym for “Transfer Control Protocol/Internet Protocol”, which is a software protocol developed by the U.S. Department of Defense for computer communication. The Internet can be described as a geographically distributed remote computer network system which executes such networking protocols to allow users to share information and interact. Because of this-kind of widely used information sharing, remote networks such as the Internet have been fully developing into the “open” systems. Therefore, users can design their software applications without constraints to perform specific operations or services. The detailed information about the Internet nodes, objects and links can be referred to in the textbook “Mastering the Internet”, authored by G. H. Cady etc., and published by Sybex Corporation in Alameda, Calif. in 1996.
The World Wide Web (WWW) is the Internet multimedia information indexing and retrieving system. WWW clients use Hypertext transfer protocol—HTTP to achieve transaction processing with the Web Server. HTTP is a well known communication protocol. It allows users to use Hypertext Markup Language—HTML, which is a standard web page description language, to access all kinds of files, such as text, graphics, image, audio and video, etc. HTML provides a basic file format, and allows developers to specify links with other servers and files.
The client/server structure is very popular in WWW. In most cases, the Web client uses a browser to send requests to the web server, and to explain and display (or play) the hypertext information and all kinds of multimedia data formats returned from the Web server.
In real client/server network applications, it is not possible for the client-end software to keep online all the time, especially for those executed on mobile devices. Currently, the widely used mobile devices include the notebook PC such as IBM ThinkPad, handheld PC such as 3COM PalmPilot and IBM WorkPad, or many other handheld devices embedded with network connection. Because of the mobility of such devices, it is inconvenient for them to connect to the net in most situations.
When network connection is impossible, it is absolutely necessary for the client side software to keep working off-line, thus not only the handy features of mobile devices but the huge advantages of the Internet could be fully utilized as well.
Currently, the client side software is unable to work normally when off-line unless it has been specifically so designed. Actually, there have been many specific methods to address this problem. But these methods are either for a specific application or for specific hardware. A common and simple method is greatly needed to keep client side software working normally even when it is off-line.
The important difference between on-line and off-line states is that during the on-line state the client can get the response from the server if necessary. But in the latter case, the client is unable to communicate with the server. So, in client/server architecture, client side software is usually unable to keep on working normally during off-line state.
The first objective of this invention is to provide an apparatus for providing responses to requests of an off-line client.
The second objective is to provide a method for providing responses to requests of an off-line client.
The third objective is to provide a computer-readable media for recording programs which respond to the requests of an off-line client.
SUMMARY OF THE INVENTION
To achieve the objectives mentioned above, this invention provides an apparatus for providing responses for requests of an off-line client, characterized by comprising:
a request-response storage ( 703 ), provided in a client machine, which stores a plurality of requests and a plurality of responses;
a network flow redirector ( 701 ), for redirecting requests of the client from a network connection to the client machine itself by modifying system configuration of the client machine when said client is in an off-line state, and for redirecting requests of the client from the client machine itself to the network connection by resuming the system configuration of the client machine when said client leaves the off-line state and enters an on-line state; and
an off-line server ( 702 ), provided in the client machine, for receiving the requests of the client redirected by said network flow redirector ( 701 ) to the client machine itself, generating responses based on requests received, said plurality of requests and said plurality of responses stored in said request-response storage ( 703 ), and returning generated responses to said client as responses of a server.
To achieve the second objective mentioned above, this invention provides a method for providing responses for requests of an off-line client, characterized by comprising steps of:
(a) providing a request-response storage in a client machine, which stores a plurality of requests and a plurality of responses;
(b) redirecting requests of the client from a network connection to the client machine itself by modifying system configuration of the client machine when said client enters an off-line state; and
(c) while said client is in the off-line state, repeatedly performing in the client machine steps of:
(c1) receiving a request redirected to the client machine itself,
(c2) generating a response based on said request, said plurality of requests and said plurality of responses stored in said request-response storage, and
(c3) returning said response to said client as a response of a server.
To achieve the third objective mentioned above, this invention provides a computer-readable media for recording programs, on which a program is recorded for performing steps of:
when it is determined that a client enters an off-line state, modifying system configuration of the client machine, such that requests of the client are redirected from a network connection to the client machine itself; and
while said client is in the off-line state, repeatedly performing following steps in the client machine:
(c1) receiving a request redirected to the client machine itself,
(c2) generating a response based on said request, said plurality of requests and said plurality of responses stored in a request-response storage provided in the client machine, and
(c3) returning said response to said client as a response of a server.
According to the method and device provided in this invention, to allow the client to keep working normally while off-line, there is no need to modify the client software itself, just make some modification in the client machine's system configuration. Thus, the mobility of the client machine is enhanced greatly. The off-line state is no longer an obstacle to the server and the client. Especially for the client-end software of Personal Digital Assistant (PDA) which is very complex, the mobility of the PDA device could be enhanced greatly because of the removal of the need to modify the client software. Furthermore, the user interface remains unchanged when both on-line and off-line, so there is no need to give additional training to the users.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of this invention will become apparent from detailed description of the preferred embodiments in conjunction with attached drawings, in which:
FIG. 1 shows a data processing system which implements this invention;
FIG. 2 shows the high level framework of the components of the data processing system shown in FIG. 1;
FIG. 3 shows a handheld data processing system which implements this invention;
FIG. 4 shows the client/server architecture of a preferred embodiment of this invention;
FIG. 5 shows the client/server architecture of the preferred embodiment of this invention in more detailed framework;
FIG. 6 shows the computer network which exemplifies the preferred embodiment of this invention;
FIG. 7 shows the detailed framework of the apparatus, which offers responses to the off-line client, provided by this invention;
FIG. 8 shows the flowchart of the method, which is used by the off-line client, provided by this invention;
FIG. 9 shows the flowchart of the method, which is used by the client when it ends its off-line state and enters on-line state, provided by this invention;
FIG. 10 gives an example to show the relationship among the internal pages of an insurance company; and
FIG. 11 gives an example to show that a browser could get appropriate responses when off-line.
DETAILED DESCRIPTION OF THE INVENTION
Several specific details will be offered in the following description. It is obviously not necessary for persons skilled in that art to implement this invention using these details. It other cases, the well-known components or circuits are presented merely in the form of a framework to avoid unnecessary details. In most cases, the details like timing sequence, are omitted if such details are not necessary to fully understand this invention and are common knowledge to persons skilled in the art.
Now refer to FIG. 1, it shows a data processing system 20 which implements this invention. This system includes processor 22 , keyboard 82 and display 96 . Keyboard 82 is connected to processor 22 by cable. Display 96 includes display screen 30 , which can be implemented by CRT, LCD or electroluminescent display, etc. The data processing system also includes a pointing device 84 , which can be implemented by tracing ball, joystick, touching board, touching screen or the mouse shown in the figure. This pointing device 84 can be used to move the arrow or cursor on the display screen 30 . Processor 22 can be connected to one or more peripheral devices, such as modem 41 , CD-ROM 78 , network adapter 90 and floppy drive 40 . Each peripheral device can be embedded inside or outside processor 22 . The output devices such as printer 100 could be connected to processor 22 .
It should be acknowledged by persons skilled in the art that display 96 , keyboard 82 and pointing device 84 can all be implemented by several currently well-known components.
Now referring to FIG. 2, the high level framework of the components of the data processing system shown in FIG. 1 are depicted. The data processing system 20 is mainly controlled by the instructions which are readable to the computer. These instructions could be in the form of software, regardless of where or how to store or access the software. The software can be executed on CPU 50 to make the data processing system 20 work.
The storage devices connected to the system bus 5 include RAM 56 , ROM 58 , nonvolatile memory 60 and the circuit used to store and access information. ROM is used to store data that couldn't be modified. On the contrary, data stored in RAM can be modified by CPU 50 or other hardware devices using DMA controller 86 . Nonvolatile memory 60 has the ability to still keep data even when power is down. Nonvolatile memory includes ROM, EPROM, flash memory and battery backup CMOS RAM. As shown in FIG. 2, this kind of battery backup CMOS RAM could be used to store system configuration information.
The extension card or board is a circuit board containing chips and other electronic components. These components are connected to offer additional functions or resources for the computer. In general, the extension card 54 with bus 6 could be used to contain storage, disk controller 66 , video card, parallel and serial port, and embedded modem. For those lap computers, handheld computers or other portable computers, extension card is usually implemented as PC card, as the similar size as the credit card and inserted into the slot beside or in the back of the computer. One example of this kind of slot is PCMCIA(personal computer memory card international association) slot, defining No. 1, 2, 3 card slot. Empty slot 68 could be used to contain all kinds of extension card or PCMCIA card.
Both disk controller 66 and floppy controller 70 include specific integrated circuits and other related circuits. It is their responsibility to instruct and control reading and writing data from/to the hard disk drive 72 and floppy drive 74 respectively. The operations handled by this kind of disk controllers include locating read/write head, arbitrating between the driver and the CPU 50 , and controlling the transmission from/to the storage. A single disk controller can control more than one disk drive. CD-ROM controller 76 could be included in the data processing system 20 , and can read data from CD-ROM 78 . This kind of CD-ROM uses laser components instead of magnetic equipment to read data.
Keyboard-mouse controller 80 is used as an interface between keyboard 82 and pointing device 84 in data processing system 20 . The pointing device is generally used to control an on-screen component. For example, an arrow-like cursor has a hot point which can specify the location of the pointing device when a user clicks on the mouse or presses a key on the keyboard. There are many other pointing devices, such as graphics input board, stylus, light pen, joystick, tracking ball, track board, and the devices with IBM's “TrackPoint” brand.
Communication between the data processing system 20 and other data processing systems can be simplified by the serial port controller 88 , which is connected to system bus 5 , and network adapter 90 . The serial port controller 88 is used to transmit information between computers ( 22 and 122 of FIG. 2 ), or between the computer and peripheral devices, one bit each time in a single line. Serial communication could be either synchronous (controlled by some standards such as clock) or asynchronous (managed by exchanging signals controlling information flow). Interface RS- 232 and RS- 422 are two examples of serial communication standard. As shown in the figure, this kind of serial interface could be used to communicate with modem 41 of FIG. 1 . Modem is a communication device which enables computer to transmit information in the standard telephone line. Modem 41 converts the digital signal of computer to internal clock signal which is suitable for transmitting in telephone line. It can be used to connect the data processing system 20 with an online information service organization such as “PRODIGY” provided by IBM and Sears. This kind of online service provider can offer many software which can be downloaded to the data processing system 20 via modem 41 . Modem 41 can provide connection to several software resources such as server, electronic bulletin board, the Internet and WWW.
The network adapter 90 could be used to connect the data processing system 20 to LAN 94 . LAN 94 can provide the device allowing users to mail and transmit software and information electronically. Besides this, it can also offer distributed processing, using several computers to share the workloads or cooperate while executing one task.
The display 96 controlled by display controller 98 is used to display the video output generated by the data processing system 20 . This kind of video output includes text, graphics, motion picture and movie. The display 96 can be implemented by CRT based video display, LCD based plane display or gas plasma based plane display. The display controller 98 is an electronic component which can be used to generate the video signal transmitted to the display 96 .
The printer 100 could be connected to the data processing system 20 via parallel port controller 102 . It is used to place the text or image produced by the computer to paper or another media such as transparent film. There are several other types of printers such as image setter, graph plotter, or slide recorder, etc. The parallel port controller 102 could be used to transmit multiple data bits and control bits in the line between system bus 5 and another parallel communication device such as printer 100 .
CPU 50 is charge of reading, decoding and executing instructions, and transmitting information from/to other resources via system bus 5 , which is the computer's main data transmitting route. This kind of bus connects all components in the data processing system 20 , also specifying the media which is used to exchange data. As shown in FIG. 2, system bus 5 connects storage 56 , 58 , 60 , CPU 50 and other devices, and enables data exchange among them. Additional bus 6 connects the CDRom 76 and other components on the extension card 54 .
Now referring to FIG. 3, a handheld data processing system 300 which implements this invention is shown. The front board of the system includes display screen 301 , hand writing area 302 , scrolling buttons 303 , and application buttons 304 . Display screen 301 is used to display the information stored in the handheld data processing system 300 . It is touch sensitive, which means it can induce when a user point-clicks the screen by a pen. It can also display the control and configuration information when an application is executing. Hand writing area 302 is used by user to write text by the pen. Scrolling buttons 303 are used to help view the text or other information beyond the display screen 301 , including up scrolling and down scrolling button. Application buttons 304 are used to activate applications, each with a special icon. The handheld data processing system 300 could be WorkPad from IBM, or PalmPilot from 3COM. As for IBM's WorkPad, there are four application buttons in its front board, corresponding to the notepad, address book, task list and memo applications, respectively. In addition, an appropriate pen (not shown in the figure) could be provided together with the handheld data processing system 300 for the special purpose of point clicking display screen 300 or writing on hand writing area 302 .
The high level framework of the handheld data processing system 300 is similar with that shown in FIG. 2 . The difference is that some components in FIG. 2 are omitted to achieve the small and handy features. In general, the handheld data processing system 300 uses a storage module instead of huge capacity outer storage devices such as disk as memory. Currently, its total memory space is less than 1M. Although the PCMCIA card can be used to extend memory space, the memory capacity after extending is still no more than several megabytes. As for IBM WorkPad, memory space is divided into ROM and RAM, located in the same storage module. ROM has the capacity of 0.5M to 1.5M, RAM has the capacity of 1M at least. The main application group is preset into ROM. Other alternate applications and system extensions can be loaded into RAM. But it is not always feasible with regard to the limitation of the capacity of RAM. Users can upgrade or improve software by changing ROM, or change the system software and application group completely by installing a single storage module. Furthermore, a typical handheld data processing system 300 usually embeds strong network communication ability, which means easy connection to the Internet or WWW.
FIG. 4 shows the client/server architecture of the preferred embodiment of this invention. As shown in this figure, client request (such as the request for news) 91 is sent to server 88 by client 92 . Server 88 could be a remote computer system accessible via the Internet or other communication networks. Client 92 could execute on computer 20 shown in FIG. 1, or the handheld computer 300 shown in FIG. 3 .
When server 88 receives the client's request, it scans and searches the original (for example, uncompressed) information (such as online news or news group), then offers the filtered electronic information as the server response 93 to the client 92 .
Client 92 could be executed on a first computer while the server process could be executed on a second computer wherein they communicate to each other via communication media, thus providing the distribution ability and allowing multiple clients to access the same server at the same time.
As for WWW, the browser process executed on the client machine is in charge of establishing and maintaining connection to the server, and providing information to the user. The server machine executes the appropriate server software, which can provide information to the client in HTTP response. The HTTP response corresponds to the Web page written in HTML, or other data generated by the server.
A uniform resource locator (URL) is used to define linkage when the HTML compatible browser executes on the client machine. The client machine requests the server marked by the linkage, and receives the files in HTML format from the server.
Any browser currently available in the market, such as Netscape's Navigator, Communicator, Microsoft's IE, Mosaic developed by NCSA, Urbana-Champaign, Ill., and Lynx browser, can be used in this invention, as well as any other browser which conforms to HTTP specification.
An Internet service is generally accessed via a unique network address, the aforementioned uniform resource locator (URL), which implies the network route to the server. URL has the special syntax for defining network connection. It is basically divided into two parts, one is the protocol name and the other is the path name of the accessed object. For example, the URL “http://www.uspto.gov” (the home page of the United States Patent and Trademark Office) defines the transfer protocol “http” and the server path “www.uspto.gov”. The server name corresponds to a unique IP address.
Now referring to FIG. 5, the client/server architecture of the preferred embodiment of this invention is shown in more detailed framework. As shown in this figure, client 92 connects to server 88 via network connection 814 . Network connection 814 could be the Internet, intranet or other well-known interconnection. As for the Internet, server 88 is one of the many servers accessible to client 92 . The label 92 represents a client which is a process executed on some client machine, such as a Web browser, mail reader, FTP client, Telnet client, etc.
The client machine could be the desktop, notebook, handheld computer or palm computer. For example, the client machine could be an IBM or IBM compatible computer with OS/2, IBM ThinkPad, another ×86 or pentium based computer with Windows 3.1 or higher version operating system. It could also be an IBM WorkPad with PalmOS, or some kind of PDA with strong network communication ability.
A typical server includes an IBM RISC/6000 with AIX operating system and server program. In this situation, the server usually receives requests from the client via dialing, then performs the appropriate tasks such as finding the specified files or objects to fulfill the client's requests. IBM has issued lots of publications to present the different types of RISC based computers, such as “RS/6000, 7013, 7016 POWERstation and POWERserver hardware technical reference manual”(SA23-2644-00). AIX is presented in detail in the first edition of “AIX operating system technical reference manual” and other publications. Although the structure mentioned above is feasible, it is not the only one, and any other suitable hardware/operating system/server combination also can implement the present invention.
FIG. 6 shows the computer network 80 , which exemplifies the preferred embodiment of this invention. Computer network 80 could be the Internet, or any other well-known computer network with client-server architecture. Persons skilled in the art should know that the Internet is not the only distributed computer network which exemplifies the preferred embodiment of this invention. Computer network 80 could certainly be implemented by other distributed computed networks such as “intranet”.
In theory, the Internet is a huge computer network which includes servers 88 . The clients, usually the personal computer users, could access these servers via some special Internet access providers 84 such as Internet America or online service providers such as America On-Line, Prodigy, Compuserve etc. Each client machine can execute one or more browsers to access servers 88 . Each server 88 is in charge of a so-called “web site”.
It is to be noted that, while the invention involves network transmission, the details of network operations are well known and need not be repeated here.
Referring to FIG. 7, illustration is given of the detailed inventive framework of the apparatus, which offers responses to the off-line client. Client 92 and server 88 shown in this figure are the same as that in FIG. 4 and FIG. 5 . The network connection 814 is identical to the one shown in FIG. 5 . The most fundamental new elements in FIG. 7 are network traffic redirector 701 , off-line server 702 and request-response storage 703 . They construct the basic apparatus of this invention. Network traffic redirector 701 has the following role. When client 92 is in an on-line state, for example, when it is using a browser to browse the web pages of server 88 , network traffic redirector 701 makes no change to the network transmission between client 92 and server 88 at all. In other words, client 92 sends its requests to server 88 via network connection 814 , and when the server 88 receives them, it performs the corresponding tasks and then returns the responses to the client 92 via network connection 814 . When the client is in off-line state, i.e., when the network connection 814 is nonexistent or unable to perform adequately, the network traffic redirector 701 will redirect the requests of client 92 to off-line server 702 in the local machine, which will then respond accordingly (as further detailed below).
The above-mentioned functions of network traffic redirector 701 can be implemented by modifying the system configuration of the client machine. As mentioned above, a URL is basically divided into two parts, one being the protocol name and the other being the path name of the accessed object. For example, the URL “http://www.ibm.com” specifies the server path “www.ibm.com”. The server path name corresponds to a unique IP address. Actually, all data transmission on the Internet is performed by IP address. When a client specifies a server path name, generally some conversion component is needed to do the conversion between server path name and actual IP address. Currently in the Internet, it is up to the domain name server to do this kind of conversion. So, what the network traffic redirector 701 does, when in the off-line state, is convert the server path name to the local IP address of the client machine.
Actually, the IP address conversion process can be performed by the following simple file operations. According to TCP/IP protocol, the operating system will search the “HOSTS” file in the local file system first when it gets a URL. For example, in Windows NT, the “HOSTS” file is stored under the directory “\NT\system32\drivers\etc\”; and for UNIX, this file is stored under the directory “/etc”; and for Windows 95, the file is stored under the directory “\Windows”. A conversion list is contained in this file. Each conversion item occupies a single line. In each line, the IP address is placed in the first column, and the server path name is in the second.
The IP address and the host name should be separated by at least one space. The following is a sample hosts file that includes two records:
102.54.94.97 rhino.acme.com
38.25.63.10 x.acme.com
Since a domain server on the Internet can translate a host name to its IP address , the hosts file in a client machine is usually empty or doesn't exist.
In this invention, the client machine's operating system will redirect requests that are sent to the host name to itself after several records have been added in its hosts file.
For example, suppose the IP address of the client machine is 9.185.8.20. The following records are added to the hosts file on the client machine:
9.185.8.20 www.ibm.com
9.185.8.20 www.uspto.gov
Requests that are sent to www.ibm.com or www.uspto.gov from the client machine would accordingly be redirected to itself If, however, the content of the hosts file on the client machine is cleared in order to recover the system setting, requests that are sent to www.ibm.com or www.uspto.gov would be sent to their real IP address by a domain server.
When the client ( 92 ) is off-line, the network traffic redirector ( 701 ) can redirect requests to the off-line server ( 702 ) and send responses that come from the off-line server ( 702 ) to the client ( 92 ) so that the client ( 92 ) can continue to work. It looks like the client ( 92 ) were on-line.
The request-response storage ( 703 ) stores multiple requests and their corresponding responses. These request-response pairs may be defined by users or be recorded automatically by the following steps according to this invention.
When the client ( 92 ) is on-line, users set its state to record so that the network traffic redirector ( 701 ) always sends requests to the off-line server ( 702 ). Once the client ( 92 ) sends a request, the off-line server ( 702 ) can intercept the request, then the off-line server ( 702 ) sends this request to the server ( 88 ) through the network connection ( 814 ) and receives the response from the server ( 88 ) (See FIG. 7 dot line), then the off-line server ( 702 ) sends the response from the server ( 88 ) to the network traffic redirector ( 701 ). At the same time, the off-line server ( 702 ) saves the intercepted request-response pairs to the request-response storage ( 703 ) in a specific data format. The data format has no restriction on this invention. Actually one can use any data format only if the off-line server ( 702 ) can generate a response according to a requests and multiple requests and responses that are stored in the request-response storage ( 703 ). After the network traffic redirector ( 701 ) receives the response, it sends the response to the client ( 92 ). The process can be repeated until users complete recording.
The content of a request or a response is different from one network protocol to another, such as HTTP ( Hypertext Transfer Protocol), FTP (File Transfer Protocol) and Telnet, as is known to persons skilled in the art.
When the client ( 92 ) is on-line, each request from the client ( 92 ) will be sent to the server ( 88 ) by the network connection ( 814 ) and each response from the server ( 88 ) will be received by the network connection ( 814 ). As mention above, when the client ( 92 ) is off-line or on record status, each request from the client ( 92 ) will be redirected to the off-line server ( 702 ) by the network traffic redirector ( 701 ). Each response from the off-line server ( 702 ) will be sent to the network traffic redirector ( 701 ), then will be sent to the client ( 92 ).
The above description is a method that is used to create multiple requests and responses stored in the request-response storage ( 703 ), defined by users or intercepted by the off-line server ( 702 ) when users set the record status. Users can edit and modify appropriately the content of requests and responses and define default responses for some specific requests in order to simulate the real world. What is more, after the content of the request-response storage ( 703 ) is generated at a client machine, one can simply copy the content to the request-response storage of other client machines in order to avoid repeating the steps of defining, intercepting and editing.
In addition, persons skilled in the art should understand that the storage described herein can be any standalone storage or part of storage at a client machine. For example, it can be a database or file on the disk ( 72 ) or a RAM ( 56 ), both of which are shown in FIG. 2 . Alternatively, it can be a storage card at a palm computer as depicted in FIG. 3 .
When the client ( 92 ) is off-line, the off-line server ( 702 ) begins to work. First of all, the off-line server ( 702 ) receives requests from the client machine itself which have been redirected by the network traffic redirector ( 701 ). Next, then the off-line server generates a corresponding response to the request according to the request and the multiple requests and responses stored in the request-response storage ( 703 ).
The following is a simple process of how the off-line server ( 702 ) generates a response according to a request and multiple requests and responses at the request-response storage ( 703 ):
Assume there are multiple requests and responses in the request-response storage ( 703 ):
R 1 (Request 1 )
S 1 (Response 1 )
R 2 (Request 2 )
S 2 (Response 2 )
Rn (Request n)
Sn ( Response n)
When the off-line server receives a request R, it constructs a response according to the formula (1):
S=f ( R, R 1 , R 2 , . . . , Rn, S 1 , S 2 , . . . , Sn ) (1)
as an example of (1), response S can be one of responses from S 1 to Sn.
Response S can be selected from Responses (S 1 -Sn) according to the formula (2):
S=S 1 , if R logically equals to R 1 ;
S 2 , if R logically equals to R 2 ; (2)
Sn , if R logically equals to Rn ;
Logical equality might be different since the network transfer protocol is different.
With HTTP as an example, suppose the content of R 1 :
GET URL 1
DATE 99.01.01/HTTP
and the content of R:
GET URL 1
DATE 99.01.10/HTTP
Obviously, the content between R 1 and R is different. But the essential part is the same:
GET URL 1 , meaning a request for the network resource marked by URL 1 , therefore the response should be the same. So the off-line server ( 702 ) makes the decision that R logically equals to R 1 and generates a response S that is the same as S 1 at the request-response storage ( 703 ).
Note that the above example is for explanation only. Actual request data may be different from the sample above. But the difference does not limit this invention.
As a general case of formula (1), the Response S can be generated based on Request R, Request R 1 to Rn and Response S 1 to Sn. For a simple example, assume the content R 1 :
http://search.yahoo.com/bin/search?p=game
and the content of R:
http://search.yahoo.com/bin/search?p=Internet
Although R 1 logically equals to R, the parameters in the URL are different. Therefore, Response S 1 don't become Response S. Then the content of Response S could be:
“Sorry, there is no sufficient local data. Cannot search Internet”
According to this invention, the off-line server ( 702 ) can be programmed using sophisticated algorithms to generate an appropriate response according to the received request and the multiple requests and responses stored in the request-response storage ( 703 ). These algorithms don't limit this invention.
The basic devices in this invention include the network traffic redirector ( 701 ), the off-line server ( 702 ) and the request-response storage ( 703 ). There are several devices that can be added to this invention: an off-line request storage ( 705 ) and an actual network service provider ( 706 ). All of them are on the client machine. When the client ( 92 ) is off-line, and upon the off-line server ( 702 ) receiving a client request, it generates a response according to the received request and the multiple requests and responses stored in the request-response storage ( 703 ). It stores the request sequentially in the off-line request storage ( 705 ). When the client ( 92 ) ends off-line state, the off-line request storage ( 705 ) has stored all requests from the client ( 92 ) when it was off-line. When the client ( 92 ) is on-line, the actual network service provider ( 706 ) starts to work. It fetches queued requests from the off-line request storage ( 705 ) one by one, and sends each request to the server ( 88 ) through the network connection ( 814 ). The server ( 88 ) then carries out the task required by the client ( 88 ).
To further enhance the apparatus, the invention may also include an off-line response storage ( 704 ), a comparison device ( 707 ) and a notification device ( 708 ), all of which are looted at the client machine. When the client ( 92 ) is off-line, the off-line server ( 702 ) sends a response to the network traffic redirector ( 701 ), then it stores this response to the off-line response storage ( 704 ) sequentially. Therefore, responses stored in the off-line response storage ( 704 ) correspond to requests stored in the off-line request storage ( 705 ). Of course, persons skilled in the art should understand that the off-line request storage ( 705 ) and the off-line response storage ( 704 ) can be separated into different storage or located at the same storage, as long as the correspondence relationship between requests and responses is maintained. This difference doesn't limit this invention.
When the client ( 92 ) ends its off-line session, not only does the off-line request storage ( 705 ) store all requests sent by the client ( 92 ) when it was off-line, the off-line response storage ( 704 ) also stores all responses that the off-line server ( 702 ) sent to Client 92 . When the client ( 92 ) is on-line, the actual network service provider begins to work. It fetches requests from the off-line request storage ( 705 ) sequentially, then sends each request to the server ( 88 ) through the network connection ( 814 ). The server ( 88 ) actually processes the request from the client ( 92 ). Then, the client ( 82 ) receives the response from the server ( 88 ) through the network connection ( 814 ) and sends it to the comparison device ( 707 ). The comparison device ( 707 ) compares the response with the one corresponding to it which is stored in the off-line response storage ( 704 ). If there is a logical error in the comparison result, the notification device ( 708 ) will be started to report the error to users. One of the effective methods is to call client service software. The actual network service provider ( 706 ) repeats the above process until all requests stored in the off-line request storage ( 705 ) have been processed.
An example that shows how the comparison device ( 707 ) works is given below. It can compare the status code of responses. Suppose Request R 1 stored in the off-line request storage ( 705 ) is sent to the server ( 88 ), then the actual network service provider ( 706 ) receives Response S:
“HTTP 1.0 302 Object Not Found”
and Response S 1 which is stored in the off-line response storage ( 704 ) and corresponding to Request R 1 is:
“HTTP 1.0 200 OK”
The comparison device ( 707 ) compares the status code of S with the one of S 1 and finds the status code does not equal, which means that there is a logical error. In other words, Response S 1 which was sent to the client ( 92 ) is wrong. So the comparison device ( 707 ) starts the notification device ( 708 ) to report this error.
There are certainly other comparison methods that can be used by the actual apparatus. But these minor differences don't limit this invention.
FIG. 8 shows the basic flow chart when the client is off-line. After step 800 , whether the client goes off-line will be decided at step 801 . If no, then it will turn to the flow chart showed in FIG. 9 . If yes, it will go to step 802 . The client machine configuration will be modified at step 802 in order to cause the network traffic to be routed back to the client machine itself The method to modify the client machine configuration has been shown in FIG. 7 and can modify the hosts file at the client machine.
At step 803 , a request from the client will be received, then it will be stored in the off-line request storage at step 804 . A response will be generated according to the received request and the multiple requests and responses stored in the request-response storage at step 805 . The method to generate the response has been described above and shown in FIG. 7 . Then the response from step 805 will be sent to the client at step 806 and stored in the off-line response storage at step 807 . The off-line response storage is also shown in FIG. 7 .
Whether the client ends the off-line operation will be decided at step 808 . If the result is false, then it will turn to step 803 and continue. Otherwise it will finish or turn to the flow chart shown at FIG. 9 . Note that the execute sequence can be changed. For example, step 804 can be executed after step 805 or after step 806 or after step 808 . It is not necessary that step 804 be executed after step 803 . Another example is that step 807 can be executed before step 806 . These subtle differences do not limit this invention. In addition, If the content of the off-line response storage won't be used later, step 807 can be deleted.
In addition, as discussed above, the off-line request storage and the off-line response storage can be separated to standalone storage or located at the same storage only if it can maintain the corresponding relation between requests and responses. This difference doesn't limit this invention.
FIG. 9 shows the flow chart when the client ends the off-line operation and goes on-line. Whether the client goes on-line will be decided at step 901 . If the result is false, then it will turn to step 910 and stop. If the result is true, then it will turn to step 902 . The client machine's configuration will be restored at step 902 in order to route the network traffic to the network connection instead of the client machine itself. The method to modify the client machine's configuration is the same as step 802 and will not be repeated.
Whether requests stored at the off-line request storage have been handled will be determined at step 903 . If the result is false, then it will turn to step 910 and end. Otherwise it will execute step 904 . A request will be fetched from the off-line storage at step 904 . Then the request will be sent to the server through the network connection at step 905 and the server will process the task that the client requests. A response will be received from the server through the network connection at step 906 . Then the response will be compared with the one which is corresponding to the request sent to the server (stored in the off-line response storage at step 807 shown in FIG. 8) at step 907 . Whether the comparison result has a logical error will be decided at step 908 . The meaning of logical error is the same as the one in the comparison device shown in FIG. 7 . If the result is false, it means that the response which was sent to the client at step 806 was correct and the process will go to step 903 . Otherwise, it will turn to step 909 . The logical error will be reported to users appropriately. Users can change the request using a proper method that can be called a client service software, then send the changed request to the server again. After step 909 , it will turn to step 903 .
FIG. 10 shows the relationship among Intranet pages at an insurance company. When a clerk of the insurance company surfs his company's Intranet site using browser (for example Netscape Communicator or Microsoft IE ), the browser sends a request “GET HTTP” to the server. The server receives the request and sends back a HTML describable home page to the browser. The browser receives this HTML file and interprets HTML tags and displays the page. The clerk will see the Intranet home page 1000 of the insurance company. There are two hot links on the page 1000:1. Sell Insurance and 2. Claim.
When the clerk clicks the first hot link (1. Sell Insurance ), the browser will get the URL of the first hot link and generate another request and send it to the server. The server will receive this request and generate a response according to the URL at the request and send it back to the browser. Then the browser will receive this response and display information. The clerk will see the “Selling Form” page 1001. There are three empty fields 1001 A, 1001 B and 1001 C on the form 1001 . When the clerk sells insurance, he will fill these three empty fields according to a customer information. Persons skilled in the art know that data filled at these three empty fields will become parameters stored at a URL. These three empty fields are an example. The number of empty fields relates to a customer information required by the insurance sales business and is not meant, in any way, to limit the invention.
There are two hot links in the page 1001: “OK” and “Cancel”. If the clerk clicks the “OK”, the browser will send a request which includes the above three parameters to the server. If the server handles this request correctly, it will send back another HTTP response and the browser will display the “Sell OK” page 1003 correspondingly. If the clerk clicks “Cancel”, the browser will display the “Sell Cancel” page 1004.
Similarly, when the clerk clicks the second hot link (2. Claim) in the page 1000, the browser will display the “Claim Form” page 1002 from the server. There are three parameters in this page. When the clerk clicks “OK” in the page 1002, the browser will send a URL request which includes three parameters to the server. If the server handles this request correctly, it will send back the “Claim OK” page 1005. If the clerk clicks the “Cancel” in the page 1002, the browser will display the “Claim Cancel” page 1006.
Since the protocol in this example is HTTP, requests and response between the browser and the server conform to the HTTP format.
Assume a clerk of the insurance company wants to visit three customers to sell insurance to two of the customers and process a claim for one of the customers. There are several ways to process this business. The first one is that the clerk invites these three customers to his company and surfs his company's Intranet site and fills the above forms 1001 and 1002 to process the business using the browser. Obviously, it is unrealistic to invite customers to the company. The second one is that the clerk visits the above three customers outside taking a notepad computer or a palm computer which has installed a browser. When he visits each customer, he connects his notepad computer or a palm computer to his company's server by dial-up networking and gets the corresponding forms and fills them and asks the server to process the insurance or claim business. Since there is no guarantee of obtaining a network connection anywhere, the second method has shortcomings considering the low Internet transport speed and the security of network transport.
Inconvenience can be overcome using this invention. For example, before the clerk goes out to visit the above three customers, he connects his notepad computer or his palm computer to the company's server and sets the status to record. Then he surfs his company's Intranet site to go through the home page 1000, Sell Form 1001, Sell OK 1003, Sell Cancel 1004, Claim Form 1002, Claim OK 1005 and Claim Cancel 1006. After he ends surfing, the request-response storage installed at his notepad computer or his palm computer has stored all kinds of requests that need to be sent to the company's server when he goes out and has stored the corresponding responses.
Of course, alternatively, data stored at the request-response storage can be preset and edited by computer professionals of the insurance company. Before each clerk goes out to do business, the preset data will be copied to the request-response storage at his notepad computer or the proper storage card will be installed to his palm computer. When the clerk goes out with the stored information, he doesn't need to connect to the company server, and he is able to work off-line as if he is connected on-line.
FIG. 11 shows how a browser gets responses when it is off-line.
For example, when the clerk visits the first customer, he starts a browser to send a request. According to the method or the apparatus of this invention that can generate a response according to the request sent by the browser and multiple requests and responses stored in the request-response storage, the browser gets the response and displays the home page 1100 . Since the clerk sells insurance to the first customer, he clicks “ 1 . Selling insurance”. The browser gets a response, according to the request sent by the browser and multiple requests and responses stored in the request-response storage, and displays the Sell Form 1101 . The clerk fills the first customer's data to these empty fields 1101 A, 1101 B and 1101 C and clicks “OK”. The browser gets the corresponding response and displays the Selling OK 1103 . Finally, the clerk closes the browser. In this process, the off-line request storage and the off-line response storage installed at the clerk's notepad computer have stored multiple requests and responses.
Similarly, after the clerk visits the second customer, the off-line request storage and the off-line response storage will have additionally stored another set of multiple requests and responses.
When the clerk visits the third customer, he starts a browser. The browser displays the home page 1100. Since he wants to process claim, he clicks “2. Claim”. The browser gets a response, based on the request sent by the browser and multiple requests and responses stored in the request-response storage, and displays the Claim Form 1102 . The clerk fills the customer's data and clicks “OK”. The browser gets the corresponding response and displays the “Claim OK” 1105 . At last, the clerk closes the browser. In this process, the off-line request storage and the off-line response storage installed at the clerk's notepad computer have again recorded the multiple requests and responses associated with the off-line customer interaction.
Therefore, the browser looks like an on-line session in the above process not only to the clerk but also to customers according to the method or the apparatus of this invention.
When the clerk comes back to his office, he connect his notepad computer to the server within the Intranet. Multiple requests stored in the off-line request storage can be automatically sent to the server according to the method or the apparatus of this invention. The server handles the real tasks: two selling insurance and one claiming. Of course, there may be logical errors that need to be reported to users in this process as mentioned above. For example, when selling insurance, the customer filled his age to 90 and the browser displayed the page “Selling OK”. According to the policy of the insurance company, there is no insurance for a person whose age is 90 or over 90. Therefore, when the server handles this task, it sends the response “Sorry, the age can not be over 90.”. So the logical error occurs. For example, the clerk is notified the logical error by the text “A customer's age can not be over 90” displayed in the browser window, then the clerk will verify this information to the customer or modify the customer's wrong data and send the request again.
In addition, the method in this invention can be implemented to a computer application and stored in readable storage media in a computer. The application can be installed to mobile devices such as client software in a practical appliance. The client software doesn't need to be modified and can work off-line. The storage media can have versatile formats, for example magnetic format or optical format. Versatile formats don't limit this invention.
While the preferred embodiments of the present invention have been described in detail with reference to the drawings, various modifications, additions and changes can be made by persons skilled in the art, without departing from the scope and the spirit of this invention as set forth in the appended claims. | An apparatus for providing responses to requests of an off-line client, comprising: a local request-response storage which stores a plurality of requests and a plurality of responses; a network traffic redirector, for redirecting requests of the client to the client machine itself by modifying the system configuration of the client machine when the client is off-line, and for redirecting requests of the client to the network connection by resuming the system configuration of the client machine when the client leaves the off-line state and enters an on-line state; and a local off-line server, for receiving a request of the client redirected to the client machine itself, for generating a response based on the request, the plurality of requests and the plurality of responses stored in the request-response storage, and for returning the response to the client. | 7 |
[0001] The present application claims the benefit of the filing date of U.S. Provisional Application Ser. No. 60/478,778, filed Jun. 16, 2003, the contents of which are hereby expressly incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates to the manufacture of three-dimensional forms and more particularly relates to the manufacture of a three-dimensional form by the successive layer-by-layer build up of a composite including particles in a hardened binder material.
BACKGROUND OF THE INVENTION
[0003] The present invention is predicated upon the discovery of improvements to materials and techniques useful for a process that has gained recognition in the art as “three-dimensional printing”. A number of efforts in this field have been made to date, including by way of example those disclosed in U.S. Pat. Nos. 6,147,138, 6,193,922, 6,423,255, 6,416,850, 6,375,874, 6,007,318, 5,204,055, 5,340,656, 5,387,380, 5,490,962, 5,518,680, 5,902,441 and PCT Application Nos. WO 02/26420 (PCT/DE01/03661), WO 02/26478 (PCT/DE01/03662), WO 02/28568 (PCT/DE01/03834), WO 02/26419 (PCT/DE00/03324), and WO 02/083323 (PCT/DE02/01103), all of which are hereby expressly incorporated by reference.
[0004] By way of illustration, U.S. Pat. No. 5,204,055 addresses a method that includes layer based deposition of untreated particulated material. A binder material is liquid dosed to selectively bind the particles. The binder is hardened and the part is unpacked. The patent is limited in its teachings with regard to sequencing for contacting of particles with agents for binding the particles.
[0005] In WO96/05038, there is disclosed a method for production of bone implants including mixing a powder with a binder, layer based deposition, selectively laser sintering or selectively spraying an agent on top of each layer to bind the particles. The document likewise is limited in its teachings with regard to sequencing for contacting of particles with agents for binding the particles.
[0006] In U.S. Pat. No. 6,416,850, there is described a method whereby certain purported non-toxic materials characterized as adhesives (e.g., water soluble polymers and carbohydrates) are mixed with particles and other ingredients and selectively aggregated by depositing a solvent in which the adhesive is highly soluble. The patent is limited in its teachings with regard to sequencing for contacting of particles with agents for binding the particles. Additionally, it is believed to not enable a process where agents are cross-linked for assisting in bonding, particularly to make a form sufficiently strong and thermal resistant to serve as a mold.
[0007] It is thus an objective of the present invention to provide improved and efficient alternatives for preparing a three-dimensional form with a layer-by-layer build-up technique, particularly through the use of a binding material system that is at least two components.
SUMMARY OF THE INVENTION
[0008] Accordingly, the present invention is predicated upon the discovery of a new method for manufacturing a three-dimensional form, comprising the steps of providing a plurality of particulates; contacting at least a portion of a surface of the particulates with an activation agent; contacting a pre-selected portion of the particulates having the activation agent with a binder material that is activatable by the activation agent; hardening the binder for forming a layer of the three-dimensional form; and repeating these steps to form the remainder of the three-dimensional form. Following the sequential application of all of the required layers and binder material to form the part in question, the unbound particles are appropriately removed (and optionally re-used), resulting in the formation of the desired three-dimensional form.
[0009] Preferably the binder material is selectively supplied to the particulates (e.g., by using an ink-jet printing technique, or other suitable technique for precise fluid dispensing), in accordance with a computer model of the three-dimensional part being formed, such as from the use of a Computer Aided Design (CAD) file (e.g., CAD file data that results from a finite element analysis). In this manner predefined sub-areas of each layer can be varied relative to adjoining layers. The agent is adapted to effectively create a binder for firmly coupling adjoining particles, whether by Van der Waals forces, cross-linking, other covalent bonding, ionic bonding, metallic bonding, combinations thereof or by another mechanism).
[0010] According to a particularly preferred approach of the present invention, each layer of the form being manufactured is initially provided as a layer including a plurality of particulates in the absence of a binder material. Preferably, the binder material is dispensed by a suitable fluid dispenser into the respective sub-areas of a layer whereupon it contacts an activation agent and is activated for hardening to form a matrix that has the particles firmly held within it.
[0011] Though it is contemplated that the binder material and the activation agent may be dispensed individually onto a layer of particles, or that particles may be dispensed onto a layer, film or other area of activation agent, it is most preferred that the binder material is dispensed onto a sub-area of a layer of particles that are contacted, prior to dispensing of the binder material with an activation agent.
[0012] It is thus found that a number of benefits are possible using the methods of the present invention. By way of example, it is possible to better manage material usage and reduce overall cost by improving control over the total amount of binder that is used (which is many instances is desirably a thermoset or crosslinkable resin that may require special handling or waste disposal). Further, the absence of a binder makes it possible to more efficiently reclaim and re-use particles in subsequent fabrications. That is, the particles will be substantially free of binder material that could preclude further use of the particles.
[0013] Thus, an advantageous method for making a three dimensional form could comprise the steps of providing a plurality of particulates; contacting at least a portion of a surface of the particulates with a multiple-component binder material system including a binder material as one of the components; hardening the binder for forming a layer of the three-dimensional form; repeating the steps to form the remainder of the three-dimensional form; and re-claiming unbound particulates, said unbound particulates being free of binder material.
[0014] In addition, it is possible to reduce the potential for nozzle clogging. It is also found that good control over the extent unreacted binder material is possible to help minimize a potential source of gas formation, which is potentially problematic in some applications (e.g., where the three-dimensional form is used as a mold for casting a high melting point material and the mold is highly complex, such as with a automotive cylinder head mold or another intricate form). The present invention affords good control over binder deposition and permits for high degrees of variations within a layer and within cross-sections of the form.
[0015] The present invention also affords other benefits. For example, in one particularly preferred aspect of the present invention, functional groups or reactive components of the binder material are susceptible to evaporation, especially at higher temperatures. The ability to better control and even delay when the binder material is going to be contacted with particles helps to. assure that a greater effective amount of the functional groups or reactive components will be present over time. Thus, consumption of overall amounts of the binder material can be further reduced, as compared with a process in which the binder material is contacted initially with particles, prior to the activation agent. To illustrate, if furane resin is employed as a binder for a sand, it is more likely that at higher temperatures, the furfurylic alcohol of the resin will evaporate at higher temperatures. That means the sand has to be used very quick (e.g., within minutes) after mixing with the furane resin, or else the sand must be sealed, in order to preserve the efficacy of the binder material. On the other hand, if the sand is contacted with activation agent first, the activation agent (e.g., an acid such as sulfuric acid that is relatively stable at normal operating conditions) will very often not be susceptible to substantial effects of temperature or atmosphere. Thus, enhanced particle stability permits for longer delays between steps, as well as the introduction of additional intermediate processing steps. Delays between steps of 2 hours or more, or as long as 12 hours are also possible, without compromising particle reactivity or stability. In one preferred embodiment, particles contacted with an activation agent as disclosed herein can await 24 hours or more and remain free of degradation to binding function, in the absence of contacting with a binder material.
[0016] It is also likely that there will be fewer adverse secondary effects caused by evaporation of functional groups or reactive components. For example, the susceptibility of the evaporated materials to re-deposit elsewhere within the system (e.g., on the print head) is reduced. This leads to longer system component cleaning cycles, which again increases the productivity.
[0017] The present invention also contemplates kits for supplying the necessary consumable materials to carry out the preferred methods. For example, one such kit for preparing a three-dimensional form, may include a first container including a binder material, and a second container including a particulated material and an activation agent for the binder material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] The present invention is predicated upon the discovery of a new method for manufacturing a three-dimensional form, comprising the steps of providing a plurality of particulates; contacting at least a portion of a surface of the particulates with an activation agent; contacting a pre-selected portion of the particulates having the activation agent with a binder material that is activatable by the activation agent; hardening the binder for forming a layer of the three-dimensional form; and repeating these steps to form the remainder of the three-dimensional form.
[0019] In an especially preferred aspect, though not intended as a limitation of the scope and applicability of the invention, the invention contemplates a method for manufacturing a mold comprising the steps of providing a plurality of particulates; contacting at least a portion of a surface of the particulates with an activation agent for causing cross-linking of an organic binder material; depositing the binder material onto a pre-selected portion of the particulates; hardening the binder for forming a layer of the mold; and repeating these steps to form the remainder of the mold.
[0020] The particles of the present invention may be any suitable finely divided material that is capable of being bonded to form an aggregate with an activated binder. The particles may be organic, inorganic, or a mixture thereof. They may be ceramic, metal, plastic, carbohydrate, small organic molecule, large organic molecule, combinations thereof or the like.
[0021] Preferably the particles are generally mono-disperse. Thus, the particles preferably have at least 80 percent by volume of an average particle size ranging from about 30 μm to about 450 μm, more preferably about 90 μm to about 210μ, and still more preferably on the order of 140 μm. Polydisperse collections of particles are also possible. Larger and smaller particle sizes are also possible and the above ranges are not intended as limiting of the invention.
[0022] A highly preferred material for use as the particles of the present invention, particularly for use in the manufacture of molds, is sand, and more particularly foundry sand. Examples of suitable sands include silica. In a more preferred aspect the sand is selected from the group consisting of quartz, zircon, olivin, magnetite, or combinations thereof. Sands may be virgin sand, reclaimed sand, or a combination thereof. The sands may also include ingredients common to foundry sand such as a binder (e.g., clay, wood flour, chemical additives, etc.), carbonaceous additives, or other ingredients.
[0023] It will be appreciated from the above, that sand particles are not the only particles useful in the present invention. Other art-disclosed particles may be employed, such as cera beads, metal particles, ceramic particles, polymeric particles, combinations thereof or the like.
[0024] The binder of the present invention may be any suitable material that is capable of firmly coupling adjoining particulates to each other. In a highly preferred aspect, the binder material is an organic compound, and more particularly an organic compound that includes molecules that cross-link or otherwise covalently bond among each other.
[0025] In a highly preferred embodiment, the preferred material for the binder includes at least one material selected from the group consisting of phenol resin, polyisocyanate, polyurethane, epoxy resin, furane resin, polyurethane polymer, phenolic polyurethane, phenol-formaldehyde furfuryl alcohol, urea-formaldehyde furfuryl alcohol, formaldehyde furfuryl alcohol, peroxide, polyphenol resin, resol ester or mixtures thereof.
[0026] Though other viscosities are possible, during dispensing through a print head, preferably, the viscosity of the binder material at 20° C. preferably ranges from 5 to about 60 cps, and more preferably 10 to 50 cps, and still more preferably about 14 to about 20 cps.
[0027] It may also be possible to employ one or more inorganic binders such as, without limitation a silicate (e.g., sodium silicate), a salt, plaster, bentonite or mixtures thereof.
[0028] Other art-disclosed ingredients may also be employed to form a binder in the present invention, such as those disclosed in U.S. Pat. No. 6,416,850, hereby incorporated by reference, including for example water-soluble polymers, carbohydrates, sugars, sugar alcohols, or proteins. Suitable water-soluble polymers include polyethylene glycol, sodium polyacrylate, polyvinyl alcohol, polyvinyl pyrrolidone, sodium polyacrylate copolymer with maleic acid, and polyvinyl pyrrolidone copolymer with vinyl acetate; carbohydrates include acacia gum, locust bean gum, pregelatinized starch, acid-modified starch, hydrolyzed starch, sodium carboxymethylcellulose, sodium alginate and hydroxypropyl cellulose. Suitable sugars and sugar alcohols include sucrose, dextrose, fructose, lactose, polydextrose, sorbitol and xylitol. Organic compounds including organic acids and proteins can also be used, including citric acid, succinic acid, polyacrylic acid, gelatin, rabbit-skin glue, soy protein, and urea. Thus it is contemplated that the binder may include a binding component that is free of a thermoset resin.
[0029] The activation agent of the present invention is preferably an ingredient that in the presence of the binder material (and optionally in the presence of another controllable atmospheric condition, e.g., heat, moisture, or otherwise), will cause the binder material to bond to itself and to adjoining particles. The activation agent is preferably provided as a solid, liquid, gel, or combination thereof. It may include an art-disclosed curing agent, initiator, or both for the above mentioned binder materials.
[0030] For example, in one particularly preferred embodiment, (e.g., where a furane resin, epoxy or both is employed), the activation agent is an agent selected from an acid, an amine, an ester or a combination thereof. Preferred acids, for example, are those having a pH of from 1 to 6, and more preferably less than 4. Examples of suitable acids include organic acids, inorganic acids, or combinations thereof, such as one or more acids selected from the group consisting of sulfuric acid, sulfonic acid (e.g., methanesulfonic acid, toluenesulfonic acid or the like), hydrochloric acid, phosphoric acid, hydrochloric acid, and nitric acid. The activation agent may be a relatively low viscosity material or a relatively high viscosity material. Thus, it is also contemplated that a dimer or trimer acid, a fatty acid, or combinations thereof may be employed. Other acids are also contemplated, including without limitation, (poly)carboxylic acids,
[0031] The activation agent may consist of a single ingredient or a plurality of ingredients. For example, as taught in U.S. Pat. No. 6,423,255, the curing agent may comprise toluene sulfonic acid in a proportion of 45 to 55 percent, diethylene glycol in a proportion of 5 to 15 percent, and sulphuric acid in a proportion of at most 1 percent.
[0032] Suitable amines are selected from primary amines, secondary amines, tertiary amines, or combinations thereof. For example, without limitation, the amine may be selected from the group consisting of aliphatic amines, aromatic amines, polyoxyalkyleneamines, phenalkamines, alkyl amines, alkylene amines, combinations thereof, or the like.
[0033] To the extent not already mentioned, other art disclosed curing agents may also be employed, such as catalytic curing agents (e.g., boron-containing complexes or compounds), amides, polyamides.
[0034] It is also possible that the activation agent may be such that it becomes active upon the liberation of a gas (e.g., a dioxide, such as carbon dioxide, sulfur dioxide) from within it. Thus, such a preferred activation agent preferably is one that is capable of liberating such a gas in the presence of the binder material.
[0035] Of course, other activation agents are also possible. For example, as described in U.S. Pat. No. 6,416,850, hereby incorporated by reference, an activating fluid may be employed, such as a solvent selected from water, methyl alcohol, ethyl alcohol, isopropyl alcohol, acetone, methylene chloride, acetic acid, and ethyl acetoacetate.
[0036] The skilled artisan will appreciate that in certain embodiments it may also be desirable to include one or more additional components such as to assist in processing of the materials, to improve a property of a material, or otherwise. Thus, it is further contemplated that in addition to the particles, binder and activation agent, there might be employed a filler, a reinforcement, a curing accelerator, a surfactant, a thickener, adhesion promoters, dyes, thermal indicators, humectants, combinations thereof or the like. Examples of fillers include, without limitation, mineral fillers, starches (e.g., maltodextrin), combinations thereof or the like. Reinforcements might include metal, plastic (e.g., aramid, polyester, cellulose, derivatives thereof or the like), ceramic, graphite, carbon or combinations thereof, and may be in the form of whiskers, fibers, combinations thereof or the like.
[0037] Other art-disclosed ingredients may include, for example, lecithin, a polyol (e.g., polyethylene glycol or polypropylene glycol), citronellol, an acetate (e.g., ethylene glycol diacetate), a sulfate (e.g., potassium aluminum sulfate), a sulfonate, an alcohol, an ether, a (meth)acrylate, a (meth)acrylic acid, a polyvinyl pyrrolidone, or combinations thereof.
[0038] It should be appreciated that any of the liquid ingredients herein may further contain additional ingredients, such as diluents (e.g., water, a ketone, or another organic solvent (e.g., toluene or the like)).
[0039] In a particularly preferred aspect of the present invention, a three-dimensional form is prepared using a layer-by-layer build-up approach, pursuant to which binder material is contacted with particles no earlier than when the binder material first contacts the activation agent. Thus, it is possible that both the binder material and the activation agent are supplied simultaneously to the particles (which are optionally pre-contacted with the activation agent). More preferably, the particles are mixed in intimate contact with the activation agent, spread over a surface and then selectively contacted in sub-areas (which can be from a small portion to the entirety of the mass of material) with the binder material.
[0040] Under the latter approach, mixing may be done in any suitable manner, and may be done by a batch mixer, a continuous mixer or a combination thereof. Preferably, the particles are mixed for a sufficient time so that a coating is developed over at least a portion of the exposed surface of the particle (which the skilled artisan should appreciate may be fully dense or porous). By way of example, without limitation a batch of about 1 to 25 kg (more preferably about 10 kg) is loaded into a rotating mixer along with an activation agent and rotated for a desired amount of time (e.g., sufficient to develop a layer around the particle to enlarge it to a diameter of about 0.25 to about 2.5 times the uncoated particle diameter, and more preferably about 1.5 times the uncoated particle diameter).
[0041] The premixed particles are then suitably transported to a work site, such as by a suitable conveyor (e.g., a screw conveyor). It is then loaded onto a work surface (e.g., via a spreading mechanism, such as in WO 02/083323 (PCT/DE02/01103), hereby incorporated by reference) or more preferably to a temporary holding container.
[0042] The work surface is preferably a workpiece platform of a suitable system for forming three-dimensional forms. An example of a suitable job box for carrying a work surface is disclosed in WO 02/26478 (PCT Application No. PCT/DE01/03662), hereby incorporated by reference. See also U.S. Pat. No. 6,423,255, hereby incorporated by reference.
[0043] A preferred system includes a binder fluid dispenser into which binder is supplied in a fluid state, a work surface upon which a plurality of particles may be loaded, such as particles contacted with an activation agent for the binder, a mechanism for spreading particulated material (e.g., a spreading mechanism includes an oscillating blade, a doctor blade, a counter rotating roller, or a combination thereof); and a processor for commanding the binder fluid dispenser to dispense the binder fluid according to data from a computer-derived model. Preferably, the binder fluid dispenser and the work surface are adapted for translation about at least three axis. For example, the binder fluid dispenser (preferably a drop-on-demand dispenser, such as an ink-jet type dispenser) might have one or a plurality of nozzles translatable in the x-y Cartesian plane, with the work surface being translatable in the z-axis. Either or both of the binder fluid dispenser nozzles or the work surface (e.g., as part of a gantry) may additionally or alternatively be rotatable about an axis.
[0044] Examples of a spreading mechanisms are described, without limitation, in WO 02/083323 (PCT/DE02/01103), or WO 02/26420 (PCT Application No. DE01/03661), both hereby expressly incorporated by reference. Accordingly, a preferred spreading mechanism includes a movable (e.g., oscillatable) hopper, into which particles are loaded. The hopper has an opening, such as a slit at the bottom, through which particles can be dispensed when the hopper is moved. A smoothing device (e.g., a blade, counter roller or the like) is preferably attached. adjacent the hopper opening. As particles are released through the opening, they are thus smoothed by the smoothing device. In this manner, a relative flat and smooth build-up of a layer of particles is possible on the work surface. Layer thicknesses may be controlled as desired. For example, layers may range in thickness from about 0.05 mm to about 1 mm are formed, and more preferably about 0.1 mm to about 0.4 and still more preferably about 0.15 to about to 0.3 mm. Smaller or larger thicknesses are also possible.
[0045] It is possible that the system may also an overflow cavity defined in it for receiving excess material, and possibly a movable cleaning element to transfer excess material to the overflow cavity. A separate partially sealed clean area may also be employed in combination with a work area. Thus, a system of the type disclosed in U.S. Pat. No. 6,375,874, hereby expressly incorporated by reference, may also be employed.
[0046] After particles are spread, they are selectively contacted with the binder material. Preferably the binder material is dispensed through at least one binder fluid dispenser, and preferably one characterized in that it employs piezoelectric jets (e.g., as described in U.S. Pat. No. 6,460,979, hereby incorporated by reference), a continuous jet spray, an intermittent jet spray, dispenses through a mask, includes a single dispensing nozzle, includes a plurality of dispensing nozzles that are clustered together, includes a heated nozzle, includes a plurality of dispensing nozzles that are spaced apart, or combinations of at least two of the foregoing characteristics.
[0047] Though a variety of other print heads may be employed, in a particularly preferred embodiment, a piezo bending transducer drop-on-demand print head is employed. One or a plurality of transducers is subjected to a triggering pulse to achieve drop discharge movement. It is also possible that, in a plural transducer head, and, each piezo bending transducer neighboring the piezo bending transducer triggered by the triggering pulse is subjected to a compensating pulse deflecting it. See also, U.S. Pat. No. 6,460,979, hereby incorporated by reference.
[0048] A preferred droplet density for dispensing fluids through a print head ranges from about 50 dpi to about 1000 dpi. A droplet line density ranging from 100 to 600 dpi is particularly preferred. Higher or lower densities are also possible. For example, a typical dispensing nozzle may range from about 20 to about 100 microns, more preferably about 30 to about 80 microns, and still more preferably about 50 to about 60 microns. Accordingly, droplet diameters less than about 100 microns, more preferably less than 60 microns are possible (it being recognized that a 60 micron diameter corresponds generally with a droplet volume of about 80 pl), and diameters as low as about 10 microns or smaller are also possible. Droplet ejection frequency may be varied as desired, but preferably it will be at least 1 Hz, more preferably at least 5 Hz. In one embodiment a frequency of 15 Hz or higher is possible.
[0049] The relative amounts of binder to activation agent materials may be selected and varied as desired. In one embodiment, the relative amount (in parts by weight) of binder to activation agent is about 1:10 to about 10:1, and more preferably it is about 1:4 to about 4:1. Still more preferably the amount of binder to activation agent is about 2:1. For example, in one preferred embodiment employing a furane resin and sand, a mixture will preferably include about 0.3 weight percent of the activation agent and about 0.6 weight percent of the binder.
[0050] Overall, it is preferred to use less than about 25%, more preferably less than 10% and still more preferably less than 2% by weight overall of a binder in a form that includes particles, binder and activation agent. Of course, higher or lower amounts are also possible.
[0051] To assist in curing of or otherwise hardening the binder material one or more additional stimuli may be employed, including without limitation heat, infrared radiation, ultraviolet radiation, moisture, air, a vacuum, an inert environment, a reactive gas environment, catalysis, combinations thereof, or the like.
[0052] In this regard, the hardening may be performed is a separate enclosed chamber to assure a particular environment. It may also be enhanced such as by heating the work surface of the system, by heating the binder material prior to dispensing (e.g., while it is in a container), during dispensing (e.g., by providing a heated dispensing head, nozzle or both), or following dispensing. A preferred temperature range for facilitating curing of the binding material is about 15° C. to about 40° C., and more preferably about 20° C. to about 30° C. (e.g., for a furane resin it preferably cures at ambient room temperature). However other resins with a curing point at higher temperature levels are also possible to use, and therefore higher temperatures (or possibly lower temperatures may also be employed.
[0053] Examples of additional techniques that may suitably be employed in the present invention include those disclosed, without limitation, in U.S. Pat. No. 6,147,138 (hardened using one or a combination of heat or a reactive gas atmosphere), U.S. Pat. No. 6,423,255; WO 02/26419 (addressing hardening selectively dosed binder in a reactive gas atmosphere).
[0054] Further, in some applications, it may be desirable to also remove the three-dimensional form from surrounding bound particle material. Any suitable process may be employed, such as that in WO 02/28568 (PCT Application No. PCT/DE01/03834), hereby expressly incorporated by reference.
[0055] Additional variations are also possible. For example, compositions of particles, binder material, activation agent, or any combination thereof may be constant throughout a form, or it may vary as between two or more different layers.
[0056] In addition, it may be possible to employ a silk screening step in delivering the binder material to a layer of particles, such as by using techniques discussed in U.S. Pat. No. 6,193,922, hereby incorporated by reference.
[0057] For one embodiment, one particularly preferred material system furane resin, which preferably contains furfuryl alcohol in a proportion of at least 50 per cent and ethane diol in a proportion of approximately 4 per cent as well as water, is preferably used as binding material. The preferred curing agent contains toluene sulfonic acid in a proportion of 45 to 55 per cent, diethylene glycol in a proportion of 5 to 15 per cent and sulphuric acid in a proportion of at most 1 per cent. For this embodiment, the preferred binder material and the preferred curing agent are preferably used in a ratio of weight of 2:1.
[0058] The present invention is useful for and is contemplated for use in a method for making any of a variety of different three dimensional forms, such as those selected from the group consisting of a casting mold (e.g., for metal castings, lost-foam castings, casting that have hollow internal portions that require an internal mold core part, ceramic castings, metal matrix composite castings, or any other castings), a die for molding (e.g. blow molding, rotational molding, injection molding), a die for thermoforming, an extrusion die, an orthopedic implant, a dental restoration, a vascular tissue, a sustained release drug form, a monochromatic prototype part, a multi-colored prototype part, a sculpture, a gradient index lens, a hollow part (e.g., a hollow metal part), an electronics component, a cutting tool (e.g., a ceramic tool such as a tungsten carbide tool or other carbide tool), and a metal matrix composite. The present invention also contemplates articles that are prepared according to the methods herein. For example articles of the invention include a plurality of layers that include particles bound together by a binder material system that is at least two components, including an activation agent and a binder material, wherein the binder material is not contacted with the particles prior to the activation agent.
[0059] The invention finds particularly attractive utility in the manufacture of molds for casting of metals. Without limitation, examples of the use of the methods of the present invention include the formation by metal casting with a mold prepared by the methods herein of an automotive vehicle component (e.g., a cylinder head, a wheel, a powertrain component, a suspension component, a housing, or otherwise).
[0060] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one step or component may be split among plural steps or components. The present invention contemplates all of these combinations.
[0061] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, 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. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. | New methods and systems for manufacturing a three-dimensional form, comprising steps of providing a plurality of particulates; contacting the particulates with an activation agent; contacting particulates having the activation agent with a binder material that is activatable by the activation agent; at least partially hardening the binder for forming a layer of the three-dimensional form; and repeating these steps to form the remainder of the three-dimensional form. Following sequential application of all required layers and binder material to make the form, the unbound particles are appropriately removed (and optionally re-used), to result in the desired three-dimensional form. The invention also contemplates a novel method for preparing a form, where unbound particulates free of binder material are re-claimed. | 1 |
CLAIM TO PRIORITY
[0001] This application claims the benefit of U.S. Provisional Application 61/606,294, entitled “Reversible Wing Plow and Methods of Rotation” filed Mar. 2, 2012, which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to snow moving equipment. More particularly, the present invention relates to a wing plow for connection to the rear of a vehicle, wherein the wing plow includes a reversible moldboard that is configurable into a variety of positions.
BACKGROUND OF THE INVENTION
[0003] In the snow removal industry it is common practice to use a plow mounted to the front of a snow removal vehicle. The plow mounted to the front of the vehicle may be raised or lowered in relation to the travelled surface. When the plow is in the lowered position it is driven along by the vehicle; thereby pushing snow to one side or the other, depending on the operators' manipulation of the angle of the plow relative to the travel direction.
[0004] Side mounted wing plows to supplement the front plow are also well known to the snow removal industry. A side wing plow is generally used when extra width of the plowing swath is desired and the perceived risks involved in the employment of a side wing plow do not exceed the benefits. Typically the side wing is mounted to the side of a moving vehicle (tractor, truck, loader or grader). Side wing plows typically include a portion referred to as a side wing plow moldboard, which is a curved metal blade used for pushing snow.
[0005] With a typical side wing plow, an operator can manipulate the side wing plow moldboard up or down relative to the surface to be plowed, as well as angle the side wing plow moldboard relative to the direction of travel. When an operator configures the side wing plow to its plowing position, and the vehicle to which the side wing plow is attached is generally moving forward, snow is discharged down the length of, and past the end of the side wing plow moldboard, thereby creating a cleared path parallel to the direction of travel of the vehicle. Accordingly, by utilizing the side wing plow, the operator can increase the width of cleared snow (i.e., the swath width) beyond that which a front plow is capable of clearing alone. This extra swath width is beneficial because it increases the amount of cleared snow and pavement in a given pass, thereby increasing productivity and reducing the overall cost of the snow removal process.
[0006] U.S. Pat. No. 4,096,652, and entitled “Retractable Snowplow Wing and Mounting Therefor” discloses a side wing plow mounted to one side of a vehicle. However, side wing plows such as this are limited to use on only one side of the vehicle, thereby limiting the operator efficiency. To accommodate for special circumstances where a side wing plow mounted to the opposite side of the vehicle is needed, oftentimes there is a one vehicle with an opposite mounted wing plow within the fleet of plows. Furthermore, when this type of side wing is in a transport, or upright position, the side wing plow greatly increases the overall width of the vehicle, thereby increasing the risk of accident.
[0007] Another demonstration of prior art can be seen in U.S. Pat. No. 3,241,254, entitled “Snow Wing for Motor Graders”. This again shows a side wing plow mounted to the side of a vehicle. Neither of these inventions allow for the immediate change of discharge of snow from one side of the vehicle to the other.
[0008] In accordance with the prior art, to accomplish snow discharge on either side of the vehicle, one would currently need to mount a large and cumbersome plowing apparatus on the rear of a vehicle; such a device is taught in U.S. Pat. No. 3,908,289, entitled “Swing-Over Snow Wing”. This device, however, is extremely large and complex, and requires a great deal of thought and manipulation by the operator to function properly. This device further causes a significant decrease in operator visibility when the wing plow is in the transport position, thereby adding an unnecessary safety risk.
[0009] Another possible solution is taught in U.S. Pat. No. 7,367,407, entitled “Towed Snowplow and Method of Plowing.” This device however, requires the plow to be trailered, thereby greatly reducing maneuverability. Accordingly, this device is not meant for use within cities where frequent backing up, or travel in reverse, may be necessary.
[0010] Collectively the prior art devices add immense weight, expense and complication to the efforts of snow removal. Moreover, because of their complexity and bulk, they decrease the operators' focus, comfort and, most importantly, public safety.
[0011] Accordingly, there is a need in the snow removal industry for a wing plow that has a moldboard that can easily be moved from one side of the vehicle to the other, thereby allowing an increased swath width on either side of the vehicle without significantly adding to the weight, expense and complication of snow removal.
[0012] Additionally, there is a need in the snow removal industry for a wing plow with a moldboard that can be transported while maximizing the visibility of the operator to improve safety.
SUMMARY OF THE INVENTION
[0013] The present invention provides embodiments of a reversible wing plow with a prime mover. The reversible wing plow is comprised of a hitch, a moldboard and a moldboard shifting mechanism. The hitch is coupleable to the prime mover at a rear of the prime mover. The moldboard has an inboard end and an outboard end. The moldboard is operably coupled to the hitch proximate the inboard end and rotatable about a first horizontal axis that extends outwardly from the hitch generally parallel to a direction of forward movement of the prime mover.
[0014] The mold board shifting mechanism includes a first linear actuator and a second linear actuator. The first linear actuator has a first fixed end coupled to the hitch and a second moving end. The second linear actuator has a second fixed end coupled to the hitch and a second movable end. The first movable end of the first linear actuator and the second movable end of the second linear actuator are coupled to a rotation crank plate on opposing sides of the rotation crank plate. The crank plate is further operably coupled to the moldboard proximate the inboard end of the moldboard via a rotation member whereby the moldboard is rotatably shiftable between a first position extending outwardly on a first side of the prime mover to a second position extending outwardly on a second side of the prior mover and to a vertically oriented transport position between the first position and the second position by coordinated extension and retraction of the first linear actuator and the second linear actuator.
[0015] The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description that follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention can be more completely understood in consideration of the following detailed description of various embodiments of the invention, in connection with the accompanying drawings, in which:
[0017] FIG. 1 depicts a side view of a prime mover with reversible wing plow deployed to the driver side plowing position mounted to the rear of the prime mover by means of a three point hitch in accordance with an example embodiment of the invention;
[0018] FIG. 2 depicts a rear view a prime mover with reversible wing plow deployed to the driver side plowing position in accordance with an example embodiment of the invention;
[0019] FIG. 3 depicts a rear view a prime mover with reversible wing plow deployed to the passenger side plowing position in accordance with an example embodiment of the invention;
[0020] FIG. 4 depicts a side view of a prime mover with reversible wing plow positioned substantially vertically in accordance with an example embodiment of the invention;
[0021] FIGS. 5A through 5C depict close-up rear view of the horizontal rotation of the wing plow moldboard as it hydraulically rotates relative to the prime mover in accordance with an example embodiment of the invention;
[0022] FIG. 6 depicts an isometric view of the operable coupling of the inboard end of the moldboard to the crank plate via a rotation member in accordance with an example embodiment of the invention;
[0023] FIG. 7A depicts an isometric view of reversible wing plow with the moldboard folded in transport mode in accordance with an example embodiment of the invention;
[0024] FIG. 7B depicts a close up isometric view of the automatic safety locking mechanism in transport mode in accordance with an example embodiment of the invention;
[0025] FIG. 8 depicts an isometric view of a prime mover with reversible wing plow including the operator-manipulated joystick and smart controller in accordance with an example embodiment of the invention; and
[0026] FIG. 9 depicts a schematic of the hydraulic control system in accordance with an example embodiment of the invention.
[0027] While the invention is amenable to various modifications and alternative forms, specifics thereof have by shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION
[0028] Referring now to the drawings and illustrative embodiments depicted therein, a reversible wing plow 10 for use with a prime mover 12 generally includes a hitch assembly 14 , a moldboard assembly 16 , a moldboard rotation assembly 18 , and an electro hydraulic control system 20 .
[0029] As best seen in FIGS. 7A and 8 , hitch assembly 14 includes an L-shaped hitch plate 22 , a vertical member 24 , a horizontal member 26 , and a rotational shaft 28 . In an example embodiment of the invention, L-shaped hitch plate 22 can be positioned between the rear of prime mover 12 and moldboard assembly 16 . L-shaped hitch plate 22 can be integrated with, or coupled to, vertical member 24 and horizontal member 26 .
[0030] Vertical member 24 has a front surface 30 , a back surface 32 and an inboard shaft support 34 . Front surface 30 includes at least one vehicle mount coupler 36 for removable connection to prime mover 12 . Prime mover 12 can be a tractor, grader, loader, truck, or other suitable piece of motorized equipment having ground engaging wheels or tracks. In an example embodiment of the invention, vehicle mount coupler 36 can be a three- point hitch. The vehicle mount coupler 36 can allow for vertical ground clearance adjustment of reversible wing plow 10 separate from prime mover 12 . Back surface 32 includes hydraulic ram supports 38 and 39 , turning cylinders 40 and 41 and locking pin receiver 42 . Hydraulic ram supports 38 and 39 provide connection points for coupling one end of turning cylinders 40 and 41 to vertical member 24 . Turning cylinders 40 and 41 include a first double acting hydraulic lift cylinder 40 and a second double acting hydraulic lift cylinder 41 . Vertical member 24 further includes locking pin receiver 42 . Inboard shaft support 34 provides a rotational coupling point to, and support for, the inboard end of rotational shaft 28 .
[0031] Horizontal member 26 includes outboard shaft support 44 and reinforcements 46 . Outboard shaft support 44 provides a rotational coupling point to, and support for, the outboard end of rotational shaft 28 . Reinforcements 46 provide ample structural support for maintaining rotational shaft 28 substantially fixed in position relative to L-shaped hitch plate 22 , particularly when subjected to external forces in operation.
[0032] Rotational shaft 28 is oriented substantially horizontal and substantially parallel to the direction of travel of prime mover 12 . Rotational shaft 28 is supported at by inboard shaft support 34 and outboard shaft support 44 . Rotational shaft 28 can be laterally secured in place relative to the L-shaped hitch plate 22 , for example by a large nut or other common retainer.
[0033] As best seen in FIGS, 2 , 4 and 7 A, moldboard assembly 16 , generally includes moldboard 48 and moldboard hinge knuckle 50 . In the depicted embodiment, moldboard 48 includes cutting edges 52 and 53 , bracing 54 , inboard portion 56 , outboard portion 58 , and folding linkage assembly 60 .
[0034] Cutting edges 52 and 53 include a first cutting edge 52 and a second cutting edge 53 . Cutting edges 52 and 53 are positioned opposite one another on the lateral edges of moldboard 48 . Cutting edges 52 and 53 can be coupled to moldboard 48 in a manner that allows ease in periodic replacement, for example with a series of bolts or other suitable fasteners.
[0035] In an example embodiment of the invention, bracing 54 provides ample structural support for substantially maintaining the shape of moldboard 48 , particularly when subjected to external forces in operation. Bracing can be coupled both horizontally and vertically along a surface of moldboard 48 .
[0036] Inboard portion 56 of moldboard 48 includes folding cylinder mount 64 , link arm mount 66 , angle cylinder mount 67 , and a portion of folding hinge 68 . Folding cylinder mount 64 provides a connection point for pivotably coupling one end of double acting folding cylinder 76 to inboard portion 56 . Link arm mount 66 provides a connection point for pivotably coupling one end of link arm 72 to inboard portion 56 . In an example embodiment of the invention, angle cylinder mount 67 , can be coupled to the side of moldboard opposite folding cylinder mount 64 and link arm mount 66 , as show in FIG. 6 . Angle cylinder mount 67 provides a connection point for pivotably coupling one end of angle cylinder 88 to moldboard assembly 16 .
[0037] In the depicted embodiment, outboard portion 58 of moldboard 48 includes pushrod mount 70 and a portion of folding hinge 68 . Pushrod mount 70 provides a connection point for pivotably coupling one end of push rod 74 to outboard portion 58 . Corresponding portions of folding hinge 68 are respectively coupled to inboard portion 56 and outboard portion 58 of moldboard 48 . These portions can be joined, for example by a pin, thereby hingedly coupling inboard portion 56 to outboard portion 58 .
[0038] Inboard portion 56 and outboard portion 58 of moldboard 48 can have a curved shape, thereby forming a channel to accommodate the flow of snow along the length of moldboard 48 when plowing.
[0039] In an example embodiment, folding linkage assembly 60 includes link arm 72 , pushrod 74 and double acting folding cylinder 76 . In an example embodiment of the invention, pushrod 74 , is pivotably coupled to outboard portion 58 at one end, and pivotably coupled to an end of link arm 72 on its other end. Link arm 72 is pivotably coupled to an end of pushrod 74 at one end and pivotably coupled to inboard portion 56 on the other end. Folding cylinder 76 is a double acting cylinder and is pivotably coupled to inboard portion 56 at one end, and pivotably coupled to an intermediate location on link arm 72 at its 76 the other end.
[0040] Moldboard hinge knuckle 50 is coupled to the inboard portion 56 of moldboard 48 , proximate the end opposite folding hinge 68 . Moldboard hinge knuckle 50 can be joined, for example, by hinge pin 94 to rotation member knuckle 92 , thereby hingedly coupling moldboard assembly 16 to moldboard rotation assembly 18 . Hinge pin 94 can be secured in place by a nut or other common retainer.
[0041] As best seen in FIGS. 5. 6 , 7 B, and 8 , moldboard rotation assembly 18 includes box channel 80 , hinge plate 82 , rotation crank plate 84 , angle cylinder support plate 86 , angle cylinder 88 , and locking cylinder 90 .
[0042] Box channel 80 is supported by, and rotationally coupled to, rotation shaft 28 . Hinge plate 82 is coupled to the end of box channel 80 distal to hitch assembly 14 . Hinge plate 82 includes rotational member knuckle 92 and hinge pin 94 .
[0043] Rotation crank plate 84 is coupled to the end of box channel 80 opposite hinge plate 82 , proximate to hitch assembly 14 . As best seen in FIGS. 5 , in an example embodiment of the invention, rotation crank plate 84 includes two similar plates 96 , a first cylinder pin 98 and a second cylinder pin 100 . The two similar plates 96 can have apertures appropriately sized to accommodate first and second cylinder pins 98 and 100 . First cylinder pin 98 pivotably couples the end of first turning cylinder 40 to two similar plates 96 . Second cylinder pin 100 pivotably couples the end of second lift cylinder 41 to two rotation crank plates 96 .
[0044] As best seen in FIGS. 6 , angle cylinder support plate 86 is coupled to box channel 80 . Angle cylinder support plate 86 pivotably couples to one end of angle cylinder 88 . The opposite end of angle cylinder 88 pivotably couples to angle cylinder support 67 of the moldboard assembly 16 .
[0045] As best seen in FIG. 7B , locking cylinder 90 includes locking pin 91 , and is coupled to, and can be positioned substantially parallel to, the length of box channel 80 such that locking pin 91 can selectively extend through an aperture in two similar plates 96 and into locking pin receiver 42 of hitch assembly 14 .
[0046] As best seen in FIGS. 8 and 9 , according to an example embodiment, electro hydraulic control system 20 includes hydraulic controls 102 and electronic control 104 .
[0047] Hydraulic controls 102 generally include angle cylinder valve 108 , accumulator 109 , lock cylinder valve 110 , folding cylinder valve 112 , turning cylinder valves 114 , float valves 116 , pressure sensor 117 , directional control valve 118 , and vehicle auxiliary 119 . Hydraulic controls 102 receive hydraulic pressure from a vehicle auxiliary 119 .
[0048] Electronic control 104 includes controller 120 , joystick 122 and button 124 . Controller 120 is a computer device that senses various electrical inputs and executes preset programs based on the sensed various electrical inputs. Controller 120 is in communication with hydraulic controls 102 . Joystick 122 and button 124 can be manipulated by an operator to provide various electrical inputs to controller 120 ,
[0049] In operation, moldboard assembly 16 can rotate about the rotational shaft 28 of hitch assembly 14 more than 180 degrees, allowing the change of plowing positions from one side of prime mover 12 to the other side of prime mover 12 . In an example embodiment of the invention, rotation of moldboard assembly 16 is caused by turning cylinders 40 and 41 . Other methods of rotation, such as chains, cable, gears and motor are also contemplated.
[0050] To rotate moldboard assembly 16 from the driver side plowing position (as shown in FIG. 5A ) to the passenger side plowing position (as shown in FIG. 5C ) the operator can manipulate joystick 122 towards the passenger side of prime mover 12 until rotation is complete. Manipulation of joystick 122 will activate controller 120 , which in this case, executes a preset program to activate the lift mode of hydraulic controls 102 . Upon activating the lift mode of hydraulic controls 102 , individual valves 114 , 116 and 118 are activated and fluid pressure is directed to turning cylinders 40 and 41 , thereby retracting turning cylinders 40 and 41 until they reach their equalized point (as shown in FIG. 5B ). Once this equalized point is reached, and no further hydraulic fluid can be displaced, a pressure spike occurs in hydraulic controls 102 . This pressure spike causes pressure sensor 117 to send a signal to controller 120 . This input from pressure sensor 117 causes controller 120 to execute a preset program to activate the drop mode of hydraulic controls 102 . Once the drop mode is activated controller 120 will take into consideration the direction in which the operator has manipulated joystick 122 . Based on a preset program, then controller 120 activates valves 114 to reverse the flow of hydraulic fluid to one of the turning cylinders 40 and 41 . The reversed turning cylinder 40 or 41 then extends, thereby overpowering the other turning cylinder 40 or 41 to continue rotation of moldboard assembly 16 in the direction that the operator has manipulated joystick 122 .
[0051] If the operator continues to hold joystick 122 in the same position after rotation of moldboard assembly 16 has subsided, controller 120 executes a preset program to activate the float mode of hydraulic controls 102 . The float mode removes retraction or extension pressure to turning cylinders 40 and 41 and allows free movement of hydraulic fluid through the turning cylinders 40 and 41 , thereby allowing gravity to keep cutting edge 52 or 53 of moldboard 48 against the plowing surface, particularly in uneven terrain. Float mode is activated by deactivating individual valves 114 and 118 , but allowing valves 116 to remain active. After float mode is activated, the operator can release joystick 122 .
[0052] Moldboard assembly 16 is pivotable about moldboard hinge knuckle 50 , so as to angle moldboard 48 in relation to the direction of travel of prime mover 12 by manipulation of joystick 122 forward or backward in relation to prime mover 12 . Manipulation of joystick 122 forward or backward sends an input signal to controller 120 . Controller 120 then directs hydraulic pressure to angle cylinder 88 via hydraulic controls 102 . Accordingly, when an operator manipulates joystick 122 forward, Moldboard assembly 16 pivots forward about moldboard hinge knuckle 50 until moldboard 48 is substantially perpendicular to the direction of travel of prime mover 12 . When an operator manipulates joystick 122 backward, moldboard assembly 16 pivots aft about moldboard hinge knuckle 50 until the discharge angle of moldboard 48 is at a maximum relative to the direction of travel of prime mover 12 . Accordingly, by adjusting the angle of moldboard 48 , the operator can change the discharge angle of the reversible wing plow 10 , thereby varying the effective swath width.
[0053] In addition to varying the swath width, there can be a safety function to allow moldboard 48 to automatically rotate about moldboard hinge knuckle 50 or angle back when encountering an obstacle. This is accomplished via accumulator 109 to create a hydraulic spring; however other methods, such as coil springs are also contemplated.
[0054] Inboard portion 56 and outboard portion 58 of moldboard 48 can pivot about folding hinge 68 , thereby allowing moldboard 48 to be folded approximately in half, or at least reducing the overall length of moldboard 48 . This folded position is intended for used primarily when in the transport mode as depicted in FIG. 7A .
[0055] Reversible wing plow 10 can be put into transport mode by depressing button 124 . Transport position is used when the reversible wing plow 10 is not in use; non-use can occur when driving from one area to another or when an increased swath width is not necessary. When controller 120 receives input that button 124 has been depressed, controller 120 executes a preset program to activate the lift mode of hydraulic controls 102 . As discussed previously, upon activating the lift mode of hydraulic controls 102 , individual valves 114 , 116 and 118 are activated and fluid pressure is directed to turning cylinders 40 and 41 , thereby retracting turning cylinders 40 and 41 until they reach their equalized point (as shown in FIG. 5B ). Once this equalized point is reached, and no further hydraulic fluid can be displaced, a pressure spike occurs in hydraulic controls 102 . This pressure spike causes pressure sensor 117 to send a signal to controller 120 .
[0056] If no further operator manipulation is sensed, the controller 120 then executes a preset program to activate hydraulic controls 102 to send fluid pressure to folding cylinder 76 , thereby retracting folding cylinder 76 and pivotally folding moldboard 48 about folding hinge 68 . After a pre-programed time has elapsed, controller 120 deactivates hydraulic controls 102 , thereby removing the pressure directed to folding cylinder 76 .
[0057] Controller 120 then executes a preset program to activate hydraulic controls 102 to send fluid pressure to locking cylinder 90 , causing locking pin 91 to drive forward and become seated in locking pin receiver 42 of hitch assembly 14 , thereby physically stopping any rotation of moldboard assembly 16 relative to hitch assembly 14 . Locking cylinder 90 is a safety mechanism so that even if there is a hydraulic failure, the moldboard assembly 16 will not inadvertently fall.
[0058] For transition from transport mode to operation mode (i.e., the driver side plowing position or the passenger side plowing position), the operator manipulates joystick 122 towards either the driver side or passenger side of prime mover 12 . Manipulation of joystick 122 activates controller 120 , which in this case, executes a preset program to activate the lift mode of hydraulic controls 102 . Upon activating the lift mode, hydraulic control 102 disengages locking cylinder 90 , thereby removing locking pin 91 from locking pin receiver 42 . Because both turning cylinders are already in the equalized point a pressure spike occurs in hydraulic controls 102 . This pressure spike causes pressure sensor 117 to send a signal to controller 120 . This input from pressure sensor 117 causes controller 120 to execute a preset program to activate the drop mode of hydraulic controls 102 . Once the drop mode is activated controller 120 takes into consideration the direction in which the operator has manipulated joystick 122 . Based on a present program, then controller 120 activates valves 114 to reverse the flow of hydraulic fluid to one of the turning cylinders 40 and 41 . The reversed turning cylinder 40 or 41 then extends, thereby overpowering the other turning cylinder 40 or 41 to continue rotation of moldboard assembly 16 in the direction that the operator has manipulated joystick 122 .
[0059] If the operator continues to hold joystick 122 in the same position after rotation of moldboard assembly 16 has subsided, controller 120 executes a preset program to activate the float mode of hydraulic controls 102 . The float mode removes retraction or extension pressure to turning cylinders 40 and 41 , and allows free movement of hydraulic fluid through the turning cylinders 40 and 41 , thereby allowing gravity to keep cutting edge 52 or 53 of moldboard 48 against the plowing surface, particularly in uneven terrain. Float mode is activated by deactivating individual valves 114 and 118 , but allowing valves 116 to remain active. After float mode is activated, the operator can release joystick 122 .
[0060] Controller 120 then executes a preset program to activate hydraulic controls 102 to send fluid pressure to folding cylinder 76 , thereby extending folding cylinder 76 and pivotally unfolding moldboard 48 about folding hinge 68 . After a preprogram time has elapsed, and moldboard 48 is fully extended, controller 120 deactivates hydraulic controls 102 , thereby removing the pressure directed to folding cylinder 76 .
[0061] The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | A reversible wing plow including a hitch, a moldboard and a moldboard shifting mechanism. The hitch is coupleable to the rear of a prime mover. The moldboard is operably coupled to the hitch proximate an inboard end and rotatable about a first horizontal axis that extends outwardly from the hitch generally parallel to a direction of forward movement of the prime mover. The moldboard shifting mechanism includes first and second linear actuators, both of which are coupled to the hitch at one end and coupled to opposing sides of a rotation crank plate on the other end. The crank plate is further operably coupled to the moldboard, whereby the moldboard is rotatably shiftable to the driver or passenger side of the prime mover, or to a vertically oriented transport position. | 4 |
The present invention relates to a pipe for carrying fluids, particularly hydrocarbons, made by assembling heat-insulated metal tubes.
It is known that in a number of cases, crude oil is extracted from the ground at a temperature which is several tens of degrees greater than the ambient temperature and that, when this crude oil contains paraffinic products, its cooling to ambient temperature (or even to temperatures greater than the ambient temperature) causes for example precipitation of these products which progressively leads to blockage of the pipe.
It has already been attempted to overcome these difficulties by surrounding the pipes with thick insulators based on expanded materials which must themselves be protected by a layer of rigid materials, so as to withstand the various stresses to which the pipe is subjected both when it is fitted and when it is used.
These insulators have the drawback of being bulky, and of considerably increasing the external dimensions of the pipe. They also greatly increase its buoyancy, which often requires its ballasting to be increased.
In the latter case, it is then necessary to weight the pipe by encasing it in concrete, which is almost always difficult to make adhere to the outer wall of the insulator.
These known pipes also have the drawback of corroding easily when the outer insulator becomes degraded or because of the thermal expansions which are different between the steel tube and the insulator.
It also been envisaged to produce insulating tube sections consisting of an outer tubular element and an inner tubular element which are welded at their ends and which contain between them an insulating element in order to constitute pipes.
The use of such tube sections has proved unsatisfactory, in particular because of the difficulties which are encountered in joining the tubular elements together in order to constitute the pipes.
The object of the present invention is to obtain, in a simple and economical manner, a pipe produced from thermally insulated steel tube sections, but which include no outer insulator and which can be handled, fitted and used for producing submerged or overland pipes, exactly in the same way as conventional steel tube sections which include no insulator.
The subject of the present invention is a pipe for carrying fluids, particularly hydrocarbons, consisting of thermally insulated steel tube sections, of the type comprising an outer tubular steel shell, an inner cylindrical steel shell of smaller diameter, the inner shell being welded in a leaktight manner to the outer shell at each of the ends of the tube sections, while leaving between the two shells a closed annular volume, preferably containing a heat insulating material, which pipe is characterized in that, at each joint between two tube sections, the ends of the inner shells of the two pipe sections are welded to one another, while a sleeve joins the ends of the outer shells, such that when traction, compression or bending forces are exerted on the pipe, the said sleeve communicates these forces to the outer shells while imparting to the pipe a mechanical strength at each joint which is at least equal to that of the tube sections.
According to a first embodiment of the invention, the sleeve is screwed onto each outer shell by a cylindrical thread, preferably with straight turn fronts, which includes between the male and female turns a clearance which is sufficient to compensate for alignment and positioning defects in the two sections when they are joined by welding their inner shells, and the space contained between the male turns and the female turns is lined with a substance, for example a polymerizable substance, which transmits the compression or traction forces which are to be exerted between the sleeve and the outer shells.
In order to do this, the total surface areas of the turn flanks must be chosen to be sufficiently large to allow for the crushing strength of the substance which is introduced between the male turns of the outer shells and the female turns of the sleeve.
This embodiment makes it possible, in a simple and economical manner, to connect two pipeline sections by a single weld which joins the inner shells in a leaktight manner, the outer shells being joined to each other by the substance, which can most often be applied cold, which is placed in the threads.
Moreover, the clearance between the turns of the sleeve and of the outer shells is sufficient to compensate for any positioning defects which may result from the joining of the two sections by welding their inner shells, either in the case of alignment defects or parallax of the axes of the two sections or alternatively shifts in pitch between the turns of the two outer shells.
The substance introduced between the turns may for example be a resin such as an epoxy resin or an araldite which polymerizes not with contraction, but preferably with expansion.
It is also possible to use polymerizable elastomers and products such as coal pitches which are applied hot and which are allowed to cool.
In a second variant of this first embodiment, the forces are transmitted between the sleeve and the outer shells of the two sections by virtue of the fact that, when the pipeline bench, the male turns of the outer shells of the two sections bear on the female turns of the sleeve. In order to allow bending of the inner shell at the joint which is sufficient to ensure compensation for the clearance existing between the turns of the sleeve and those of the outer shells, the collars joining the inner and outer shells to the end of each section are welded onto the inner shells at a sufficient distance from the ends of the inner shells.
In this variant, a free length of inner shell is left at a joint which may for example be of the order of one meter.
This characteristic is also advantageous in the first variant of this embodiment because it makes it possible to ensure mechanical continuity of the pipeline, even in the event that the substance injected only partially occupies the space between the turns of the sleeve and of the outer shells, and therefore has only an insufficient mechanical strength.
In a second embodiment of the invention, the sleeve is fitted at one of its ends with an internal thread which is screwed onto a corresponding external thread made on the end of the outer shell of a first tube section, such that the other end of the said sleeve is applied against a stop integral with the outer tubular shell of a second neighbouring tube section with a sufficient force for the pipe to have, at the joints between the various sections, a mechanical strength at least equal to that of the other parts of the pipe.
According to a preferred variant, the thread by which the sleeve is screwed onto the outer tubular shell of the first tube section is a cylindrical thread with bearing turn fronts substantially perpendicular to the axis of the pipe, so as to allow compensation for the slight parallaxes which may be produced when the inner tubular shells are joined by welding and which lead to the axes of the various sections of the pipe being slightly offset, albeit remaining parallel to each other.
According to this embodiment, the sleeve is screwed so as to impart to it, during mounting, an axial compression of a value greater than the maximum extension that some of its generatrices may undergo when the pipe is fitted or used.
According to the invention, it is advantageous, after screwing, for the sleeve to be welded at at least one of its ends onto the outer shell of one of the sections, so as to prevent it unscrewing accidentally.
The welding at each end of the sleeve makes it possible to isolate the annular volume contained between the sleeve and the inner shells, and thus to prevent introduction into this volume of fluids outside the pipe which might cause corrosion.
In one variant of this second embodiment, the stop on which the threaded sleeve bears when it is screwed onto the other section is fitted with a spherical ring which makes it possible automatically to compensate for the defects in alignment between the axis of the sleeve and that of the stop.
According to the two embodiments described hereinabove for preventing the introduction of external fluids into the annular volume contained between the sleeve and the inner shells, this volume may be filled for example with a bituminous substance or a cellular material such as a polyurethane foam, which has the additional advantage of increasing the insulation of the pipe.
In a preferred implementation of the invention, the welding of the ends of the inner shell and of the outer shell of the same section is carried out after having imparted to the inner shell an extension with respect to the outer shell which corresponds substantially to that which exists when the inner shell is subjected, with respect to the outer shell, to a temperature difference which is approximately equal to half the temperature difference which will exist when the pipe is in use and which will cause heating of its inner shell.
According to an advantageous implementation of this characteristic, the inner shell is preheated to approximately half the temperature difference which is to exist between the inner shell and the outer shell when the pipe is used, and the ends of the two shells are then connected by welding them in this state.
The result of this is that, when a tube section according to the invention is at a homogeneous temperature, the inner shell is in a state of extension, whereas the outer shell is in a state of compression. This situation develops progressively when a hot fluid is made to flow-inside the pipe, the outer shell then being progressively compressed, whereas the inner shell enters progressively into traction [sic].
According to the invention, it is advantageous when the pipe is to be used for carrying a fluid at high temperature, to make the inner shells and possibly the collars from a metal which has a low coefficient of expansion, such as for example the one known under the designation Invar.
It is thus possible to use the pipe according to the invention for carrying steam at more than 100° C.
According to the invention, the inner and outer shells may have equal thicknesses, but it is in general advantageous for the inner shells of the sections which are to be welded together for making the pipe sections to have a thickness greater than that of the outer shells whose continuity is ensured by the sleeve.
Thus, the inner shell may for example have a thickness approximately 3 to 4 times greater than that of the outer shell.
According to a particular embodiment of the invention, the inner and outer shells are joined together by welding using collars whose thickness is substantially equal to the thickness of the thinnest shell.
In order to limit the magnitude of the thermal bridges which result from their presence, these collars extend over a length which preferably lies between 3 and 5 times the distance which separates the outer face of the inner shell from the inner face of the outer shell.
In one particular embodiment of the invention, the collars which join the two shells at their ends have a cross section in the general shape of an S or of a half sine wave.
In one variant, the collars have a cylindrical shape and their ends are welded onto annular bosses integral with the ends of the inner and outer shells which they join.
In another variant, the collars each have a cylindrical central part extended by two frustoconical parts welded directly to the outer tubular shell, and to the inner tubular shell.
According to the invention, the collars may advantageously be made from an alloy which has a low sensitivity to heat, such as that known under the name Invar.
According to preferred embodiment of the invention, the closed annular volume contained between the two steel shells is lined with a plurality of thin sheets of an anti-thermal radiation insulator, the said sheets being preferably separated by cavity structures which do not conduct heat, which prevent them being applied against each other. Such insulating sheets may for example consist of aluminium sheets with a thickness of a few hundredths of a millimeter.
According to another embodiment of the invention, the closed annular volume may be filled with an expanded synthetic material such as for example expanded polyurethane or polyethylene.
Considering the fact that tube sections which are usually available have lengths of approximately 12 meters, and that these tubes are subjected, especially when fitting the pipe, to strong bending forces, provision is made according to a preferred embodiment of the invention, to locate at appropriate intervals, for example every meter or every two meters, spacer members which are placed between the inner shell and the outer shell.
These spacer members must be made of a material which has sufficient mechanical strength but which is not a good conductor of heat, for example from a synthetic material.
In order to limit the thermal bridges constituted by the said spacer members, it is recommended according to the invention not to give them a constant cross section over the entire perimeter of their winding. These members may for example be in the form of blocks which are of sufficient size to prevent, during for example bending stresses, the inner shell from collapsing against the outer shell, the said blocks being joined together by thinner sections of material, which thus limits heat transfer.
According to the invention, it is advantageous, when the tube section is subjected to no abnormal stress, for the spacer members to come into contact with only one of the shells.
According to another preferred embodiment of the invention, the insulating character of the pipe is substantially improved by creating in the space contained between the inner shell and the outer shell a high vacuum which may for example be of the order of 10 -5 to 10 -8 bar.
This evacuation may be carried out by conventional techniques which generally involve prior degassing of the metal surfaces by cleaning or by heating.
In one variant, the annular volume contained between the inner shell and the outer shell may be filled with a gas which is a poorer conductor of heat than air, such as for example carbon tetrachloride or chloroform.
BRIEF DESCRIPTION OF THE DRAWINGS
With the aim of better explaining the invention, a description will now be given, by way of illustration and without any limiting nature, of several embodiments thereof represented on the attached drawing, in which:
FIG. 1 is a view in axial section of a first embodiment of the joint between two pipe sections according to the invention,
FIG. 2 is a view in axial section of a second embodiment of the joint between two pipe sections according to the invention,
FIG. 3 is a view of the part III in FIG. 2 on a larger scale,
FIG. 4 is an enlarged sectional view of one variant of the bearing of the end of the sleeve in FIG. 2,
FIG. 5 is a sectional view of one variant of the embodiment in FIG. 2,
FIG. 6 is a sectional view representing a device which makes it possible to create the vacuum between the two shells of a section, and
FIG. 7 is a view in longitudinal section of one variant embodiment of the joint in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows the connection of the ends of the two pipe sections each comprising an inner tubular shell 1 and an outer tubular shell 2.
In this embodiment, near the end of each of the elements of one of the inner shells 1, an overthickness 4 is made by adding metal, the outer surface of which overthickness is then machined so as to make it cylindrically coaxial with the inner shell 1.
A cylindrical collar 6 is fixed at one of its ends by a weld bead 5 on the overthickness 4 while a shaped piece 7 attached by welding to the end of each of the outer shells 2 is connected onto the circular collar 6 by a weld bead 8.
The piece 7 has on its outer periphery a thread 9b whose turns have in the present case a rectangular cross section.
A cylindrical sleeve 9 comprises at each of its ends a female thread whose turns 9a also have a rectangular cross-sectional shape.
As can be seen in FIG. 1, there is a large clearance between the turns 9a and 9b, so that the sleeve 9, which has been engaged on one of the two pipe sections before joining the inner shells 1 by the weld 3, can be screwed at these two ends onto the turns 9b of the end elements 7 of the outer tubular shells 2.
This clearance between the turns 9a and 9b must be sufficient to compensate on the one hand for the alignment defects of the two inner shells 1 joined by the weld bead 3 (parallax defect between the axes of the two shells 1 and parallelism defect of these two axes) as well as for the difference in pitch which may exist between the turns 9b of one of the tube sections and the turns 9b of the other section.
According to this first embodiment of the invention, a material such as for example an epoxy resin or an araldite resin, is injected between the turns 9a and 9b, preferably a resin with rapid polymerization and which polymerizes without contraction and if possible with expansion.
The manner in which this material occupies the entire space contained between the turns 9a and 9b is represented as 10 in FIG. 1.
This filler material can be injected easily between the turns 9a and 9b from one or more orifices (not shown) made in the outer wall of the sleeve 9.
FIGS. 2 and 3 represent a second embodiment of the invention.
The inner 1 and outer 2 tubular shells are again seen in FIG. 2.
The inner shells 1 are extended by elements 4a provided with an overthickness 4 which are welded at 4b onto the inner shells 1.
As in the embodiment previously described, the ends of the inner 1 and outer 2 shells of each pipe section are joined together via collars 6 welded at 5 onto the overthickness 4 and at 8 onto the end 7 of the outer shell 2.
The two ends 7 of the outer shells 2 may either be attached by welding onto the tubes constituting the shells 2 or forged and machined at the ends of these tubes.
In order to produce the pipe represented in FIG. 1, steel is first added on in order to form an overthickness 4 near the ends of the tubes constituting the shells 1, then the outer surface of these overthicknesses is machined in order to make them concentric with the inner shell 1.
The ends 7 of the outer shells 2 are attached by welding onto the tubes constituting these shells 2, then one end of the collars 6 is welded at 8 onto the inner surface of the ends 7 of the outer shells 2.
The inner shell 1, possibly fitted with its insulating coating (not shown in FIG. 1) is then engaged inside the outer shell 2, fitted at each of its ends with a collar 6. Then, at one end of the tube section, the free end of the collar 3 is welded at 5 to the overthickness 4 of the inner shell 1.
According to one preferred embodiment of the invention, at the other end of the tube section, the welding 5 of the collar 6 onto the overthickness 4 of the inner shell 1 is performed while placing this inner shell 1 in a state of extension, whereas the outer shell 2 is placed in a state of compression.
By joining the inner and outer shells of the same pipe section by welding while the inner shell is stretched and the outer shell is compressed, a better distribution of the general stresses on the pipe when a hot fluid is made to flow inside the latter is obtained, which has the effect of causing extension of the inner shell 1.
When the various pipeline sections have been produced in this manner, after having engaged a sleeve 9 on the outer shell of each section, the various sections are butt joined by the weld beads 3 which thus ensure continuity of the inner shells 1.
It is then sufficient to move and screw the sleeve 9 onto the turns 9b of the two pipe sections and to inject the joining material between the turns 9a and 9b in order to obtain the pipe according to the invention.
According to the invention, in order to reduce the number of joints on the pipe, it is advantageous to produce sections by butt welding at least two 12 meter tubes to produce the tubular shells of each pipe section.
In this second embodiment of the invention, the sleeve 9 includes at one of its ends a female thread 9a which is engaged in a corresponding male thread 9b of the extension of the outer shell 2.
At its other end, the sleeve 9 bears against a shoulder 7a by its end which does not include any thread.
The part III in FIG. 2 has been represented on a larger scale in FIG. 3.
As can be seen in FIG. 3, the turns 9a and 9b have a bearing flank perpendicular to the axis of the pipe and there is moreover a relatively large clearance between the diameters of the turns 9a and 9b.
In this manner, it is possible, according to the invention, to compensate for errors of parallax which may result from the joining of the inner shells 1 by the weld 3.
FIG. 4 represents one variant of the stop of the right-hand end of the sleeve 9 in FIG. 2.
In this variant, there is located between the end of the sleeve 9 and the outer shell 2 a mobile ring 7b which has on its left a planar face against which the right-hand end of the sleeve 9 can slide and which has on its right a spherical surface which bears against a concave surface of the same shape which is produced on the piece 7.
In this manner, the defects in parallelism and in alignment of the axes of the two inner shells 1 of the two sections are compensated for.
In order to carry out the mounting of the pipe according to this second embodiment, it is sufficient to engage the thread 9a of the sleeve 9 onto the thread 9b of the outer shell of the pipe section which is situated on the left, in order that the right-hand end of the sleeve bears against the stop 7a, the sleeve 9 then being compressed by virtue of the turns 9a and 9b. The magnitude of this compression of the sleeve 9 is easily controlled by the angular rotation which is imparted to it with respect to the pipe.
According to the invention, the compression communicated to the sleeve 7 must be sufficient for the sleeve to remain compressed, whatever the stresses and in particular the bending stresses to which the pipe is subjected when it is fitted or when it is used.
The sleeve 9 is then immobilized by the welds 20 and 21.
FIG. 5 represents a third embodiment of the invention, in which the inner tubular elements 1 do not include a shaped piece but are joined directly by a weld bead 5.
In this embodiment, the outer tubular elements 2 are joined by weld beads 17 and 18, one to a shaped piece 16 fitted with an external thread 9b, the other to a shaped piece 15 acting as a stop.
The ends of the elements of the tubular shell 2 may also be forged and machined so as to take on a corresponding shape.
In this third embodiment of the invention, the collars 6 have an S-shaped cross-section, which allows them to be attached directly by a weld bead 5 to the outer surface of the inner shell 1 and by a weld bead 8 to the inner surface of the outer tubular shell 2.
According to a preferred implementation of the invention, the inner and outer elements are respectively set in tension and compressed before joining all the ends of the inner and outer shells.
In the embodiment shown in FIG. 5, the sleeve 9 is not welded onto the outer shells 1 and 2, but the space contained between the sleeve 9 and the inner shells 1 is filled with a substance 19 which may for example be a bituminous substance or alternatively a substance in the form of a foam which, in addition to the fact that it occupies the space situated below the sleeve 9 and thus prevents corrosion, supplements the thermal insulation.
In the embodiment shown in FIG. 5, a plurality of thin sheets 22 whose reflecting power constitutes efficient heat insulation has been placed between the tubular shells 1 and 2 of the various sections.
These thin sheets, which are for example, sheets of aluminium or sheets made of a synthetic material such as the one known under the trademark Kevlar, are advantageously separated from each other by a cavity structure 23 made from a material which is a poor conductor of heat.
Spacer members 24 are placed periodically between the inner and outer shells so as to maintain the distance between these two shells in spite of the stresses to which the pipe is subjected, in particular bending stresses.
These elements, members 24, are advantageously made of plastic and they have a shape such that they come into contact with the walls of the shells 1 and 2 only periodically, in order to limit the thermal conductivity.
FIG. 6 represents one embodiment in which a relatively strong vacuum is formed between the inner and outer shells of each section.
For this purpose, an orifice 25 connected to a tubing 26 is made for example in the overthickness of the piece 4a so as to make it possible to connect the space contained between the inner and outer shells with a vacuum pump.
When the desired vacuum is obtained, it is then sufficient to fill the tubing 26 in order to maintain the vacuum inside the volume in question.
In one variant, the volume between the inner and outer shells may be occupied by a gas which is a poor conductor of heat, such as for example carbon tetrachloride or chloroform.
FIG. 7 represents one variant embodiment of FIG. 1 in which the ends 7 of the outer tubular shells 2 each include male turns 9b on which the female turns 9a of the sleeve 9 engage with a sufficient clearance to compensate for the inaccuracies in pitch and the alignment defects resulting from the welding 3 of the inner tubular elements 1.
In this variant, the inner tubular shells 1 have, in line with the sleeve 9, a zone of sufficient length in which they are independent from the collars 6 and from the outer shells 2, so as to be able to undergo, in this zone, sufficient elastic bending for the male turns 9b of the ends 7 of the outer shells 2 to be able to bear on the female turns 9a of the sleeve 9, while compensating for the clearance existing between these turns so as to transmit the compression or traction forces between the sleeve and the ends of the outer tubular elements 2, in order to ensure continuity of the mechanical strength of the pipe at the joint.
According to the variant represented in FIG. 7, the collars 6, which have a central cylindrical part extended by two frustoconical surfaces 6a and 6b are welded at one of their ends at 8 to the end of the tubular shells 2 and at their other end at a point 5 which is relatively distant from the weld 3 which joins the two inner tubular elements 1.
By way of example, the welds 5 of the two collars 6 onto the inner shells 1 may be approximately 1 meter apart.
Such an arrangement can also be used in the embodiment shown in FIG. 1, which has the advantage of ensuring security for the mechanical holding of the join in the event that the polymerizable substance which is injected between the sleeve 9 and the ends 7 of the outer shells 2 does not occupy the entire volume left free by the clearance between the turns, and thereby does not by itself ensure mechanical solidity of the whole. In this case, this substance would be partially crushed and the forces would be taken up as has just been described for FIG. 7.
Conversely, it is advantageous in the variant represented in FIG. 7 to inject a substance at the ends of the sleeve, through orifices (not shown), for example a polymerizable substance, which blocks the clearance between the turns, so as to prevent liquids, and in particular water, from being able to penetrate into the volume contained between the sleeve 9, the collars 6 and the ends of the inner shells 1, which volume is advantageously lined with a heat insulating substance.
It is clear that the embodiments which have been described hereinabove are in no way limiting, and that any desirable modifications can be made to them. | The invention describes a pipe for carrying fluid, including thermally insulated steel pipe sections of a type including an outer tubular shell, an inner cylindrical shell of smaller diameter, in the inner shell being sealingly welded to the outer shell at each of the ends of the pipe sections. It is characterized in that at each joint, the ends of the two inner shells are welded to each other, and a sleeve links to the ends of the outer shells so that when traction, compression or bending forces are exerted on the pipe, the said sleeve transmits these forces to the outer shells. | 8 |
BACKGROUND
[0001] The present disclosure relates to computer servers, and more specifically to identification of idle servers.
[0002] Data centers are facilities used to house computer systems and associated components. Servers in a data center perform work for client systems, such as running jobs, executing specific tasks, or performing arithmetic calculations. Servers that are idle (i.e. not performing useful work) still use energy. The wasteful use of energy on idle servers can be prevented by identifying and removing the idle servers.
SUMMARY
[0003] According to embodiments of the present disclosure, a method for identifying idle servers is disclosed. The method includes receiving power consumption data, for a server, for a period of time and receiving temperature data, for the period of time, from a location containing the server. It is determined that variation in the power consumption data exceeds a first threshold level. It is determined, in response to determining variation in the power consumption data exceeds the first threshold level, variation in the temperature data does not exceed a second threshold level. It is determined, in response to determining variation in the temperature data does not exceed a second threshold level, variation in the power consumption data follows a cyclic pattern. The server is identified as idle in response to determining the variation in the power consumption data follows the cyclic pattern.
[0004] Further disclosed herein are embodiments of a system and a computer program product for performing the disclosed method.
[0005] The above summary is not intended to describe each illustrated embodiment or every implementation of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The drawings included in the present application are incorporated into, and form part of, the specification. They illustrate embodiments of the present disclosure and, along with the description, serve to explain the principles of the disclosure. The drawings are only illustrative of certain embodiments and do not limit the disclosure.
[0007] FIG. 1 depicts a graph of power consumption versus utilization for two example servers.
[0008] FIG. 2 depicts a graph of power consumption over time of an example server at three different temperatures.
[0009] FIG. 3 depicts graph of power consumption over time for a server performing a system memory scrub.
[0010] FIG. 4 depicts a graph of power consumption over time for a server going through processor sleep mode cycling.
[0011] FIG. 5 depicts a flow diagram of an example method for identifying idle servers using power consumption and temperature data.
[0012] FIG. 6 depicts a block diagram of an example system for identifying idle servers using power consumption data and temperature data.
[0013] FIG. 7 depicts a high-level block diagram of an example computer system that may be used in implementing one or more of the methods, tools, and modules, and any related functions or operations described herein, in accordance with embodiments of the present disclosure.
[0014] While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
DETAILED DESCRIPTION
[0015] Aspects of the present disclosure relate to identifying idle servers based on power consumption, and more particular aspects relate to identifying idle servers based on correlation of power consumption to temperature and cyclic idle processes. While the present disclosure is not necessarily limited to such applications, various aspects of the disclosure may be appreciated through a discussion of various examples using this context.
[0016] Power consumption of a server increases with workload. Thus, low constant power consumption by a server may indicate an idle server. Referring to FIG. 1 , a graph 100 of power consumption versus utilization for two example servers is depicted. Line 110 represents a first example server and line 120 represents a second example server. As depicted, power consumption for the first and second server increase with utilization. The first example server, represented by line 110 , increases its power consumption by an average of 7.99% for each 10% increase in utilization. The second example server, represented by line 120 , increases its power consumption by an average of 3.69% for each 10% increase in utilization. Thus, as depicted in FIG. 1 , increased power consumption by a server may indicate increased utilization of the server.
[0017] However, temperature can also affect power consumption by a server as it can affect fan usage and fan speed for the server. Referring to FIG. 2 , a graph 200 of power consumption over time of an example server at three different temperatures is depicted. As depicted, power consumption increases with increased temperature. Graph 200 shows power consumption of an example server at 20° C., 31° C., and 42° C. Thus, as shown, a change in power consumption by a server may be due to a change in inlet temperature at the server.
[0018] Further, servers may perform background processes, not associated with work for a client system, which may cause fluctuations in power consumption of an idle server. FIG. 3 and FIG. 4 depict power consumption of a server performing example background processes. Background processes running on an idle server, such as those depicted in FIG. 3 and FIG. 4 , result in a cyclic pattern of power consumption for the server.
[0019] Referring to FIG. 3 , a graph of power consumption over time for a server performing a system memory scrub is depicted. Memory scrubbing consists of reading from each memory location, correcting bit errors with an error-correcting code (ECC), and writing the corrected data back to the same location. When the server is executing the system memory scrub, the power consumption increases to a higher level. When the server is not executing the system memory scrub, the power consumption returns to a lower baseline level. There is pattern of power consumption over time where the power consumption quickly transitions between the lower baseline level and the higher level.
[0020] Referring to FIG. 4 , a graph 400 of power consumption over time for a server going through processor sleep mode cycling is depicted. As the server goes in and out of sleep mode the power consumption cycles between a lower power sleep state and a higher power non-sleep state.
[0021] Embodiments of the present disclosure may provide for identifying idle servers using power consumption and temperature data over time. Power meters may measure power consumption for each server in a data center and communicate the power consumption data to an idle server identification module. One or more temperature sensors in the data center may measure the temperature in the data center and communicate the temperature data to the idle server identification module. The idle server identification module may be configured to monitor the power consumption data and temperature data over a period of time to determine if a server is idle. The idle server identification module may be configured to identify idles servers using the method described below in reference to FIG. 5 .
[0022] Referring to FIG. 5 , a flow diagram of an example method 500 for identifying idle servers using power consumption and temperature data is depicted. Method 500 begins at block 510 . At block 520 , it is determined whether there is a significant variation in power consumption by a server over a period of time. In some embodiments, determining whether there is a significant variation in power consumption includes determining whether variation in power consumption exceeded a threshold level. For example, the threshold may be 1% of the lowest measured power. The threshold level may be set at a level such that small variations in power consumption that indicate an idle server fall below the threshold level. If the variation in power consumption is not significant, the server is identified as idle at block 570 .
[0023] If the variation in power consumption is significant, it is determined, at block 530 , whether the inlet temperature at the server has remained stable over the period of time. In some embodiments, the temperature is considered stable if its variation is less than a threshold level. For example, the temperature may be considered stable if the variation in temperature is less than 2° C. The threshold temperature may be set at a level such that temperature variations below the threshold are unlikely to cause a significant change in power consumption by the server.
[0024] If the temperature is not stable, it is determined, at block 540 , whether there is a correlation between the power consumption of the server and temperature around the server. As depicted in FIG. 2 , an increase in temperature can cause an increase in power consumption and a decrease in power consumption can cause a decrease in power consumption. If the power consumption variations correlate with variations in temperature, the server is identified as idle at block 570 .
[0025] If, at block 530 , it is determined that the temperature around the server is stable or, at block 540 , it is determined that at least some variations in power consumption do not correlate with variations in temperature, it is determined whether the variations in power consumption follow a cyclic pattern indicative of a background process at block 550 . A cyclic pattern indicative of a background process may include the power consumption cyclically transitioning between a higher level and a lower level of power consumption. Examples of cyclic patterns indicative of a background process are shown in FIG. 3 (system memory scrub) and FIG. 4 (processor sleep mode cycling). If there is not a cyclic pattern in the power consumption, the server is identified as not idle at block 560 . If there is a cyclic pattern in the power consumption, the server is identified as idle at block 570 .
[0026] Identifying the server as idle in block 570 may be performed in many ways. In some embodiments, a data structure indicating the status of one or more servers is modified to indicate that the server is idle. This data structure may be accessed by users to identify idle servers. In some embodiments, a notification is communicated to a user indicating that the server is idle. This communication could take many forms. For example, a window with the notification may be displayed in a graphical user interface on a display device, such as a monitor, attached to the computing device that identified the idle server or another computing device. In another example, an email or other electronic message with the notification may be sent to a user.
[0027] Referring to FIG. 6 , a block diagram of an example system for identifying idle servers using power consumption data and temperature data is depicted. As depicted, data center 630 contains server 640 a , server 640 b , and server 640 c (collectively 640 ). Data center 630 further contains power meter 650 a , power meter 650 b , and power meter 650 c (collectively 650 ). Power meter 650 a is configured to monitor power consumption of server 640 a , power meter 650 b is configured to monitor power consumption of server 640 b , and power meter 650 c is configured to monitor power consumption of server 640 c . Power meters 650 are further configured to communicate power consumption data from servers 640 to computer system 610 . Power meters 650 may be any device capable of monitoring power consumption of a server. Data center 630 further contains a temperature sensor 660 . Temperature sensor 660 is configured to monitor the temperature within data center 630 and transmit the temperature data to computer system 610 .
[0028] Computer system 610 contains idle server identification module 620 . Idle server identification module 620 may identify servers which are idle using the power consumption data and temperature data. Idle server identification module may be configured to perform method 500 described in reference to FIG. 5 . In some embodiments, computer system 610 may further contain a server status data structure 670 that identifies the status, such as idle or not idle, for servers 640 . Idle server identification module 620 may be configured to modify server status data structure 670 to indicate a server is idle when the server is identified as idle. Data structure 670 may be any type of data structure capable of storing this information. In some embodiments, computer system 610 may be associated with a display for displaying a notification to a user indicating an idle server.
[0029] Although computer system 610 is depicted outside of data center 630 , in some embodiments, computer system 610 may be within data center 630 . Computer system 610 may be any type of computing system. Computer system 610 may be connected directly to power meters 650 and temperature sensor 660 or may be connected remotely over one or more networks. The networks can include, but are not limited to, local area networks, point-to-point communications, wide area networks, the global Internet, or combinations thereof.
[0030] In some embodiments, computer system 610 may be further configured to turn off power to a server in response to identifying a server as idle. This may involve activating a switch or otherwise disrupting the supply of power to the server.
[0031] Referring now to FIG. 7 , shown is a high-level block diagram of an example computer system (i.e., computer) 001 that may be used in implementing one or more of the methods, tools, and modules, and any related functions or operations, described herein (e.g., using one or more processor circuits or computer processors of the computer), in accordance with embodiments of the present disclosure. For example, computer system 001 may be used to implement computer system 610 described in reference to FIG. 6 . In some embodiments, the major components of the computer system 001 may comprise one or more CPUs 002 , a memory subsystem 004 , a terminal interface 012 , a storage interface 014 , an I/O (Input/Output) device interface 016 , and a network interface 018 , all of which may be communicatively coupled, directly or indirectly, for inter-component communication via a memory bus 003 , an I/O bus 008 , and an I/O bus interface unit 010 .
[0032] The computer system 001 may contain one or more general-purpose programmable central processing units (CPUs) 002 A, 002 B, 002 C, and 002 D, herein generically referred to as the CPU 002 . In some embodiments, the computer system 001 may contain multiple processors typical of a relatively large system; however, in other embodiments the computer system 001 may alternatively be a single CPU system. Each CPU 002 may execute instructions stored in the memory subsystem 004 and may comprise one or more levels of on-board cache.
[0033] In some embodiments, the memory subsystem 004 may comprise a random-access semiconductor memory, storage device, or storage medium (either volatile or non-volatile) for storing data and programs. In some embodiments, the memory subsystem 004 may represent the entire virtual memory of the computer system 001 , and may also include the virtual memory of other computer systems coupled to the computer system 001 or connected via a network. The memory subsystem 004 may be conceptually a single monolithic entity, but, in some embodiments, the memory subsystem 004 may be a more complex arrangement, such as a hierarchy of caches and other memory devices. For example, memory may exist in multiple levels of caches, and these caches may be further divided by function, so that one cache holds instructions while another holds non-instruction data, which is used by the processor or processors. Memory may be further distributed and associated with different CPUs or sets of CPUs, as is known in any of various so-called non-uniform memory access (NUMA) computer architectures.
[0034] In some embodiments, the main memory or memory subsystem 004 may contain elements for control and flow of memory used by the CPU 002 . This may include all or a portion of the following: a memory controller 005 , one or more memory buffers 006 A and 006 B and one or more memory devices 025 A and 025 B. In some embodiments, the memory devices 025 A and 025 B may be dual in-line memory modules (DIMMs), which are a series of dynamic random-access memory (DRAM) chips 007 A- 007 D (collectively referred to as 007 ) mounted on a printed circuit board and designed for use in personal computers, workstations, and servers. The use of DRAMs 007 in the illustration is exemplary only and the memory array used may vary in type as previously mentioned.
[0035] Although the memory bus 003 is shown in FIG. 7 as a single bus structure providing a direct communication path among the CPUs 002 , the memory subsystem 004 , and the I/O bus interface 010 , the memory bus 003 may, in some embodiments, comprise multiple different buses or communication paths, which may be arranged in any of various forms, such as point-to-point links in hierarchical, star or web configurations, multiple hierarchical buses, parallel and redundant paths, or any other appropriate type of configuration. Furthermore, while the I/O bus interface 010 and the I/O bus 008 are shown as single respective units, the computer system 001 may, in some embodiments, contain multiple I/O bus interface units 010 , multiple I/O buses 008 , or both. Further, while multiple I/O interface units are shown, which separate the I/O bus 008 from various communications paths running to the various I/O devices, in other embodiments some or all of the I/O devices may be connected directly to one or more system I/O buses.
[0036] In some embodiments, the computer system 001 may be a multi-user mainframe computer system, a single-user system, or a server computer or similar device that has little or no direct user interface, but receives requests from other computer systems (clients). Further, in some embodiments, the computer system 001 may be implemented as a desktop computer, portable computer, laptop or notebook computer, tablet computer, pocket computer, telephone, smart phone, network switches or routers, or any other appropriate type of electronic device.
[0037] It is noted that FIG. 7 is intended to depict the representative major components of an exemplary computer system 001 . In some embodiments, however, individual components may have greater or lesser complexity than as represented in FIG. 7 , components other than or in addition to those shown in FIG. 7 may be present, and the number, type, and configuration of such components may vary.
[0038] The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
[0039] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
[0040] Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
[0041] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
[0042] Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
[0043] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
[0044] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0045] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
[0046] The descriptions of the various embodiments of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. | Power consumption data for a server and temperature data from a location containing the server are received. It is determined that variation in the power consumption data exceeds a first threshold level. It is determined, in response to determining variation in the power consumption data exceeds the first threshold level, variation in the temperature data does not exceed a second threshold level. It is determined, in response to determining variation in the temperature data does not exceed a second threshold level, variation in the power consumption data follows a cyclic pattern. The server is identified as idle in response to determining the variation in the power consumption data follows the cyclic pattern. | 8 |
FIELD OF THE INVENTION
The invention relates to reactive hot melt compositions (RHM's) useful as adhesives, sealants, coatings, or the like.
DESCRIPTION OF THE PRIOR ART
RHM's are thermosetting adhesives. These materials are known in the prior art, and are known to have various disadvantages.
Canadian Patent No. 1,229,192 of Nov. 10, 1987, to S. C. Lin, describes an RHM comprising an epoxy urethane containing compound, which thermosets on heating.
U.S. Pat. No. 3,723,568 teaches the use of polyepoxides and optional epoxy polymerization catalysts. U.S. Pat. No. 4,122,073 teaches thermosetting resin obtained from polyisocyanates, polyanhydrides and polyepoxides. Crosslinking in these patents is achieved by reaction with available sites in the base polymers. U.S. Pat. No. 4,137,364 teaches crosslinking of an ethylene/vinyl acetate/vinyl alcohol terpolymer using isophthaloyl, bis-caprolactam or vinyl triethoxy silane whereby crosslinking is achieved before heat activation with additional crosslinking induced by heat after application of the adhesive. U.S. Pat. No. 4,116,937 teaches a further method of thermal crosslinking by the use of polyamino bis-maleimide class of flexible polyimides, which compounds can be hot melt extruded up to 150° C. and undergo crosslinking at elevated temperatures thereabove. In these latter two patents, thermal crosslinking is also achieved by reactions of the particular crosslinking agent with available sites of the base polymers.
U.S. Pat. No. 3,505,283 teaches the use of simple, organic di- and polyisoyanates as chemical thickeners when reacted with hydroxyl-containing epoxy resins at temperatures between 50° and about 200° C. in the presence of carboxylic acid anhydride as a curing agent. Material prepared from this process is not suitable as a reactive, hot melt adhesive since the high application temperatures required to afford processability may trigger the crosslinking reaction of the thermosetting material prematurely. Similarly, U.S. Pat. No. 3,424,719 teaches the use of simple diisocyanates to react with the glycidyl polyether of dihydric phenols in solvents, thereby increasing the crosslinking density which results in improved heat distortion temperatures. The solvent is necessary for processability of the solid forms of glycidyl polyether dihydric phenol and avoid the high temperature conditions required for polymerization which creates not only process problems but also may induce instability of the reactant mixture after blending with a latent curing agent.
OBJECTS OF THE INVENTION
Strong structural adhesives and sealants are needed for bonding substrates loaded with significant mechanical stress at the interface. Such adhesive materials must have the following requirements:
High production rates with short, unvarying times for each operation in assembly line use.
Minimal prior cleaning of surfaces to be bonded.
Minimal health and safety hazards.
Optimum balance between open time and development of handling strength.
Maximum bond strength.
Maximum thermal and environmental resistance.
Based on these requirements, typically thermosetting materials such as epoxy resins, phenolics, polyesters, and polyurethanes are used as structural adhesives. After the crosslinking reaction the adhesive becomes part of the structural component and provides the required bond strength and thermal resistance. Normally, the structural adhesive is composed of liquid resins and curing agents in either two-package or single package form depending on the reactivity between the resin and the curing agent under storage conditions.
The liquid structural adhesive has the advantage of easy application to the substrate over the solid adhesive. However, the liquid adhesive, in two-package form after mixing, has a certain length of pot-life which is the time required to stay as liquid for application purposes. Consequently, the handling strength (minimum strength necessary to maintain adhering substrates together) cannot be rapidly developed. Further, from a safety and health hazard viewpoint, the liquid adhesive usually causes more contamination of the work place than the solid form. Thus, the two-package structural adhesive requires a very precise measurement and extremely good mixing to obtain any consistency of property control.
The one package liquid adhesive was designed to solve mixing and metering difficulties. To achieve one package reactive adhesive preparation, techniques such as chemical blocking and phase separation are being used in the adhesive industry. The crosslinking reaction has to be triggered by heating or other techniques which are difficult to control resulting in long time periods to develop handling strength.
Two forms of solid adhesives, powder and hot melt can be used instead of liquid adhesives. Because of the phase separation between resin powder and curing agent powder, the one package adhesive can be obtained very easily. However, the application, handling cost and safety considerations make the powder adhesive less attractive to the adhesive industry.
The other solid form of adhesive is hot melt which is a thermoplastic in general. The hot melt adhesive provides a bond between substrates upon cooling the molten adhesive to room temperature. The bonding process is fast and simple. The disadvantage of a thermoplastic hot melt adhesive is the fast decrease in its bonding strength upon reheating because of the nature of thermoplastics. Thus, it cannot be considered as a structural adhesive unless it is further modified.
Conventional solid adhesive such as high molecular weight epoxy resin can be applied as a reactive hot melt adhesive. Without modification, this type of solid adhesive provides poor adhesion properties such as impact resistance and lap shear strength. Modification of this material such as reacting it with a carboxyl-terminated poly(butadiene-co-acrylonitrile) increases the impact resistance and the lap shear strength. However, this modification is carried out at elevated temperature, 100°-150° C., in the presence of a catalyst, thus making the addition of a latent curing agent such as dicyandiamide and curing accelerator difficult since the curing reaction is activated by the catalyst at room temperature. Hence, due to the combination of a high cost factor and preparation difficulties, this type of adhesive is not attractive commercially.
This invention is concerned with the development of a class of reactive hot melt adhesives which will provide rapid development of handling strength and, also, maximum bond strength and thermal resistance as thermosetting adhesives. This invention also relates to a process to utilize the reaction between diisocyanates and hydroxyl groups of the diol and epoxy resin to prepare the reactive hot melt adhesives having latent curability, long storage life, internally modified adhesion properties and well controlled application rheology. The materials for the preparation of this particular reactive hot melt adhesive include a polyisocyanate, a hydroxyl-containing epoxy resin for introducing reactive pendent groups and a diol, preferably a difunctional primary alcohol, for improving the physical properties and for reducing the viscosity of the bulk polymerization medium. Optionally, a reactive plasticizer for reducing the viscosity of bulk polymerization and adjusting the application temperature can be added to the system.
One object of the instant invention is to produce a composition, usable as an adhesive, sealant or coating, which is solventless. Another object of the invention is to produce a composition which can be applied as a hot melt. Still another object of the instant invention is to produce a composition which is heat curable in a minimum time period. A further object of the invention is to produce a novel compound which in combination with a heat reactive epoxy curing agent will result in a thermoset coating, adhesive or sealant on heating. Yet another object of the invention is to produce a thermoplastic composition which can be applied as a hot melt and thereafter cured by a thermally triggered initiator to a thermoset adhesive, sealant or coating at a more elevated temperature. A further object of the instant invention is to produce one or more methods for making a thermoplastic composition which can be applied as a hot melt. Other objects will become apparent from a reading hereinafter.
DESCRIPTION OF THE INVENTION
My RHM composition is an improvement in the single-package epoxy RHM adhesive where the composition contains the hardener or catalyst, which is dormant until heat-triggered, whereupon the composition then crosslinks and thermosets. The improvement is several fold, as compared with various commercial single-package RHM adhesives presently used in the auto industry, viz.:
______________________________________ Composition I (This invention) Composition X (1)______________________________________Shear strength, psi.sup.(2) 3000 1800Peel strength, pli.sup.(3) 45-50 0Impact strength.sup.(4) 60" lbs 10" lbsGreen tack to oily metal 30 sec. 30 seconds______________________________________ .sup.(1) A singlepackage RHM adhesive used for auto door hemflanging, in current commercial use. .sup.(2) Shear strength by ASTM D1002. .sup.(3) Peel strength by ASTM D1876, modified by pulling at 0.5"/min.
DEFINITIONS
Epoxy resins
Those used in the invention are so-called DGEBA-type, i.e., reaction products of diglycidyl epoxide with Bis-phenol A. All are commercially available from Shell Chemical Co.
Epon-872 has the formula ##STR1## where X is ##STR2## where R is --CH 2 CH(OH)CH 2 --
K is ##STR3## Q is ##STR4##
Epon-1001 F is Q--K--[--R--K--] n --Q, with 2.2 --OH groups/molecule wherein n=2-4.
Epon-828 is Q--K--Q, with 0.2 --OH groups/molecule, average MW, 350-400.
Other materials
NYAD-400; calcium silicate powder, from Nyco Co.
N-70-TS; fumed silica powder, from Cabot Co.
CK-2500; a non-heat reactive high melting phenolic resin from Union Carbide Corp. Softening point 235°-290° F.
A-187; glycidyl trimethyl silane, from Union Carbide Corp.
Olin 55-28 is a 4000 g/mole ethylene oxide end-capped polypropylene glycol triblock polymer, with primary hydroxyl groups: --EO--PO--EO--.
Olin 20-28 is a 4000 g/mole polypropylene glycol homopolymer with secondary hydroxyl groups.
MP-102 (BASF) is a prepolymer made by adding tripropylene glycol to MDI to make a 50:50 MDI:MDI adduct which is liquid at room temperature.
______________________________________ Parts by WeightPremix A Broad NarrowComponents Range Range Specific______________________________________Olin 55-28 5-100 20-25 22.80Olin 20-28.sup.(1) 0-50 20-25 22.80Phenyldiethanolamine.sup.(2) 0-2 0-1 0.47MP-102.sup.(3) 5-20 5-9 6.97Epon-1001F 0-50 15-20 18.82Epon-872 10-50 26-30 28.14______________________________________ .sup.(1) When the amount is zero, a more moisture sensitive compound is made. .sup.(2) When the amount is zero, a softer polymer is made. .sup.(3) Amount of MP102 selected such that the ratio of molecular NCO to polyol OH is greater than 1 but less than 2.
Premix A is a urethane oligomer and is used in TABLE I in the above specific amounts in preparing Composition I. It can be used in modifications of Composition I within the above ranges.
In preparing Composition I (TABLE I), the order of mixing is not critical. However, I prefer to add the dicyandiamide last, with mixing for a short time, to prolong shelf life.
TABLE I______________________________________Composition I Parts by Weight Broad Narrow Range Range Specific______________________________________Premix A 50-800 100-300 250Epoxy mixture.sup.(1) 10-500 50-400 200Epon-828 10-200 25-125 50CaSiO.sub.3 0-200 50-150 100CaO 10-100 25-75 50Fumed SiO.sub.2 5-80 20-60 40CK-2500 Phenolic resin 0-100 15-75 20Zn.sub.3 (PO.sub.4).sup.2 5-100 5-50 10Dicy/Epoxy mix.sup.(2) 50-150 60-120 80Glycidyl trimethyl 1-10 3-7 5silane______________________________________ .sup.(1) Epon872, Epon1001F, 3:1. .sup.(2) Epon828/dicyandiamide, 2:1.
When reference is made to Composition I, it is the Composition with the Specific amounts in TABLE I unless otherwise noted. Such Composition is preferred for use herein.
EXAMPLE 1
This example is partially hypothetical in that is is based on properties of my Composition I that I have established in the laboratory. Composition I use is demonstrated on a section of an auto assembly line, viz., an adhesive/sealant for door hem flange binding.
(1) Composition I at room temperature is a viscous liquid (a semi-solid). For application it must be heated, e.g., to 80° C., to liquefy it. At 80° C. it has zero strength and is easily handled. This temperature is too low to trigger the curing mechanism. Composition I at about 80° C. is applied around the interior rim of the outer plate (cold rolled steel--"CRS", optionally galvanized) of a car door. This application is preferably by spraying, but it can be by melt extrusion or other system.
(2) The inner plate (CRS) is now pressed ("fixtured") against the outer plate. One or both parts may be oily. In such case Composition I quickly penetrates the oil and forms an adhesive bond to the part. At this stage (room temperature) the Composition provides a strength of about 10 psi, enough to hold the two plates together under non-stress conditions.
(3) The flanges of the outer plate are now folded over the perimeter of the inner plate. In this operation, Composition I is squeezed into the flange crevices, providing a good seal all around the perimeter. The strength of the green adhesive at this stage is still about 10 psi.
(4) The door is assembled onto the metal body of the car. Here, if need be, the door can be bent and twisted to fit the automobile. If the adhesive bond is broken, possible sites for corrosion are not made because the adhesive softens in Step 6. At this stage the door is dimensionally stable because of the viscosity of the Composition (about 10 psi).
(5) The assembled car body is dipped into E-coat primer bath (a room-size vat). At this point many commercial adhesives tend to dissolve or be partially washed off into the primer baths and to redeposit on the car body surfaces. Composition I does not dissolve in these baths and hence avoids this problem. In this operation, Composition I has a strength of about 10 psi.
(6) The assembled body is removed from the E-bath and taken to the baking oven, where it is heated to about 350° F. (177° C.). Composition I at first melts and passes again through zero strength, then quickly begins to cure and soon attains its maximum strength, taking about thirty minutes for this. In its molten condition it spreads further into all cracks and crevices and ensures thorough coating and sealing between the two door plates, thereby minimizing future vapor/liquid penetration between the plates and consequent corrosion. A modification of Step 6 is discussed later on when I describe my Composition II.
The process outlined above has a general applicability. The substrates (adherends) are suitably metal parts. Parts such as refrigerator doors, stove and oven doors, parts for washers and driers, double-walled panels for vans and trucks, and hardware for marine, air, and rail vehicles and accessories can be assembled by my process, using the compositions of this invention. The invention compositions can also be used as gaskets, can sealants, and the like.
Referring now back to Stage (4) above, at this point parts adhered with conventional adhesives are customarily visually inspected. Frequently the parts will be very slightly out of true with respect to each other and/or to the car body framework. Manual adjustments (pounding, pulling, pressure) are made at this stage to bring the elements back into true. In current practice, using commercially available structural adhesives, this type of forcible adjustment tends to produce minute cracks in the adhesive, which is a semi-solid at this stage in the process (i.e., after application but before curing). Such cracks presage corrosion and eventual bond-failure. It would be a great advantage if the adhesive could momentarily cease to be a viscous solid and become a liquid with zero strength. My Composition I will in fact do exactly that. Thus, at 100°-160° C. Composition I melts but does not cure. Above 160° C. it cures. Thus, when heating to 180° C., the Composition must pass through 100°-160° C., so it softens.
This behavior provides a "window" within the process program which permits adjustments, and within which complete assemblies can be structured and/or restructured (i.e., the adherends can be moved with respect to each other). At temperatures below this window my Composition I is a semi-solid or viscous liquid, with very low adhesive strength (ca. 10 psi). At the window, the strength is zero. At temperatures substantially above he window temperature, Composition I will cure, solidify, and develop maximum strength.
Composition II
For assembly lines where Stage (6) above requires something between zero strength and a small but useful strength (e.g., 10 psi), I modify Composition I to Composition II. Composition II is like Composition I in that it is sufficiently liquid to withstand minor adherend adjustments without rupture or development of cracks. On the other hand, it is sufficiently viscous to provide a strength of about 1 psi at the curing temperature (177° C.), which is helpful in maintaining dimensional stability of the bonded adherends, especially where the Composition is affixed around the entire perimeter of the door or like part. Like Composition I, Composition II can be used to provide two metal substrates having between them the respective composition in uncured molten condition at a temperature of about 80°-150° C.
Composition II is a moisture-curing RHM adhesive, and is described below.
TABLE II______________________________________Composition II Parts by weight Broad Range Narrow Range Specific______________________________________Premix A 200-1000 400-600 500CKOO36 Phenolic.sup.(1) 5-50 10-30 18.5CaCO.sub.3 powder 0-200 50-150 111Fumed Silica 0-50 15-25 22.2Dicy/Epoxy Mix.sup.(2) 5-50 15-25 22.2Schiff base.sup.(3) 5-50 15-25 22.2Glycidyl trimethyl silane 1-10 1-5 3______________________________________ .sup.(1) A nonheat reactive high melting phenolic resin from Union Carbid corp., with a softening point of about 190-235° F. .sup.(2) Epon828/dicyandiamide wt. ratio: 2:1 .sup.(3) The Schiff base reacts with atmospheric moisture to regenerate the component amine and aldehyde or Ketone. The amine then catalyzes the cure. Substantially any Schiff base is suitable. The adduct of methyl isobutyl ketone and ethylene diamine is useful and cheap, and is availabl from Shell Chemical Co. as "H2" (trademark).
The specific formulation in Table II gave a shear strength of 800 psi and peel strength of 10 pli, by ASTM procedures, supra.
The two Compositions (I and II) described in Tables I and II are species of the broader genus set forth in Table III.
TABLE III______________________________________Reactive Hot Melt AdhesivesComponent Parts by Weight______________________________________Premix A 50-1000Epon-872/Epon-1001F, 3:1 10-500Epon 828 10-200Calcium Silicate.sup.(1) 0-200CaO (2) 0-100Fumed silica.sup.(1) 0-80Phenolic resin 5-100Zn.sub.3 (PO.sub.4).sub.2 5-100Epon-828/dicyandiamide, 2:1 5-150Glycidyl trimethyl silane 1-10Schiff base.sup.(2) 0-50Calcium carbonate powder (1) 0-200______________________________________ .sup.(1) Provided that the total of calcium silicate, fumed silica, and calcium carbonate is in the range of about 10-30 (preferably about 20) weight % of the total composition. The amount of fillers is needed to modify the rheology of the liquid mixture and to reinforce the cured product. .sup.(2) When Schiff base is present, CaO is zero, and vice versa. CaO is present to remove all moisture in the composition, whereas Schiff base reacts with atmospheric moisture to regenerate component amine (which is catalyst) and ketone or aldehyde.
Variations
The use of Epon-1001 F is not critical. Various other Epons are useful, e.g., Epon-836, which is: a Bis-phenol A adduct with Epon 828, viz., QKRKQ, where Q, K, and R are as above defined. whole or in part for Epon-872 (though I prefer the latter).
Substantially any polyisocyanate can be used, substituting in whole or in part for MDI, viz.:
Diisocyanates such as hexamethylene diisocyanate, m-phenylene diisocyanate, 2,4-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate, dianisidine diisocyanate, tolidine isocyanate, isophorone diisocyanate, 4,4-dicyclohexylmethane, chlorophenylene-2,4-diisocyanate, 1,5-naphthalene diisocyanate, ethylene diisocyanate, diethylidene diisocyanate, propylene-1,2-diisocyanate, cyclohexylene-1,2-diisocyanate, 3,3'-dimethyl-4,4'-biphenylene diisocyanate, 3,3'-dimethoxy-4,4'-biphenylene diisocyanate, 3,3'-diphenyl-4,4'-biphenylene diisocyanate, 4,4'-biphenylene diisocyanate, 3,3'-dichloro-4,4'-biphenylene diisocyanate, and furfurylidene diisocyanate.
Triisocyanates such as biuret of hexamethylene diisocyanate and triphenylmethane triisocyanate.
Polyisocyanates such as polymeric diphenylmethane diisocyanate.
Heating
The heating step to cure my epoxy, urethane-containing, hot melt adhesive compounds to thermoset materials is usually carried out for a period of 10 seconds to 30 minutes at a temperature of 100°-300° C., preferably 150°-200° C., which is sufficient to fully cure the composition to a solid thermoset adhesive, coating or sealant.
The heating step to cure the compound can be accomplished in several ways. In simple adhesive systems, the composition can be applied by manual means to an adherend, contacted with another adherend and the assembled systems heated in a forced air oven until a thermoset bond results. | Novel reactive hot melt structural adhesives comprising urethane oligomer and epoxy mixture in specified ratios. The compositions offer very high shear, peel, and impact strengths, properties of particular value in bonding adherends in an auto body assembly line. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to testing systems for electronic components and, more particularly, to a method and an apparatus for determining the failing operation of a device-under-test (DUT).
[0003] 2. Description of Related Art
[0004] Testing of hardware and software generally involves executing a set of instructions and/or commands and comparing the actual results with the expected results. If the actual results match the expected results, the test case was successful. If the actual results do not match the expected results, then the test case failed.
[0005] Generally, determining where in the failed test case that the failure actually occurred, i.e., the failed instruction, is a manual process. One technique of determining the failed instruction utilizes a pattern generator to reconfigure the DUT to a repeatable starting state, allowing for a repeatable instruction stream. This technique, however, is limited to the number of instructions generated by the pattern generator.
[0006] Another technique, commonly utilized in situations where the instructions comprise a set of uncontrollable source code, such as an operating system boot sequence, is to configure a host computer to halt the DUT at various cycles. The state of the DUT is evaluated and compared to the state of a known, good device in a similar state.
[0007] These techniques, however, are generally time consuming and complicated. The results and or the state of the DUT is not always readily available or apparent and may require additional analysis.
[0008] Therefore, there is a need to provide a method and an apparatus to automatically test a DUT and to identify the failing instruction.
SUMMARY
[0009] The present invention provides an apparatus and a method for testing one or more electrical components. The apparatus and method performs a test segment for N cycles on a known device that performs the test segment successfully and a device-under-test (DUT) that performs the test segment unsuccessfully. The expected results, i.e., the results of the known device, are compared to the actual results, i.e., the results of the DUT. The value of N is increased if the expected results match the actual results, and the value of N is decreased if the expected results do not match the actual results. The testing and the adjustment of N is performed iteratively until the failing instruction is identified.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings, in which:
[0011] [0011]FIG. 1 is a schematic diagram of a typical testing environment that embodies the present invention; and
[0012] [0012]FIG. 2 is a data flow diagram illustrating one embodiment of the present invention in which the failing instruction of a DUT is automatically identified.
DETAILED DESCRIPTION
[0013] In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail.
[0014] It is further noted that, unless indicated otherwise, all functions described herein may be performed in either hardware or software, or some combination thereof. In a preferred embodiment, however, the functions are performed by a processor such as a computer or an electronic data processor in accordance with code such as computer program code, software, and/or integrated circuits that are coded to perform such functions, unless indicated otherwise.
[0015] Referring to FIG. 1 of the drawings, the reference numeral 100 generally designates a test system embodying features of the present invention. The test system 100 generally comprises a host computer 110 , such as a Workstation Model 270 manufactured by IBM Corporation, connected to a test platform 112 . The test platform 112 preferably comprises a known device 114 and a DUT 116 . The DUT 116 is a device, such as a microprocessor, or the like, that has been identified as failing one or more tests. The known device 114 is generally a device similar to the DUT 116 that has been identified as passing all relevant tests, and will be used to compare the results of the DUT 116 to aid in identifying the failing instruction. Preferably, the test platform 112 is capable of receiving the known device 114 and the DUT 116 simultaneously to allow fully automated test procedures to be performed, as is discussed in greater detail below.
[0016] In an alternative embodiment, however, the test platform 112 receives the known device 114 and the DUT 116 separately. In this alternative embodiment, the known device 114 and the DUT 116 are switched during the testing of the devices. The method and system of switching the known device 114 and the DUT 116 during the testing of the devices is considered known to a person of ordinary skill in the art upon a reading of the present disclosure.
[0017] The host computer 110 , via a debug controller (not shown) operating on the host computer 110 , is configured to control the operation of the known device 114 and the DUT 116 by providing instruction sets, start/stop locations, and the like. Additionally, the host computer 110 is configured to provide test case information to the test platform 112 and to receive test case results from the test platform 112 . Other components, such as memories, a bus arbiter, I/O chipset, debug connectors, and the like, which may be necessary for the operation of the present invention, are considered well known to a person of ordinary skill in the art, and, therefore, are neither shown nor discussed in greater detail. A preferred embodiment of the test platform 112 is more particularly described in copending and coassigned U.S. patent application Ser. No. 09/998,390, entitled “Method and System for Testing Electronic Components”, which is incorporated by reference herein for all purposes.
[0018] In operation, the host computer 110 loads test case information, such as a test segment comprising one or more instructions, memory, register values, and/or the like, onto the test platform 112 , preferably into one or more memories (not shown). As discussed in greater detail below with reference to FIG. 2, the host computer 110 instructs the known device 114 and the DUT 116 to perform the test case. The results of the known device 114 , i.e., the expected results, are compared with the results of the DUT 116 , i.e., the actual results. The test segment is adjusted accordingly and the test re-executed until the failing instruction is identified.
[0019] [0019]FIG. 2 is a flow chart depicting steps that may be performed by the test system 100 in accordance with one embodiment of the present invention that determines the failing instruction of the DUT 116 . Processing begins in step 212 , wherein the debug controller configures a cycle counter that indicates the portion of the test segment that is to be performed by the known device 114 . Preferably, the test segment is a section of instructions or code that has been identified as failing one or more tests. The cycle counter represents the number of instructions, clock cycles, and/or the like, that the device, i.e., the known device 114 and/or the DUT 116 , is to perform.
[0020] In step 214 , the debug controller loads the test segment onto the test platform 112 . Loading the test segment onto the test platform may require the initialization of memories, registers, ports, interrupt lines, and/or the like. The loading of the test segment onto the test platform is considered known to a person of ordinary skill in the art upon a reading of the present disclosure.
[0021] In step 216 , the known device 114 begins performing the test segment. As discussed above, a cycle counter is configured to control the amount of the test segment that is to be performed. Accordingly, in step 218 , a determination is made whether the cycle counter has been reached. If, in step 218 , a determination is made that the cycle counter has not been reached, then processing returns to step 216 , wherein the known device 114 continues performing the test segment.
[0022] If, however, in step 218 , a determination is made that the cycle counter has been reached, then processing proceeds to step 220 , wherein an expected result is determined. Preferably, the expected result comprises a Cyclic Redundancy Checker (CRC) value as described in the copending and coassigned U.S. patent application Ser. No. 09/998,399, entitled “Method and Apparatus for Test Case Evaluation Using a Cyclic Redundancy Checker”, which is incorporated by reference herein for all purposes. Briefly, a CRC value is determined by performing a CRC algorithm over a section of memory. Disparities between the operation of multiple devices may be easily found by performing a similar test on each device, calculating the CRC value over a similar section of memory of each device, and comparing the CRC values. Alternatively, other values or algorithms may be used to determine the expected result. For example, the expected result may comprise of one or more sections of memory, the values of one or more scan chains, and/or the like.
[0023] In step 222 , the debug controller configures a cycle counter that indicates the portion of the test segment that is to be performed by the DUT 116 . The cycle counter is preferably set in a manner as described above, with reference to step 212 , for the known device 114 .
[0024] In step 224 , the debug controller loads the test segment onto the test platform 112 in preparation of being executed by the DUT 116 . In step 226 , the DUT 116 begins performing the test segment. As discussed above, the cycle counter is configured to control the amount of the test segment that is to be performed. Accordingly, in step 228 , a determination is made whether the cycle counter has been reached. If, in step 228 , a determination is made that the cycle counter has not been reached, then processing proceeds to step 230 . In step 230 , a determination is made whether the DUT 116 has timed out.
[0025] Preferably, the DUT 116 is allowed a predetermined amount of time, i.e., the timeout value, to perform the test segment, after which time it will be deemed that the DUT 116 has failed the test. The predetermined amount of time is preferably set such that the DUT 116 has sufficient amount of time to execute the test segment plus an additional amount of time to allow for irregularities in the timing and operation of the DUT 116 . For example, the predetermined amount of time for the timeout value may be set to the time the known device 114 requires to execute the equivalent test segment plus an additional amount, such as 10%-500%. Alternatively, the timeout value may be set to a static value and/or the like.
[0026] If, in step 230 , a determination is made that the DUT 116 has not timed out, then processing returns to step 226 , wherein execution of the test segment continues on the DUT 116 .
[0027] If, in step 228 , a determination is made that the cycle counter has been reached, i.e., the DUT 116 has executed the section of the test segment identified by the cycle counter, then processing proceeds to step 234 , wherein an actual result is determined. The actual result is preferably determined similarly to the expected result, as described above with reference to step 220 , over an equivalent section of memory. In step 234 , a determination is made whether the expected result determined from the execution of the test segment by the known device 114 in step 220 is substantially equivalent to the actual result determined from the execution of the test segment by the DUT 116 in step 234 .
[0028] If, in step 236 , a determination is made that the expected result is not substantially equivalent to the actual result, or, in step 230 , a determination is made that the DUT 116 has timed out, then processing proceeds to step 232 , wherein a failure is recorded. As a result of recording a failure, processing proceeds to step 238 , wherein a binary-search-backward function is performed.
[0029] Generally, if the DUT 116 fails a test, then the error occurred prior to the completion of the test segment. Therefore, it is desirable to reduce the number of instructions that are to be executed in the test segment in an attempt to identify the failing instruction. In the preferred embodiment, a binary search algorithm is utilized to quickly identify the failing instruction by increasing and/or decreasing the number of instructions to be executed in the test segment until the failing instruction may be identified.
[0030] Accordingly, in step 238 , a new test segment is identified to be tested by decreasing the cycle counter. Preferably the new test segment is identified by modifying the cycle counter to be substantially equivalent to the value midway between the current cycle counter and the cycle counter value for the previously successful test, or midway between the current cycle counter and the beginning of the test.
[0031] Furthermore, in step 240 , if a determination is made in step 236 that the expected result is equivalent to the actual result, a binary-search-forward function is performed. Preferably, the cycle counter is modified to be substantially equivalent to the value midway between the current cycle counter and the cycle counter value for the previously failed test, or midway between the current cycle counter and the end of the test.
[0032] In step 242 , a determination is made whether, as a result of the binary-search-backward function and/or the binary-search-forward function, the failing instruction has been identified. As one skilled in the art will appreciate, performing the above-described process in an iterative manner will effectively identify the failing instruction.
[0033] Accordingly, if, in step 242 , a determination is made that the failing instruction has been identified, then processing proceeds to step 244 , wherein the failing instruction is reported to the user. If, however, in step 242 , the failing instruction has not been identified, then processing returns to step 212 , wherein the testing process described above is repeated with a new cycle counter identifying the new test segment.
[0034] It should be noted that the foregoing disclosure discusses the invention in terms of the preferred embodiment in which the host computer is an external host computer configured to control the execution of test cases and the like. The invention, however, is equally applicable to the situation in which the host computer is integrated into the test platform. The use of the present invention in such an environment is considered to be within the skills of a person of ordinary skill in the art upon a reading of the present disclosure.
[0035] It is understood that the present invention can take many forms and embodiments. Accordingly, several variations may be made in the foregoing without departing from the spirit or the scope of the invention. For example, other algorithms besides a binary search algorithm may be used to identify the failing instruction, other algorithms besides the CRC algorithm may be used to determine the expected and actual results, and the like. It is also understood that the expected value can be determined by simulation runs or by manual calculation. Both of these techniques imply the use of additional tools and resources available to those skilled in the art to predict the normal state of the DUT at any given cycle during the execution of a known instruction set.
[0036] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered obvious and desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | The present invention provides an apparatus and a method for testing one or more electrical components. The apparatus and method execute similar portions of a test segment on a known device, i.e., a device for which it has been determined that the test segment executes successfully, and on a device-under-test (DUT), i.e., a device for which it has been determined that the test segment does not execute successfully. The results of the tests are compared to determine if the test passed or failed. The test segment is executed iteratively on the known device and the DUT, increasing or decreasing the amount of the test segment that is executed each pass until the failing instruction is identified. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for fastening a profiled connecting section of a partition for wet rooms, i.e. shower stalls or bath rooms, to a room surface, i.e. a room wall, especially a tile wall, or a room ceiling. The invention further relates to a profiled connecting section which is particularly well suited for carrying out this method.
2. Description of the Prior Art
Sliding partitions and stationary partitions are placed on the rim of a bath tub or shower tub in order to prevent the shower water from splashing out. For connecting the partition to the room wall and possibly, the room ceiling, a profiled connecting section is required which is connected to the room wall, for instance, by dowels according to German Published Prosecuted Application No. 24 07 230. If the room wall consists of tiled walls, holes must be drilled into the tiles.
Further, there exists the problem of a tight connection between the profiled connecting section and the room surface. Difficulties can arise if the room surface is uneven. In that case, it is known to provide resilient sealing strips between the room surface and the profiled connecting section.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a profiled connecting sect;ion and a method for fastening the profiled connecting section to a room surface in which the dowelling operation for fastening the connecting section to the room surface, i.e. room wall or room ceiling, may be eliminated.
A further object of the invention is to provide a profiled connecting section and a method for fastening the profiled connecting section to an uneven room surface, achieving a secure seal between the profiled connecting section and the room surface without the previous practice of additional sealing strips.
With the foregoing and other objects in view, there is provided in accordance with the invention a method for fastening a profiled connecting section having a substantially rectangular side, of a partition for a wet room to a room surface which comprises disposing the side of the profiled connecting section adjacent to but away from the room surface, tacking the profiled connecting section to the room surface while retaining the connecting section adjacent to but away from the room surface, and subsequently permanently cementing the long edges of the rectangular side of the profiled connecting section to the room surface by means of an elastic adhesive sealing compound while retaining the connecting section adjacent to but away from the room surface.
In accordance with the invention, there is provided a profiled connecting section of a partition for a wet room for fastening to a room surface, having a substantially rectangular side to face the room surface, a recess facing the room surface in a wall of the rectangular side, said recess extending parallel to the long edges of said rectangular side, and an elastic adhesive strip disposed in the recess for tacking the profiled connecting section to the room surface, said adhesive strip extending beyond the recess to retain the connecting section adjacent to but a desired distance away from the room surface.
There is provided a profiled connecting section of a partition for a wet room for fastening to a room surface, having an H-shape with the H-cross wall extending parallel to the room surface and two H-legs facing the room surface and two H-legs facing away from the room surface, a plurality of suction cups carried by said H-cross wall for tacking the profiled connecting section to the room surface, said suction cups extending beyond the two H-legs facing the room surface to retain the connecting section adjacent to but a desired distance away from the room surface.
In accordance with the invention a profiled connecting section of a partition for a wet room for fastening to a room surface, having an H-shape with the H-cross wall extending parallel to the room surface and two H-legs facing the room surface and two H-legs facing away from the room surface, one of said two H-legs facing the room surface is formed by an angle section detachably held at the H-cross wall, said angle section having an extension parallel to the room wall, a recess facing the room surface in said extension, an adhesive strip disposed in said recess for tacking the angle section to the room surface, said adhesive strip extending beyond the two H-legs facing the room surface to retain the connecting section adjacent to but a desired distance away from the room surface.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method for fastening a profiled connecting section of a partition for wet rooms to a room surface, and profiled connecting section applicable thereto, it is nevertheless not intended to be limited to the details shown, since various modifications may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, however, together with additional objects and advantages thereof will be best understood from the following description when read in connection with the accompanying drawings, in which:
FIG. 1 shows a top view of a shower cabin built into the corner of a room with a sliding partition and a stationary partition,
FIGS. 2, 3 and 4 diagrammatically show three different embodiments of the profiled connecting section fastened to the room surface according to the invention, and
FIGS. 5, 6 and 7 diagrammatically show three additional different embodiments illustrating the fixation of the H-adapter section to the U-shaped part of the profiled connecting section in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
The two problems of the art discussed previously are overcome in accordance with the invention by the provision that the profiled connecting section is first tacked to the room surface elastically and with little spacing therefrom and that subsequently, the long edges of the profiled connecting section adjacent to the room surface are permanently cemented to the room surface by means of an elastic adhesive sealing compound.
The profiled connecting section is advantageously tacked to the room surface by at least one adhesive strip and/or suction cups. As soon as the profiled connecting section is temporarily fixed to the respective room surface, the elastic sealing compound is applied into the gaps between the long edges of the profiled connecting sections on the one hand and the room surface on the other hand. Thereby, equalization also of major unevennesses of the room surface is achieved as well as also the mounting of the profiled connecting section, without using any tools and without damaging the tiles.
The small distance left in the temporary fixing between the profiled connecting section and the room wall must be large enough, considering the existing unevenness of the room surface, to enable the sealing compound to penetrate into the gap between the long edges of the profiled connecting section and the room surface. This distance will be dependent on the unevenness of the room and may vary from 1/8 inch or less to 3/8 inch or more.
The temporary fixing with the elastic adhesive strip or the suction cups facilitates the attachment of the profiled connecting section greatly. The installation is independent of unevennesses of the wall surfaces. The expansion occurring during temperature cycles of the profiled connecting sections, which are usually made of extruded aluminum, versus the material of the room surface does not loosen the attachment according to the invention, since expansion differences can be taken up by the elastic adhesive strips or the suction cups and the likewise elastic adhesive sealing compound, all of which are conventional materials. There is no danger that cracks could occur in the cemented joints or that these cemented joints could become loose.
A profiled connecting section suitable for carrying out the method, which uses at least one adhesive strip, is advanageously characterized by the feature that it has in its connecting wall at least one recess which runs parallel to its two long edges and in which the elastic adhesive strip is held. This adhesive strip extends beyond the connecting wall of the profiled section by the desired small distance.
Another profiled connection section which is suitable for carrying out the method using suction cups, is advantageously H-shaped, with the H-cross wall extending parallel to the room surface and carrying two H-legs facing the room surface and two H-legs facing away from the room surface. Further, the H-cross wall carries the suction cups which protrude by the desired small distance beyond those two H-legs facing the room surface.
In this second profiled connecting piece, the H-cross wall advantageously has an undercut longitudinal slot of T-shaped cross section, in which the T-head of the suction cups is seated with a press fit.
Another profiled connecting section suitable for carrying out the method using an adhesive strip, is characterized by the feature that it is H-shaped, with the H-cross wall extending parallel to the room surface and carrying two H-legs facing the room surface and two H-legs facing away from the room surface. One of the two H-legs facing the room surface is formed by an angle section detachably held at the H-cross wall. This angle section carries an extension parallel to the room wall. This extension has a recess in which an elastic adhesive strip is held which protrudes by the desired small distance beyond those two H-legs which are facing the room surface. On occasion, the width of the partition is smaller than the wall surface to be covered, so that there is a gap between the profiled connecting section and the room wall. It is a further object of the invention to describe a profiled connecting section, the width of which can be adjusted in such a manner that such a gap can be bridged. It is desirable in this connection to make possible a continuous adjustment of the width of the profiled connecting section and to secure the adjusted width without the use of tools.
Such settability of the width of the profiled connecting section which can be carried out without the use of tools is desirable, particularly if no tools of any kind are used in fastening the profiled connecting section to the room wall.
A continuously adjustable profiled connecting section advantageously has two legs which are arranged at the connecting wall or the H-cross wall of the U-shaped part. The two legs extend perpendicular to the room surface and face away from the latter. These two legs are surrounded by two legs of an H-adapter section, the other two legs of which accept or receive the movable or stationary panel of the partition. The H-adapter section may be fixed at different distances from the connecting wall or the H-cross wall by moving the two legs of the H-adapter closer to or further from the wall. For fixing the H-adapter section to the U-shaped part at mutually touching surfaces extending perpendicular to the room surface of the U-shaped part on the one hand and of the H-adapter section on the other hand, slots filled with adhesive are advantageously provided.
Advantageous embodiment examples of the invention are shown schematically in the drawings.
FIG. 1 shows in a top view a shower stall which is arranged in the angle between two room walls 2 and 4. The shower stall has a sliding partition 9 with movable wall panels and a stationary partition 8 with immovable panels. The shower stall is entered and left through the sliding partition 9.
The fastening of the sliding partition 9 to the room wall 4 is designated by A in FIG. 1. Different embodiments of this fastening are shown in FIGS. 2, 3 and 4.
As can be seen from FIG. 2, the profiled connecting section 10 has a cross section of substantially H-shape. The H-legs 13 and 14 intended for the connection to the room wall have extensions 16 and 17 which are parallel to the H-cross wall 15 of the connecting section 10 and which H-legs extend toward each other. The left H-leg 13 as well as its extension 16 are part of the angle section 12. Angle section 12 with its part 18 which extends parallel to the H-cross wall 15 holds H-cross wall 15.
A recess 21 open toward the room wall 4 is located in the extension 16. The sealing strip 3, cemented into this recess 21, protrudes by the small distance a beyond the H-legs 13 and 14 of the profiled connecting section 10.
The two rounded longitudinal corners 6 and 7 are cemented to the room wall 4 or a room ceiling by means of an elastic sealing compound 80.
The two-part design of the profiled connecting section 10 shown in FIG. 2 permits, first, a temporary fixation of the angle section 12 by means of the adhesive strip 3. Then, the remaining part of the profiled connecting section 10 is placed on the angle section 12 and is connected to the angle section 12 via a tongue-and-groove joint 19, preferably without the use of screws. Ultimately, the two gaps between the longitudinal corners 6 and 7 of the profiled connecting section 10 and the room wall 4 are sealed by means of the sealing compound 80.
In FIG. 3, another profiled connecting section 10 according to the invention is shown. It may be used as the connecting section designated A in FIG. 1. The profiled connecting section 10 of FIG. 3 has a U-shaped cross section. It has a recess 21 in the connecting wall 5 facing the room wall 4, extending in the longitudinal direction of the section 10. The sealing strip 3 is arranged in this recess 21. The sealing strip 3 extends, as per FIG. 2 beyond the connecting wall 5 by the minimum distance a.
After the connecting section 10 shown in FIG. 3 is temporarily fixed by means of the adhesive strip 3 to the room wall 4, the two rounded longitudinal corners 6 and 7 are connected firmly to the room wall or the room ceiling 4 by means of the elastic adhesive sealing compound 80.
FIG. 4 shows a connecting section of H-shaped cross section. The H-cross wall 15 extends parallel to the room surface 4. The H-cross wall 15 carries two H-legs 40 and 42 extending from wall 15 toward the room surface 4 and further H-legs 44 and 46 extending away from the room surface 4.
The H-cross wall 15 carries on its side facing the room surface 4, longitudinal webs 23 and 24 which extend in the lengthwise direction of the section and carry strips facing each other; these strips together with the longitudinal webs 23 and 24 form a T-shaped undercut longitudinal slot.
The suction cups 20 (of approximately rotation-symmetrical cross section) carry T-heads 22. The T-heads 22 sit in the longitudinal slot with a press fit, lined up one after the other.
Like the adhesive strip 3 in FIGS. 2 and 3, the suction cups 20 extend beyond the H-legs 40 and 42 by the distance a, so that this minimum distance a between the profiled connecting section 10 and the room surface or room wall 4 is assured and enough sealing compound 80 can be placed in the gap between the longitudinal corner 6 and 7 on the one hand and the room surface 4 on the other hand to obtain good adhesion.
FIGS. 5, 6 and 7 show parts 82 of a connecting section which have a substantially U-shaped cross section. These parts are tacked to the room surface 4, similar to the connecting section shown in FIG. 3, by means of adhesive strips 3 and are cemented by means of a sealing compound 80.
The lateral U-legs 84 and 86 of the U-shaped part 82 are surrounded by the H-legs 88 and 90 of an H-adapter section 89. The two other H-legs 92 and 94 of the H-adapter section 89 accept or receive the movable or stationary wall panels of the partition.
The H-adapter section 89 is movable in the direction of the double arrow 106 relative to the U-shaped part 82 to adjust the width b of the profiled connecting section. In this process, the H-legs 88 and 90 of the H-adapter section 89 slide on the U-legs 84 and 86 of the U-shaped part 82.
The desired adjustment is fixed by the provision that surfaces of the U-shaped part 82 extending perpendicularly to the room surface 4 on the one hand, and of the H-adapter section 89 on the other hand, have slots which are filled with adhesive. If the surfaces of the U-shaped part 82 extending perpendicularly to the room surface 4 on the one hand, and of the H-adapter section 89 on the other hand, move relative to each other, some adhesive is distributed on the surfaces that slide on each other. In the desired end position, the adhesive sets and thereby causes the desired fixation of the final position.
The arrangement of the slots is shown in three different embodiments in FIGS. 5, 6 and 7.
According to FIG. 5, and undercut T-slot is provided in the H-web 96 of the H-adapter section 89 as well as at the opposite surface of the U-shaped part 82. These two undercut T-slots are opposite each other. The holding plate 98 of a pin 100 is attached with a press fit in the undercut T-slot of the H-adapter section 89. This cylindrical pin 100 fits closely into the cylindrical opening of a cylindrical chamber 102 which is seated via a further holding plate 104 in the undercut T-slot of the U-shaped part 82.
Since the undercut T-slots have the same cross section, the parts 100 and 102 can be interchanged, or these parts can be mounted alternatingly at the top or at the bottom.
The two parts 100 and 102 touch each other in cylindrical surfaces which extend perpendicular to the wall surface 4. In one of these cylindrical surfaces (in the embodiment example shown, in the cylindrical outside surface of the pin 100), slots are provided which are filled with adhesive. If the H-adapter section 89 is moved in the direction of the double arrow 106, adhesive is distributed on the cylindrical surfaces of the parts 100 and 102. In the final position reached the adhesive sets and fixes this end position, so that the desired width b is set.
According to FIG. 6, the H-web 96 of the H-adapter section 89 has, in addition to the two H-legs 88 and 90, parallel ribs 108, 110, 112 114, 116 and 118. The leg 88 with the rib 108 encloses the U-leg 84 of the U-shaped part 82. Similarly, the leg 90 with the rib 118 encloses the U-leg 86 of the U-shaped part 82. The two pairs 110, 112 and 114, 116 of ribs enclose the two ribs 120 and 122 of the U-shaped part 82 between them.
The ribs and H-legs (88, 108, 110, 112, 114, 116, 118 and 90) of the H-adapter section 89 touch the U-legs and ribs (84, 120, 122, 86) of the U-shaped part 82 in plane surfaces which extend perpendicular to the room wall 4 in the longitudinal direction of the connecting section. Slots arranged in these plane surfaces are filled with adhesive like the slots of the cylinder surfaces of the pins 100 in FIG. 5. If the H-adapter section 89 is adjusted in the direction of the double arrow 106, then the adhesive is distributed on the plane sliding surfaces which are perpendicular to the wall surface 4. When the adjustment process is completed, the adhesive sets and fixes the H-adapter section 89 in the desired position relative to the U-shaped part 82.
FIG. 7 shows an arrangement similar to FIG. 6, but without the inner ribs 110, 112, 114, 116, 120 and 122. A large number of longitudinal slots extending perpendicular to the drawing plane are provided on the insides of the U-legs 84 and 86 of the U-shaped part 82. These U-legs are surrounded by the H-legs or ribs 88, 108, 118 and 90 of the H-adapter section. Depending on the range, in which the width b of the H-adapter section 89 is to be adjusted, a higher slot 121 or a lower slot 123 or, as shown, a middle slot is filled with adhesive. The adhesive is spread by movement in the direction of the double arrows 106 on the surfaces touching each other of the U-legs 84, 86 and the ribs 108, 118 in a manner similar to the case of the profiled connecting section of FIG. 6. After the adjustlment is completed, the adhesive sets and fixes the H-adapter section 89 of the profiled connecting section at the U-shaped part 82 of the profiled connecting section. | Profiled connecting section of a partition for a wet room and method of fastening it to a room surface. The connecting section is disposed a short distance from the room surface and then temporarily tacked to the room surface while retaining the section away from the room surface. Subsequently, the connecting section is permanently fastened while retaining it away from the room surface by permanently cementing the long edges of connecting section to the room surface by means of an elastic adhesive sealing compound. | 4 |
FIELD OF THE INVENTION
This invention relates generally to wire-line equipment used in conducting down-hole well operations including well completion activities, well servicing activities, and the installation and removal of various down-hole well tools. More particularly, the present invention concerns an enclosed radial cable conveyance mechanism through which a wire-line passes as the wire-line is being run into or extracted from a well bore and wherein the conveyance mechanism is capable of containing well pressures in the range of 10,000 psi or greater and to provide for continuous grease injected sealing of the wire-line while in a number of configurations.
BACKGROUND OF THE INVENTION
It is frequently necessary during drilling or completion operations to conduct well bore logging activities. Such activities involve the use of a logging tool run into the well to evaluate the progress of the well's bore and to identify various characteristics of the earth formation adjacent the well bore. Logging operations are typically carried out by running various logging tools into the well using a variety of wire-line cables. Various other well servicing activities are often conducted using down-hole tools that are run into well bores or well casing using wire-line apparatus. When wells are being logged or completed on live wells high-pressure conditions are often encountered. When such high pressures are encountered, wire-line pipe risers of significant height are often employed within the well derrick or above the well head in order to provide the wire-line pipe risers with sufficient length to house the down-hole tool and a sufficient length of weight bar to overcome the well pressure and thus pull the tool and its logging cable into the well bore. These wire-line risers incorporate grease wipers and/or wire-line packers in addition to various valves necessary to render the wire-line apparatus safe for containing the well's pressure.
Typically an open upper sheave is mounted above the wire-line riser and the wire-line cable being run into or exiting the well extends above the riser and passes around the upper sheave and thence downwardly to a lower sheave near drill floor level in route to a wire-line cable winch typically mounted on a wire-line service vehicle located adjacent the derrick. More recently, rather than providing extremely tall wire-line risers, especially where the height of the wire-line riser may be restricted, it has become customary to provide a pressure containing upper sheave which may be located at the upper end of a wire-line riser and incorporated therein and to provide a grease seal conduit extending downwardly from the upper pressure-containing sheave head thus providing a wire-line riser containing apparatus of sufficient length for efficient pressure containing capability but with approximately half overall height. An example of a pressure-containing sheave disposed in pressure connection with a wire-line riser and a grease seal conduit is presented by U.S. Pat. No. 5,188,173 of Richardson, et al, and U.S. Pat. No. 5,662,312 of Leggett, et al. These types of pressure-containing sheaves have deficiencies in that they are restricted relative to their weight and pressure containing capability due to the significant area of the housings. The housings are also subject to considerable pressure induced side loading that, especially under high-pressure conditions, can significantly distort the body structure to the extent that the sheaves can become inoperative. It is therefore desirable to provide a light weight, radial pressurized cable conveyance mechanism having high pressure capability for wire-line well servicing apparatus and other completion activities utilizing wire-line services that are also configurable to produce multiple radial bends that reduce or eliminate the need for open or closed sheaves all together.
SUMMARY OF THE INVENTION
The instant invention is a relatively light weight radial wire-line conveyance mechanism capable of sustained high pressure which may be incorporated into a wire-line riser configuration and configured to allow multiple radial bends thus eliminating the need for sheaves. The features of this invention are realized through the provision of a tubular body structure capable of being pressurized defining a radius between 0 and 180 degrees including a threaded connection at each end or by any other suitable means for connection to down-hole tubular joints. The tubular body structure defines an internal bore within which is located a series of connected tubular blocks each of which includes a longitudinal bore and roller therein defining a wire-line pathway for receiving a wire-line that passes through each of said tubular blocks located throughout the body structure. The rollers in each of the tubular blocks are directly lubricated by grease that is continuously pumped into the internal bore.
It therefore is an object of the radial wire-line conveyance mechanism or carrier to reduce the overall height of the wire-line lubricator string resulting from crane height limitations.
Another object of the invention is to reduce pollution by reducing the height of the external sheave and grease head associated with wire-line operations.
Yet another object of the invention is to eliminate wire-line cable from jumping external sheaves.
Another object of the invention is to reduce length of lubrication hoses associated with wire-line injection operations and thus increase visibility of the wire-line insertion operation by reducing the illuminated area required.
Still another object of the invention is to prevent spinning and twisting of the wire-line by the wire-line sheave.
Yet another object of the invention is to simplify pick-up and lay-down of lubricator and eliminating external top sheaves in some cases.
Another object of the invention is to provide an enclosed, pressurized, radial, light weight wire-line conveyor that reduces bearing loading, especially with large diameter cable.
Still another object of the invention is to provide a means for radially conveying a wire-line in multiple planes thereby permitting pivotal “Chickson” type lubricator section set up for wire-line operations.
These and other objects may be better seen and described by the drawings and detailed descriptions to follow.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature and objects of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which, like parts are given like reference numerals, and wherein:
FIG. 1 is vertical elevation view of the preferred embodiment of the radial cable conveyer adapted to a wire-line riser attached to a wellhead and supported by crane;
FIG. 2 is vertical elevation view of the preferred embodiment of the radial cable conveyer adapted to wire-line riser with free-point rig-up in a derrick;
FIG. 3 is a vertical elevation view of a second embodiment of the radial cable conveyer and wire-line riser with free-point rig-up in a derrick adapted for use with top drive;
FIG. 4 is a vertical elevation view of the prior art free-point rig-up;
FIG. 5 is a vertical elevation view of a third embodiment of two 90-degree radial cable conveyers connected in tandem in a free point riser rig-up for use with elevators;
FIG. 6 is a vertical elevation view of a fourth embodiment of a radial cable conveyer with parallel riser member connector bracing;
FIG. 7 is a vertical elevation view of a fifth embodiment utilizing multiple radial cable conveyers within a wire-line;
FIG. 8 is a cross-section view of the radial cable conveyer capable of being pressurized;
FIG. 9 is a partial isometric view with cut-away view of the roller assembly;
FIG. 10 is a side view of the roller assemblies connected in tandem showing pivotal movement in phantom;
FIG. 11 is a cross-section view of the roller assembly taken along sight line 11 — 11 seen in FIG. 10 ;
FIG. 12 is a side elevation cross-section view of the roller assembly;
FIG. 13 is an exploded cross-section view of the coupling assembly;
FIG. 14 is an isometric view of a 90-degree and 180-degree radial cable conveyer connected in tandem with ends in different planes;
FIG. 15 is an isometric, cut-away view of a second embodiment of the cable carrier means;
FIG. 16 is an isometric, cross-section view of the second embodiment of the cable carrier means; and
FIG. 17 is a cross-section end view of the second embodiment of the cable carrier means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The wire-line cable riser rig-up assembly 10 illustrated in FIG. 1 would seem to be impractical due to the friction and wear factors associated with simply bending a pipe or tube as seen at the top of the riser in a 180-degree arch. However, as disclosed herein, utilizing a 180-degree cable conveyer located within the tubular member to form a high pressure, wire-line cable conveyor assembly 12 , allows the grease head assembly 14 to be located closer to ground level. The arrangement further eliminates the need for a large, heavy diameter sheave and the problems associated therewith when this arrangement is currently attempted. The wire-line 16 can still be fed to the grease head assembly 14 from the reel assembly 18 utilizing the lower temporary sheave 20 . The riser assembly 10 in this embodiment is illustrated as being attached to a wellhead assembly 22 and supported by a crane cable 24 .
As illustrated in FIG. 2 , the 180-degree cable conveyor assembly 12 and riser assembly 10 may be utilized with a derrick 25 in a free-point rig-up arrangement whereby the riser assembly 10 and multiple joint sections of pipe located within the well bore 26 may be lifted by the rig cable line 28 by utilizing a free-point riser set-up as shown here. In this case the wire-line cable 16 is passed though a deck sheave 30 to an intermediate derrick supported sheave 32 before being passed to the lower temporary sheave 20 leading vertically to the grease head 14 . In this arrangement a temporary shut-in valve 34 is used to close off wellhead pressure leading to the riser assembly 10 . It should also be noted that due to excessive weight on the joints, lifting requires threaded pipe joints 36 rather than BOWEN™ (registered mark of BOWEN™ c_Tool, Inc.)-type quick couplings generally used for making up wire-line riser assemblies. However, when using the bent cable conveyer assembly 12 as illustrated in FIG. 2 , joints located between the conveyer assembly 12 and the lower sheave 20 can still use the Bowen™ quick fittings.
Looking now at FIG. 3 we see that the same set-up and riser assembly seen in FIG. 2 may be used with a top drive derrick. However, in this case, the bent 180 degree cable conveyer assembly 12 in the previous figures has now been modified for top drive connection and lifting apparatus by forming an “h” configuration designated here as item 40 and referred to as the top drive 180 degree cable conveyor. This configuration is by far easier to control than the “Y” arrangement in current practice as illustrated in FIG. 4 . In this configuration the riser assembly 42 is by necessity quite lengthy, thus placing the “Y” sub 44 and the grease head 14 very high in the derrick 25 , requiring very long grease lines 46 . The arrangement also utilizes the elevators 48 for lifting the pipe string and riser assembly 42 from the well bore 26 .
In some cases it may be advantageous to route the wire-line riser assembly high in the derrick with a free-point arrangement as seen in FIG. 5 without using the “Y” sub 44 shown in FIG. 4 . In this case the riser assembly 42 is supported or lifted by the elevators 48 and the wire-line cable 16 is fed through on two sheaves, the temporary derrick sheave 32 and deck sheave 30 . However, the traveling block from which the elevators 48 are suspended creates interference problems with the grease head if allowed to remain vertical along the centerline of the wellhead. Therefore, by utilizing a pair of 90-degree high-pressure wire-line conveyer assemblies, 50 the grease head can be offset to avoid the traveling block.
In some cases the bent riser assembly, as previously described in FIG. 1 , forming “U” shape of parallel riser members may need additional cross bracing between the parallel riser members as seen in FIG. 6 to insure unit integrity. This may be achieved with one or more pipe hanger clamps 52 .
As illustrated in FIG. 7 the riser assembly previously illustrated in FIGS. 1 and 7 may also include additional conveyor assemblies 50 as necessary to route the wire-line to the cable reel by the shortest and most direct route, thereby reducing stress on the cable.
Looking now at FIG. 8 we see that the high pressure wire-line conveyer assembly 12 includes the radial tubular member 54 which may be bent to any arc between 0 and 180 degrees, a removable coupling assembly 56 located at each end configured for adaptation to any pipe or tube connection composing the riser assembly 10 . The coupling assemblies 56 may also be threadably adapted to box and pin joint connections, flange fittings or adaptively welded to pipe or tubing 58 as shown in FIG. 8 . In any case, at least one of the coupling assemblies 56 must be removable from the tubular member 54 to allow for insertion and removal of the roller assembly 60 . The roller assembly 60 as shown in more detail in FIG. 9 includes a plurality of cylinders 62 linked together in tandem. Each cylinder 62 has an aperture for passing the wire-line cable 16 supported upon a roller assembly 64 . As seen in FIG. 10 , each of the cylinders 62 is linked by a pin and connector 66 , seen in cross section in FIG. 8 and in phantom here, allows the cylinders to articulate relative to each other thereby conforming to the radius of the tubular member 54 . The Wire-line cable 16 is supported by a grooved roller 68 supported at each end by sealed bearings 70 as shown in FIG. 11 . This arrangement insures that the cable 16 passing through the longitudinal aperture 72 remains in contact with the roller 64 , thereby reducing binding and cut cables usually found when using sheaves. Each end of the cylinder 62 is tapered and flared to maximize free running of the cable 16 through the cylinder assembly 60 as seen in detail in FIG. 12 .
Looking now at FIG. 13 the radial tube 54 housing the roller assembly 60 is attached to an adaptor member 76 having external threads and an O-ring seal 78 . The threads 76 are cooperative with the internal threads of the body member 80 of the coupling assembly 56 . A second adaptor member 82 is slidably connected to the body member 80 and sealed with a second O-ring 78 ′ and fitted with a rotatable nut 84 having internal threads cooperative with external threads 86 located on the body member 80 . The second adaptor is then adaptively attached to other tubular members of the riser assembly 10 .
It should be noted that although any arc with any radius desired may be used to convey the wire-line cable around such bends, it may be more practical to make up 90 or 180 degree assemblies and use combinations thereof for various applications which may include applications where each end of the assembly is in a different plane as seen in FIG. 14 .
The conveyance of a wire-line cable around a bend within a pressurized tubular member may be achieved by the alternative method illustrated in FIG. 15 . As seen here, the cable 16 is threaded through a series of ball rollers assemblies 88 . Each ball roller assembly 88 has a plurality of rolling balls that allows the cable 16 to pass freely through its longitudinal bore. The ball assemblies may be inserted in tandem into the bent housing 54 as seen in FIG. 16 and may carry cables sizes up to the maximum ball inner diameter as shown in FIG. 17 .
Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in any limiting sense. | A relatively light weight radial wire-line conveyance mechanism capable of sustained high pressure incorporated into a wire-line riser set-up and configured to allow multiple radial bends without sheaves. The conveyance mechanism includes a tubular body structure capable of being pressurized defining a radial arc of between 0 and 180 degree having a threaded coupling at each end for connection to riser tubular joints. The tubular body contains a series of connected tubular blocks, each of which includes a longitudinal bore and a roller or ball assembly therein defining a wire-line pathway for receiving a wire-line that passes through each of said tubular blocks, fully contained therein. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE01/00465, filed Feb. 7, 2001, which designated the United States and was not published in English.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a semiconductor component having an MIM capacitor and to an associated fabrication method.
[0003] To produce integrated electronic circuits, integrated passive components such as resistors, inductors and capacitors are also needed. For many applications, integrated capacitors need to have series resistances and losses whose magnitudes are as negligible as possible, while having a low area requirement and a low coupling to the substrate. The demand for low series resistances can be met ideally by using metal-insulator-metal (MIM) capacitors. If the metallization planes and intermetal dielectrics normally present in a multilayer metallization are used, capacitors with a very small specific capacitance per unit area (typically below 0.1 fF/μm 2 ) and relatively high tolerances above 20% can be produced. For optimized MIM capacitors, a separate insulating layer and usually a separate thin top metal electrode are generally used.
[0004] When integrating an MIM capacitor into a fabrication process for an integrated circuit, there are fundamentally two problems. The process cycle and to some extent also the layer sequence are significantly changed to some extent in the case of the usual methods. The differences between the fabrication methods for components with an integrated MIM capacitor and without an MIM capacitor result in different properties for the metallization system, particularly as regards reliability of the circuit. It is also difficult to achieve high specific capacitance per unit area values for the MIM capacitor, since reliability and tolerance problems quickly arise when using relatively thin capacitor dielectrics. The reason for this is that the typical granular structure of the bottom electrode, which is normally AlCu or AlSiCu, results in that the electrode has a relatively rough surface which can even change in the rest of the process cycle. In addition, with the normal method, the surface is subjected to a series of process steps that can impair the surface quality further. Following deposition and before the top electrode is applied, the capacitor dielectrics are also subjected to process steps which can adversely affect their surface or their layer property.
[0005] U.S. Pat. No. 5,391,905 describes an integrated circuit and an associated method for fabricating the circuit, where a top electrode made of polysilicon for a capacitor is deposited together with a contact electrode for a transistor after a bottom electrode made of polysilicon for the capacitor and a capacitor dielectric have been produced.
[0006] Published, Non-Prosecuted German Patent Application DE 198 38 435 A1 describes a method for fabricating a semiconductor memory where a bottom capacitor electrode made of polysilicon is deposited into an opening in an insulating film.
SUMMARY OF THE INVENTION
[0007] It is accordingly an object of the invention to provide a semiconductor component and a fabrication method which overcome the above-mentioned disadvantages of the prior art devices and methods of this general type, which can easily be fabricated using conventional fabrication processes and in which the difficulties specified in the introduction are circumvented.
[0008] With the foregoing and other objects in view there is provided, in accordance with the invention, a semiconductor component. The semiconductor component contains a topside for making electrical contact, and a capacitor having a bottom electrode, a top electrode disposed closer to the topside than the bottom electrode, and a capacitor dielectric. The bottom electrode is formed by a specially provided metal electrode layer, and the top electrode is formed by a metallization plane for interconnects.
[0009] In the case of the inventive component, the capacitor dielectric and the thin top electrode are not, as is usual, applied to a relatively thick, rough metal layer originating from the standard metallization, but rather, conversely, an optimum thin bottom electrode layer with an optimally protected capacitor dielectric is first produced and structured. A metallization plane is applied thereto and structured, which metallization plane is provided for the normal interconnects and electrical connections of further integrated components. The capacitor dielectric can therefore be deposited on a very smooth, preferably metal (bottom electrode), surface (e.g. TiN) and, following deposition, can be sealed and protected by a thin, likewise preferably metal, layer (e.g. TiN), so that it is not thinned or damaged by other process steps. A particular advantage is that the additionally provided layer which forms the bottom electrode of the MIM capacitor is provided only in the region of the MIM capacitor, which results in that the rest of the layer configuration is not altered as compared with a configuration without a capacitor. The inventive component therefore allows a capacitor with small manufacturing tolerances to be integrated using a normal fabrication process without the previous semiconductor structures of a configuration without a capacitor needing to be changed.
[0010] In accordance with an added feature of the invention, a further dielectric is provided and covers and forms the topside. The further dielectric is a passivation layer or an intermetal dielectric layer. The capacitor dielectric that is disposed between the bottom electrode and the top electrode has a relatively high dielectric constant.
[0011] In accordance with an additional feature of the invention, the capacitor dielectric is formed of Si 3 N 4 or tantalum oxide.
[0012] In accordance with a further feature of the invention, the top electrode has a given surface and the bottom electrode has a surface having a lower roughness than the given surface of the top electrode. The capacitor dielectric covers the surface of the bottom electrode.
[0013] With the foregoing and other objects in view there is provided, in accordance with the invention, a method for fabricating a semiconductor component having an integrated capacitor. The method includes applying a passivation to a topside of a component structure, depositing a metal layer onto the passivation and the metal layer functions as a bottom electrode of the integrated capacitor, depositing a dielectric layer on the metal layer, and depositing a metallization plane on the dielectric layer. The metallization plane is structured to form interconnects and/or contact areas, and to form a top electrode of the integrated capacitor. At least one covering dielectric is deposited and contact holes for at least one of the bottom electrode and the top electrode are formed in the covering dielectric. The contact holes are then filled with an electrically conductive material.
[0014] In accordance with an added mode of the invention, there are the steps of producing further contact holes in the passivation before performing the step of depositing the metal layer, and filling the further contact hoes with contact hole fillings formed from an electrically conductive material for producing an electrically conductive connection to a contact area situated below the passivation and for electrically connecting the bottom electrode. The metal layer is deposited above the contact hole fillings during the step of depositing the metal layer.
[0015] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0016] Although the invention is illustrated and described herein as embodied in a semiconductor component and a fabrication method, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0017] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1 A- 1 F are diagrammatic, sectional views showing steps for the construction of a first embodiment of a semiconductor component according to the prior art;
[0019] FIGS. 2 A- 2 F are diagrammatic, sectional views showing steps for the construction of a second embodiment of the semiconductor component according to the prior art;
[0020] FIGS. 3 A- 3 E are diagrammatic, sectional views showing steps for the construction of a third embodiment of the semiconductor component according to the prior art;
[0021] FIGS. 4 A- 4 F are diagrammatic, sectional views showing steps for the construction of a first embodiment of the semiconductor component according to the invention; and
[0022] FIGS. 5 A- 5 F are diagrammatic, sectional views of the construction of a second embodiment of the semiconductor component according to the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Referring now to the figures of the drawing in detail and first, particularly, to FIGS. 1 A- 1 F thereof, there is shown various intermediate product stage of a known fabrication method. In the case of the layer structure shown in cross section in FIG. 1A, right at the bottom, there is a passivation 10 which can be applied to a semiconductor layer structure 100 as an insulating layer, for example, or can be a top dielectric layer of a metallization with intermetal dielectrics which contain one or more metallization planes. In this example, a standard metallization applied thereto has a sandwich structure with a bottom electrically conductive layer 11 and a top electrically conductive layer 12 which have an insulating layer 13 situated between them. The top electrically conductive layer 12 is used as the bottom electrode of the MIM capacitor. Onto the layer 12 , a capacitor dielectric 3 is deposited (e.g. a plasma nitride with a thickness of less than 0.1 μm) followed by a further thin metal layer 2 used as the top electrode 2 of the capacitor (e.g. TiN with a thickness of approximately up to 0.1 μm). A suitable mask is used to structure the top electrode 2 , with either the capacitor dielectric 3 or the electrically conductive layer 12 below that being used as an etching stop layer. The result of the step is shown in FIG. 1B. This is followed, in line with FIG. 1C, by structuring of the standard metallization 1 to form a portion for the MIM capacitor 123 and a portion for the interconnect 14 . FIG. 1D shows that a topside of the structure is embedded into a covering dielectric 5 . In line with FIG. 1E, contact holes 6 provided for electrical connection of the metallizations are etched into the dielectric 5 . The contact holes 6 are filled in a manner that is known per se, so that the structure shown in FIG. 1F is produced. A base metal 7 (usually Ti/TiN) can also first be deposited in the contact holes 6 before the actual contact hole filling (typically tungsten) is introduced into the contact holes 6 . This produces the electrical connections for the bottom capacitor electrode (contact hole fillings 81 ), for the top capacitor electrode (contact hole fillings 82 ) and for the interconnects (contact hole fillings 83 ).
[0024] An alternative to the known method is shown in FIGS. 2A to 2 F. Again, starting from the standard metallization 1 , the metallization is now structured in line with FIG. 2B before the top capacitor electrode is applied. Only when the interconnects 14 have been structured are the capacitor dielectric 30 and the thin electrically conductive layer 20 provided for the top capacitor electrode applied. When the top conductive layer 20 has been structured, the capacitor dielectric 30 also remains in the region of the interconnects 14 on the topside of the structure, which results in that the interconnects 14 are surrounded by the dielectric 30 on three sides. In line with FIGS. 2D to 2 F, the covering dielectric 5 is then applied, the contact holes 6 are etched and the base metal and the contact hole fillings are introduced into the holes, in line with the variant shown in FIGS. 1D to 1 F. When etching the contact holes 6 in line with FIG. 2E, it is also necessary to etch through the capacitor dielectric 30 . If the capacitor dielectric 30 is completely removed from the rest of the surfaces at the same time as the top capacitor electrode is structured, then there is the risk that the normally applied top antireflective layer (usually TiN) will also be removed from them. The antireflective layer, the actual interconnect material (e.g. AlCu) and the base metal situated below that form a sandwich structure whose integrity is crucial for the electromigration strength of the metallization system. The etching process destroys or at least damages the sandwich structure. In the region outside the MIM capacitor that is to be produced, the capacitor dielectric is therefore not removed from the surfaces of the conductive layers (generally metal layers) until the contact holes 6 are produced.
[0025] Another option for producing MIM capacitors is, in line with FIGS. 3A to 3 E, to follow the application of an intermetal dielectric 4 to the structured standard metallization with the production of a cutout 9 in the dielectric 4 , shown in FIG. 3B, as a window above the top conductive layer 12 . The capacitor dielectric 30 is then deposited on the surface and into the cutout 9 , in line with FIG. 3C. The contact holes 6 are then etched in line with FIG. 3D. When the contact hole fillings are introduced after the base metallization 7 has possibly also been applied, the electrical connections for the bottom capacitor electrode (the contact hole filling 81 ) and for the interconnect (the contact hole filling 83 ) are then produced. The cutout 9 is likewise filled with the metal for contact hole filling. This produces a top capacitor electrode 80 . Drawbacks of this method are that, before the base metalization is deposited, a cleaning step needs to be performed in order to improve the contact resistances. The cleaning step thins the capacitor dielectric exposed at this time and possibly also damaging it, and that the capacitor dielectric is retained as an additional layer in the layer structure with the intermetal dielectric 4 and can have an adverse effect on the properties of the metallization system (stress, barrier effect for H 2 diffusion)
[0026] [0026]FIGS. 4A to 4 F and 5 A to 5 F show cross-sectional views of intermediate products after various steps in fabrication methods according to the invention.
[0027] As FIG. 4A shows, the thin conductive layer 2 , preferably a metal, is first deposited on the insulating passivation 10 (this can be an intermediate oxide or an intermetal dielectric) as a bottom electrode 2 . As soon as possible thereafter, an electrically insulating layer 3 is applied thereto as a capacitor dielectric 3 . The capacitor dielectric 3 likewise has the smallest possible layer thickness and is preferably made of a material with a high dielectric constant (e.g. Si 3 N 4 or tantalum oxide). Finally, a conductive top layer 11 can be applied to seal the dielectric 3 and is a top electrode 11 of the capacitor that is to be produced. Quickly sealing the capacitor dielectric 3 with the conductive layer 11 protects the dielectric 3 from thinning and from other damage resulting from further process steps. The layers 2 , 3 , 11 can be produced using normal method steps such as sputtering, vapor deposition, chemical vapor deposition (CVD), physical vapor deposition (PVD) or electrodeposition.
[0028] In line with FIG. 4B, the deposited layer sequence 2 , 3 , 11 is then structured using a photographic technique and a suitable etching step. Following removal of the photoresist used in this context and any necessary cleaning, the processing as customary in a multilayer metallization process continues with deposition of a metallization layer (e.g. interconnect metal and antireflective layer) and the structuring thereof.
[0029] [0029]FIG. 4C shows such a structure with a standard metallization 1 and an interconnect 14 structured therein. The top electrode 11 of the capacitor is now part of the standard metallization 1 . In this example shown in FIG. 4D, more extensive structuring exposes part of the capacitor dielectric 3 . In this case too, the standard metallization 1 contains, as an example, a sandwich structure containing the conductive layer 11 , a top conductive layer 12 and an insulating layer 13 disposed between them. The structure is covered with the dielectric 5 in which the contact holes 6 are produced in line with FIG. 4E. In the region of the contact holes 6 provided for the bottom electrode, the capacitor dielectric 3 exposed there in a prior structuring step is etched through. In line with FIG. 4F, the contact hole fillings produced on the base metal 7 in accordance with the prior art are used to produce the electrical connections for the bottom electrode (the contact hole filling 84 ), the top electrode (the contact hole fillings 85 ) and the interconnects (contact hole fillings 83 ). The contact holes 6 can each be individual cylindrical openings. As shown by the illustration of the cross sections in FIGS. 4E and 4F, a circular annular opening disposed along the edge of the respective capacitor electrode can also be produced, however.
[0030] The structuring of the metallizations applied above the capacitor dielectric 3 in order to obtain the structure shown in FIG. 4C can also entail the capacitor dielectric 3 even then being removed from the regions of the surface of the bottom electrode 2 which are at the side of that region above which the top electrode 11 of the finished capacitor is disposed. When producing the contact holes 6 as shown in FIG. 4E, the dielectric 5 can then be etched out directly on that surface of the bottom electrode 2 which is not covered by the capacitor dielectric 3 . This simplifies etching of the contact holes 6 , since it is only necessary to etch through one dielectric 5 and not additionally through the capacitor dielectric 3 that is preferably made of a material having a relatively high dielectric constant.
[0031] In the embodiment shown in FIGS. 5A to 5 F, production of the connection for the bottom electrode 2 differs from that in the exemplary embodiment already described. FIG. 5A shows that, in the case of the embodiment, the contact holes in the passivation 10 which are filled with a contact hole filling 18 , preferably on a base metal 17 , before the bottom electrode 2 is deposited are provided for connecting the bottom electrode 2 . The rest of the method steps are based on the exemplary embodiment in FIGS. 4 A- 4 F, but with the difference that, in line with FIG. 5E, no contact holes need to be produced in the dielectric for the bottom electrode 2 of the capacitor. | A thin lower electrode layer having an optimally protected capacitor dielectric is produced and structured. A conventional metallization layer for strip conductors is placed thereon as an upper electrode and structured. The capacitor dielectric can be deposited on a very even, preferably metallic surface (e.g. preferably TiN), sealed by a thin, preferably metallic layer (e.g. TiN) and protected so that is does not become thinned or damaged by other process steps. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and apparatus for registering and representing signals within integrated circuits, in which the signals have two logic levels.
2. Description of the Prior Art
In the internal testing of digital integrated circuits, the chronological position and the steepness of the signal edges must be identified first and foremost.
The foregoing is possible by quantitative signal curve measurement, for example with the assistance of electron beam mensuration technology, but is very time-intensive. The status changes in the internal testing of digital integrated circuits are, in fact, quickly acquired with logic analysis. circuits.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method and an apparatus with which signals within digital circuits can be very quickly acquired such that the chronological position and the steepness of signal edges can also be identified.
The above object is achieved, according to the invention, for signals have two logic levels in that a respective threshold is defined for each logic level and the chronological position of a signal edge and the steepness of the signal edge are determined with the assistance of the logic levels. More specifically, the two logic levels are employed for reproducing a time diagram of a registered signal, whereby the transitions between the two logic levels are indicated by slanting lines in accordance with the measured edge steepness.
A probe, for example a pulse electron beam or a laser scanner, is directed to a measuring point within a digital integrated circuit and releases particles, for example secondary electrons, which supply information regarding the potential curve at this measuring point. How a potential curve can be sampled with the assistance of an electron probe is disclosed, for example, in U.S. Pat. Ser. No. 4,277,679, fully incorporated herein by this reference. In contrast to logic analysis, a lower threshold and an upper threshold for the registered signal curve are taken into consideration given the method of the present invention. Since only a single threshold is taken into consideration in the known method of logic analysis, a digital signal can only be represented given the known method such that it either assumes the status "0" or the status "1". There are only abrupt changes between the states "0" and "1" in representation of a digital signal which had been picked up with the assistance of the known method of logic analysis. Since there is an upper threshold and a lower threshold for the signal registration given the method of the present invention, there are regions in the reproduction of a digital signal picked up according to the invention where the reproduced signal assumes the value "0" and there are regions where the digital signal assumes the value "1". In addition, there are also regions where the digital signal picked up with the assistance of the method of the invention assumes neither the value "0" nor the value "1", but where this digital signal is in transition either from the value "0" to the value "1" or from the value "1" to the value "0". Since a digital signal is reproduced as a function of time upon reproduction, a narrow transition region between two different logic levels represents a steep edge rise or, respectively, edge decay and a broad transition between two different logic levels represents a relatively flat edge rise or, respectively, edge decay. The two thresholds that are employed in the method can be matched to the logic family to be investigated in a manner similar to that by which the single threshold employed in the known method of logic analysis can be matched to the logic family to be investigated in that method.
Since only a single threshold is employed in the known method of logic analysis, only the two possibilities that a signal value either lies above or below this threshold exists given a known method. With the method of the present invention having an upper threshold and a lower threshold, there are three possibilities, namely, first, that the signal value is above the upper threshold, second that the signal value is between the lower and upper thresholds, and, third, that the signal value is below the lower threshold. When the signal value is located between the lower and upper thresholds, then there is a transition region between the lower logic level and the upper logic level.
The measuring speed in the method of the present invention can be increased in that the sampling of the signal at an internal point of the digital circuit occurs first in rough steps or with a broad sampling pulse until a transition region between upper and lower thresholds, i.e. a signal edge, is perceived. The position of this signal edge and its steepness can be precisely determined by fine scanning or sampling in the environment of this transition region between the upper and lower thresholds, i.e. in the environment of the signal edge. The result of this determination can be stored in a relatively compressed form such as, for example, one datum as to whether the signal edge is rising or decaying, one datum with respect to the chronological position of the signal edge, and a further datum with respect to the steepness of the signal edge.
A representation similar to a logic diagram representation is recommendable for the reproduction of a digital signal registered with the present invention. Only the logic levels "0" and "1" are represented given such a reproduction of a digital signal acquired with the present invention. The status transitions are specified by slanting lines corresponding to the measured edge steepness.
The control of a measured value pick-up preferably occurs with a programmed jog sequencer, for example with a microcomputer system.
The method of the present invention can be utilized not only to pick up digital signals at points within digital circuits, but also to pick up digital signals at outputs of digital circuits.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention, its organization, construction and operation will be best understood from the following detailed description, taken in conjunctign with the accompanying drawing, on which:
FIG. 1 is a graphic illustration of the underlying principle of the present invention; and
FIG. 2 illustrates, in schematic form, an apparatus for setting thresholds and reading transgressions thereof connected to an electron beam probe system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 explains the underlying principle of the invention. The upper portion of FIG. 1 illustrates a signal S existing at a measuring point and its assignment to the two thresholds, namely a lower threshold U0 and an upper threshold U1. The measured signal D acquired from the signal S existing at the measuring point is illustrated in the lower portion of FIG. 1. Both of the signals S and D are specified as functions of time t. The voltage values U of the signal S existing at the measured point are therefore illustrated as a function of time t. First, the signal S has a voltage U that is higher than threshold U1. The digital measured signal D therefore initially assumes the logical value "1". The signal S then descends with a relatively steep edge below the threshold U0. The signal D therefore first shows a steep signal decay in order to then assume the logical value "0". After a further relatively steep rise at the signal S beyond the upper threshold U1 and again a steep edge decay of the signal below the value U0, a relatively flat signal rise again beyond the upper threshold U1 and, finally, a relatively steep signal decay below the lower threshold then occur. The signal D reflects this up and down change of the signal S in a simplified form, whereby, in contrast to the known art, however, the signal D does not only assume the logical value "0" or the logical value "1", but also reproduces the position and the steepness of the leading edges and trailing edges of the signal S present at the measuring point in transition regions between these two logical values. An evaluation of the dynamic properties of the circuit portions is thus enabled.
FIG. 2 illustrates, on the left, an electron probe system of the type set forth in the aforementioned U.S. Pat. No. 4,277,679. The probe system comprises an electron gun EG for generating a primary electron beam PE which impinges on a specimen IC by way of a beam blanking system BBS connected to a pulse generator BBG and deflection coils SC connected to a scan generator SG. The primary electron beam PE causes the emission of secondary electrons SE from the specimen IC which are detected by a detector DT and amplified by an amplifier PA to produce an output signal S.
FIG. 2 also illustrates an apparatus for setting thresholds, in particular two thresholds. The apparatus for the determination of a threshold essentially comprises a comparator whose inverting input can be set as a reference voltage for upper threshold U1 or, respectively, for a lower threshold U0. The signal S is respectively applied to the non-inverting input of such a comparator. Since an apparatus for the implementation of the method of the invention requires an upper threshold U1 and a lower threshold U0, two comparators are therefore provided for the apparatus to implement the method, the signal S taken at the measuring point being respectively applied to the non-inverting inputs thereof. A voltage corresponding to the upper threshold U1 is applied as a reference voltage to the inverting input of the apparatus for the determination of the upper threshold U1. A voltage corresponding to the lower threshold U0 is applied as a reference voltage to the inverting input of the apparatus for the determination of the lower threshold U0. A logical "1" occurs at the output of the apparatus for fixing the upper threshold U1 when the value of the signal S is greater than the upper threshold U1 and a logical "0" appears when the value of the signal S is lower than the upper threshold U1. A logical "1" occurs at the output of the apparatus for the determination of the lower threshold U0 when the value of the signal S is greater than the lower threshold U0 and a logical "0" appears when the value of the signal S is lower than the threshold U0. When both outputs of the two comparators are combined in an AND gate, then a logical "1" occurs as the output of the AND gate when the value of the signal S is greater than the upper threshold U1. When the inverted output of the circuit for determining the upper threshold U1 is combined in an AND gate with the output of the circuit fixing the lower threshold U0, then a logical "1" occurs at the output of this AND gate when the value of the signal S is greater than the lower threshold U0 and lower than the upper threshold U1. When the inverted outputs of the two circuits for fixing the upper and lower thresholds are combined in an AND gate, then a logical "1" occurs at the output of this AND gate when the value of the signal S is lower than the lower threshold U0.
Although I have described my invention by reference to a particular embodiment thereof, many changes and modifications of the invention may become apparent to those skilled in the art without departing from the spirit and scope of the invention. I therefore intend to include within the patent warranted hereon all such changes and modifications as may reasonably and properly be included within the scope of my contribution to the art. | A respective threshold circuit is provided for defining upper and lower thresholds representing logic levels of signals occuring within integrated circuits. The chronological position of a signal edge and the steepness of the signal edge are defined with the assistance of the two thresholds. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates generally to apparatus for forming concrete or other flowable paving material into a paved surface and, more particularly, to such a paving apparatus of the self propelled type for continuous slip-form paving of roadways, sidewalks and like concrete pavement surfaces.
Self-propelled construction vehicles and other construction equipment of diverse types are well known. One type of such construction equipment are so-called slip-form paving machines essentially adapted to continuously form concrete or another flowable paving material along the ground or other base surface, for example, to form a roadway. Diverse forms of such machines have been described in prior patents, representative examples of which may be found in U.S. Pat. Nos. 3,175,478; 3,264,958; 3,637,026; 3,771,892; 3,970,405; 4,197,032; 4,360,293; 4,925,340; 4,948,292; 5,044,820 and 5,590,977.
Conventionally, it is commonplace for paving equipment of this type to support the machine frame on a plurality of drivable transport assemblies, such as so-called crawler track assemblies, adapted to facilitate steerable driving of the paving machine over substantially any ground surface along which a roadway or like surface is to be paved. The frame of the machine is equipped with various devices and mechanisms to perform various functions of the paving operation, including typically an auger or other suitable mechanism for distributing the paving material laterally across the front of the machine, followed by a vertically disposed plate or like structural member, commonly referred to as a strike-off plate, positioned with a lower edge thereof at a desired elevation with respect to the ground surface to be paved to control the amount of paving material passing thereunder and thereby to initially form the material generally as a slab of the desired thickness, and then followed by a substantially horizontally disposed undersurface, commonly referred to as a screed, for purposes of leveling and finishing the concrete material.
In basic operation, a continuous supply of concrete or other suitable paving material is deposited in front of the paving machine between its transport assemblies as the machine is driven over the intended path of the pavement surface, with the auger mechanism initially distributing the paving material laterally, after which the lower edge of the plate “strikes off” a rough slab form of a desired thickness of the concrete material which then is more precisely spread, leveled and finished by vibration devices followed by the screed.
Once such a paving machine is under operation, it is a relatively simple matter to maintain ongoing operation on a substantially continuous basis, absent any malfunctions in the machinery itself, merely by maintaining a sufficient supply of concrete in front of the advancing machine. However, the initial start-up of a paving operation, including beginning operation at the start of each work day or otherwise after a period of sufficiently extended inactivity in the paving operation by which the concrete of a previously paved section of roadway has solidified and begun to cure, requires special efforts and can be much more problematic.
Specifically, the initial start-up of a slip-form paving operation, especially when continuing the paving of a previously formed section of pavement, requires that a sufficient starting supply of concrete be deposited not only in front of the auger mechanism and the strike-off plate but also therebehind beneath the screed fully up to the previously formed section of pavement, so as to ensure that there will be no interruption in the continuity nor the quality of the pavement slab. Generally, the only reliable way of accomplishing start-up of a slip-form paving machine under such circumstances is to position the machine immediately above the previously formed section of pavement and then to have workers manually shovel and preliminarily level a sufficient quantity of new wet concrete beneath and behind the auger mechanism, the strike-off plate and the screed, in addition to depositing a supply of concrete in front of the auger mechanism, whereupon operation of the machine can begin. This process is not only labor-intensive, time-consuming, expensive and inefficient, it is also difficult to ensure that the starting portion of the new section of pavement is of comparable quality and uniformity to that of the previously-formed section.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved slip-form paving apparatus which will address and overcome the disadvantages of the known paving apparatus as discussed above. More particularly, it is an object of the present invention to provide a slip-form paving apparatus which will better facilitate the deposition of a supply of concrete beneath the apparatus for starting up a new paving operation.
Briefly summarized, the present invention is basically applicable to any slip-form paving apparatus having a frame supported on a steerable self-propelled transport arrangement with a pavement forming assembly or like means disposed on the frame at a forward side thereof. In accordance with the present invention, the pavement forming assembly is movable with respect to the frame between an operative position disposed relative to a ground surface to be paved for distributing and forming a paving material on the ground surface generally into a desired form of pavement and an inoperative position disposed at a greater elevation relative to the ground surface than in the operative position for permitting access beneath the frame during an initial start-up of the apparatus so as to enable a starting quantity of the paving material to be readily deposited thereat.
In a preferred embodiment, the pavement forming assembly comprises a spreading mechanism or like means for distributing paving material across the forward side of the frame, e.g., an auger mechanism, a plow-type spreader, or the like, and a strike-off member or like means for generally leveling the pavement material on the ground surface. The spreading mechanism and the strike-off member, such as a strike-off plate, are integrally mounted pivotably to the frame for pivoting movement between the inoperative and operative positions. Thus, with the pavement forming assembly pivoted or otherwise moved into its inoperative position, workers have ready access to deposit and preliminarily work a starting supply of concrete or other paving material beneath the paving apparatus behind the normal operative disposition of the spreading mechanism and the strike-off member, after which the pavement forming assembly may be pivotably moved into its operative position for beginning the paving operation.
Other details, features and advantages of the present invention will be described and understood from a detailed description of a preferred embodiment of the invention set forth below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a slip-form paving apparatus equipped with a retractable pavement forming assembly in accordance with the present invention, illustrating the pavement forming assembly in operative disposition; and
FIG. 2 is another front perspective view of the slip-form paving apparatus of FIG. 1, illustrating the pavement forming assembly in retracted disposition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, a self-propelled slip-form paving apparatus in accordance with the present invention is indicated in its totality at 10 . The paving apparatus 10 basically comprises a structural framework 12 supported substantially horizontally on four front and rear steerable transport assemblies 14 , 16 , each preferably comprising a so-called crawler assembly of the endless track type, disposed at the four corners of the structural framework 12 in laterally and longitudinally spaced relation to provide stable suspension of, and steering control for, the framework 12 . An internal combustion engine (not shown) or other suitable self-contained power generator, preferably in conjunction with a hydraulic pump (also not shown), is mounted to the structural framework 12 to provide drive power to and steering control of the transport assemblies 14 , 16 , and to otherwise supply operational power to the various systems of the paving apparatus.
The embodiment of the paving apparatus 10 depicted in the accompanying drawings is particularly adapted for use in road construction for the continuous slip-form paving of a slab-type concrete roadway, the lateral width of the apparatus 10 between the front and rear transport assemblies 14 , 16 being sufficient for the formation simultaneously of two road lanes side-by-side one another. However, as those persons skilled in the art will understand, the essential features and inventive concepts forming the present invention are equally well-adapted to substantially any other form of self-propelled slip-form paving apparatus.
The paving apparatus 10 is equipped with a screw-type auger assembly 18 transversely spanning the framework 12 at the forward leading side thereof, comprised of two aligned auger sections 18 A, 18 B each of which is selectively driveable in opposite rotational directions independently of the other auger section, for laterally distributing a supply of concrete, or another suitable flowable paving material, deposited in front of the apparatus across the ground structure over which the roadway is to be paved. However, as those persons skilled in the art will recognize, other types of mechanisms for spreading the paving material may also be utilized instead of the auger assembly, e.g., a plow-type spreader or the like. Immediately rearwardly of the auger assembly 18 , a vertically disposed plate 20 , commonly referred to as a strike-off plate, is supported by the framework 12 with a lower edge 20 A of the plate 20 extending laterally across substantially the full width of the apparatus 10 at an elevation essentially corresponding to the desired elevation to which the roadway slab is to be paved, to act as a metering gate controlling the level of concrete material passing underneath the strike-off plate 20 .
A series of vibratory devices, only partially visible at 22 in FIG. 1 but more fully shown in FIG. 2, are mounted to the framework 12 at regular spacings across the transverse width of the paving apparatus 10 immediately behind the strike-off plate 20 to further assist in the leveling and settlement of the distributed concrete material by imposing a rigorous vibratory action on the concrete material passing under the strike-off plate 20 . A finish screed 24 is disposed rearwardly of the vibratory devices 22 and is preferably in the form of a substantially horizontal plate extending transversely across the width of the paving apparatus 10 and rearwardly from the vibratory devices 22 .
Thus, the basic operation of the paving apparatus 10 will be understood. As the paving apparatus 10 is self-propelled via the front and rear crawler assemblies 14 , 16 on the ground surface over which the roadway slab is to be formed, a suitable supply of concrete is maintained continuously in front of the auger assembly 18 . The operator of the paving apparatus 10 actuates and deactuates one or both of the sections 18 A, 18 B of the auger assembly 18 in either direction as necessary to distribute the concrete material with general uniformity laterally across the forward side of the paving apparatus. As the paving apparatus 10 advances, the vertically-disposed plate 20 strikes off a limited amount of the concrete material and partially compacts it to a uniform density, following which the vibratory devices 22 serve to expel any air bubbles from the concrete material and to further settle and smooth the upward surface of the concrete material. As the paving apparatus 10 continues to advance forwardly, the screed 24 is then drawn over the vibrated depth of the concrete material, performing a final compacting thereof and smoothing of its upper surface.
To the extent thus far described, the basic structure and operation of the paving apparatus 10 is essentially conventional. As already described above, it will be recognized that the operative disposition of the auger assembly 18 and the strike-off plate 20 substantially closes off access to the underside of the paving apparatus 10 and makes difficult the delivery, manually or otherwise, of a suitable quantity of concrete or other paving material underneath the apparatus for start-up purposes.
Accordingly, the present invention deviates from the structure and operation of conventional paving apparatus by mounting the strike-off plate 20 pivotably to the forward side of the framework 12 for selective retraction of the strike-off plate upwardly away from its normal operative disposition. Specifically, a laterally-extending support member 26 is supported from an elevated forwardly-facing portion 12 A of the framework 12 by two crank arms 28 affixed rigidly to the support member 26 at a spacing therealong and, in turn, pivotably affixed to correspondingly spaced support brackets 30 on the frame member 12 A. The strike-off plate 20 is rigidly affixed to the support member 26 for depending relation therefrom in its operative disposition via a pair of bracket arms 32 . Pivoting movement of the support member 26 , the crank arms 28 , the bracket arms 32 , and the strike-off plate 20 about the pivot axis P is controlled via extension and retraction of a linear actuator 34 , preferably in the form of an hydraulic piston-and-cylinder assembly 34 the cylinder body of which is mounted at an elevated disposition on the framework 12 via an upstanding mounting bracket 36 , with the piston extending downwardly to a point of affixation to one of the bracket arms 32 .
Additionally, in accordance with the present invention, the auger assembly 18 is affixed integrally with the strike-off plate 20 via a pair of support arms 38 extending forwardly in spaced facing relation to one another from the opposite lateral ends of the strike-off plate 22 , and an intermediate support bearing 40 disposed midway therebetween. Each support arm 38 carries an hydraulic motor 42 from which a respective one of the auger sections 18 A, 18 B extends in alignment with the other auger section to the intermediate support bearing 40 to which each of the auger sections 18 A, 18 B is rotationally mounted.
The operation of the present invention may thus be understood. As a result of the mechanical arrangement described above, the auger assembly 18 , the strike-off plate 20 , the bracket arms 32 , the support member 26 , and the crank arms 28 are rigidly affixed with respect to one another for pivoting movement as a unit relative to the pivot axis P defined by the two brackets 30 . With the piston-and-cylinder assembly 34 fully extended, the auger assembly and the strike-off plate unit 20 is pivoted downwardly in its normal operational disposition wherein the auger assembly 18 and the strike-off plate 20 face forwardly from the paving apparatus 10 in relatively close adjacency to the ground surface on which the paving apparatus 10 is supported, so as to operate in the normal manner already described above to distribute, compact and preliminarily level concrete material deposited in front of the paving apparatus 10 as it advances, as illustrated in FIG. 1 . However, upon full retraction of the piston-and-cylinder assembly 34 , the unit of the auger assembly 18 and the strike-off plate 20 is pivoted approximately 90 degrees upwardly and then rearwardly to dispose the auger assembly 18 and the strike-off plate 20 at a substantial elevated spacing from the ground surface and thereby exposing the vibratory devices 22 and the screed 24 to ready access by workers, as illustrated in FIG. 2 .
Thus, with the auger assembly 18 and the strike-off plate 20 in the inoperative disposition of FIG. 2, the ability of workers to quickly and easily deposit a start-up supply of concrete, or other paving material, beneath and forward of the screed 24 behind the normal operating disposition of the auger assembly 18 and the strike-off plate 20 is greatly facilitated and simplified. Preparation of the paving apparatus 10 for beginning a new paving operation, whether at a new paving location or continuing from the terminal point of an ongoing paving operation can be accomplished with less labor and in a shorter period of time and, hence, more efficiently and less expensively than with conventional paving apparatus. Once the appropriate start-up supply of concrete has been deposited beneath the paving apparatus 10 , the auger assembly 18 and the strike-off plate 20 are pivoted downwardly as a unit into their normal operative disposition via extension of the piston-and-cylinder assembly 34 to begin the paving operation. An additional benefit of the present invention is that the overall width of the paving apparatus is reduced with the auger assembly 18 and the strike-off plate 20 pivoted upwardly into the inoperative position, which achieves a narrower configuration to better facilitate over-the-road transport of the apparatus.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | In a slip-form paving apparatus, a forwardly disposed pavement forming assembly, such as an auger assembly and a strike-off plate, are pivotably mounted to the apparatus frame for movement between an operative disposition disposed adjacent a ground surface for distributing and forming paving material thereon generally into a desired form of pavement and an inoperative position more elevated from the ground surface for permitting access beneath the apparatus for depositing a starting quantity of the paving material during an initial start-up of the apparatus. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional application 61/022,981 filed Jan. 23, 2008. The contents of this document are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a method for regulating expression of at least one virulence gene of Agrobacteria . In particular, this invention relates to the stimulation of embryonic cereal cells for the production of phenolic and/or other compounds. In addition, this invention relates to the use of the secreted phenolic and/or other compounds for activation of the vir-operon of Agrobacteria resulting in transformation of the embryonic cereal cells.
[0003] Agrobacterium tumefaciens has been extensively exploited as an important gene delivery tool for most of the families of higher plants. Under laboratory conditions, it has been shown that the host range of Agrobacterium can be extended to include virtually any living cell, for example, other prokaryotes like Streptomyces lividans , yeast, fungi and cultured human cells.
[0004] Agrobacterium achieves the transformation of its hosts by transferring a well defined segment of DNA (called transfer DNA (T-DNA)) from its tumour inducing (Ti) plasmid to host cells. The transfer process requires a number of components: chromosomal and Ti plasmid-encoded gene products. Virulence (vir) genes are contained within the Ti (tumour inducing) plasmid and encode proteins required for processing and transfer of T-DNA.
[0005] With respect to plant transformation, the vir region of the Ti-plasmid is activated by a two component system, Vir A/Vir G and a galactose binding protein ChvE in response to phenolic compounds and sugars exuded from wounded plant cells. In a manner similar to bacterial two-component systems, Vir A, a periplasmic membrane-spanning protein, senses the phenolic compound(s)/simple monosaccharide stimuli and autophosphorylates at its histidine residue in the cytoplasmic C-terminus. The Vir G protein is considered to act as a signal-response regulator, because after receiving a phosphate (through transphosphorylation) from the Vir A phospho-histidine (Vir A sensor kinase), it activates transcription of the vir genes by binding to the vir boxes in the promoters of vir genes and activates their gene expression. This enables the processing and transport of the T-DNA through a T-pilus-associated type IV secretion system (T4SS) from Agrobacterium into the plant nuclear genome where the T-DNA is integrated into chromosomal DNA, thus completing the transfer of any transgenes that might have been cloned within the T-DNA boarders of Agrobacterium tumefaciens.
[0006] Acetosyringone, a plant cell wound product, is one of the major plant phenolic inducers of the two-component Vir A/Vir G system in Agrobacterium tumefaciens . Other secreted plant diffusible factors which induce T-DNA circularization and vir gene expression have been identified and include small (<100 Da) diffusible plant metabolites produced by actively metabolizing plant cells, catecol, sugars and amino acids. Many of these factors are produced both in monocotyledonous and dicotyledonous plants, and this partially explains why some monocotyledonous plants are susceptible to Agrobacterium tumefaciens . There is, however, a distinction between the ability of these factors to act as chemo-attractants to Agrobacterium (a phenomenon that brings the bacterium within close proximity to susceptible host cells) and the ability to induce vir gene expression, which is required for T-DNA transfer. Chemo-attraction is very sensitive and occurs at low molar concentrations of the diffusible products, whereas higher concentrations (as occurs in the proximity of secreting cells) of the products are required to induce vir gene expression. This perhaps explains why many monocotyledonous plants have been regarded as recalcitrant to Agrobacterium tumefaciens -mediated transformation, and often require supplementation with synthetic acetosyringone when Agrobacterium is employed as a preferred vehicle for transformation. In rice, for example, supplementation with acetosyringone is required and contributes to higher T-DNA transfer if used at the early initial stages of bacterial infection and also during co-cultivation. For wheat, higher amounts of acetosyringone (200 μM instead of the usual 100 μM) lead to higher levels of T-DNA transfer and transformation efficiency. Studies with barley revealed that the effects of acetosyringone on transformation efficiency are dependent on the plant species concerned. In the case of barley, acetosyringone concentrations in the range between 200-1000 mg/l (higher than for rice) can be used effectively. There are a few exceptions within monocotyledonous plants, depending on the target explant tissue used for transformation, where the addition of acetosyringone may not be effective. In lillies (ornamental monocotyledonous plants), for example, the addition of acetosyringone does not have any effect on transformation efficiency. Generally, it is well documented that wounded dicotyledonous plant tissues produce phenolic compounds such as acetosyringone (4-acetyl-2,6-dimethoxyphenol), and that monocotyledonous plants may fall into two categories: those that do not produce phenolic compounds and those which may produce acetosyringone despite the levels being so low as not to affect vir gene induction.
[0007] In certain instances, acetosyringone alone may not efficiently induce vir genes in Agrobacterium tumefaciens . It has been shown that when the concentration of acetosyringone is limited (as occurs in some monocotyledonous plants), a group of aldoses (for example: L-arabinose, D-xylose, D-glucose, D-mannose, D-idose, D-galactose and D-talose) can effectively enhance acetosyringone-dependent expression of vir genes. This suggests that other factors, sugars in this particular case, directly enhance a signaling process initiated by phenolic inducers to result in an increase in the expression of vir genes of Agrobacterium . The protein ChvE, which binds glucose-galactose and interacts with the vir A protein, was specifically identified and implicated in broadening the phenolic recognition profiles of Agrobacterium vir A protein and hence vir gene expression, especially when it was available at high levels. Other enhancers of vir gene expression include phosphate starvation and acidic culture medium. When acetosyringone alone is used to induce vir gene expression, Agrobacterium transformation efficiency for sorghum is very low, even when the current best protocols are used (Zhao et al., 2000. Plant Mol. Biol. 44: 789-798).
[0008] U.S. Pat. No. 5,641,644 teaches a method for reproducibly and efficiently transforming the genome of a monocotyledonous plant, and in particular a gramineous plant such as a cereal. This disclosure concentrates on the use of compact embryogenic callus or intact tissue capable of forming compact embryogenic callus. Transformation by this method is, however, limited to electroporation and is silent regarding Agrobacterium -mediated transformation. Furthermore, no mention is made regarding the use of endogenous compounds to facilitate and enhance transformation.
[0009] The methodology taught in U.S. Pat. No. 5,641,644 was subsequently extended to cereal crops in general (U.S. Pat. No. 5,712,135), and specifically to rice (U.S. Pat. No. 6,002,070).
[0010] The applicants have therefore identified a need to increase the Agrobacterium -mediated transformation efficiency of cereals, especially sorghum.
SUMMARY OF THE INVENTION
[0011] According to a first embodiment of the invention, there is provided a method for regulating expression of at least one virulence gene of Agrobacterium , the method comprising the steps of:
[0012] stimulating cereal cells to produce at least one active compound; and
[0013] contacting or exposing the Agrobacterium to the active compound(s).
[0000] The Agrobacterium is typically Agrobacterium tumefaciens.
[0014] The expression of the virulence gene, for example the virA and/or virG gene, is preferably up-regulated so as to induce and/or enhance transformation of cereal cells exposed to the Agrobacterium and active compound(s).
[0015] The active compound produced by the stimulated cereal cells may be phenolic compound(s).
[0016] The cereal cells which are stimulated to produce the active compound(s) may be sorghum cells.
[0017] The cereal cells which are transformed may be sorghum cells, or alternatively may be non-sorghum cells such as maize, wheat, barley, millet and/or rice.
[0018] The method may be performed without the addition of exogenous acetosyringone, sinapinic acid, syringic acid, vanillin, ferulic acid, 3,4 dihydroxy-benzoic acid, catechol, p-hydroxy-benzoic acid, vanyllyl alcohol, 3,4 dihydroxy-benzalhyde, vanillic acid and isovanillic acid.
[0019] Alternatively, the method may be performed in the presence of at least one of exogenous acetosyringone, sinapinic acid, syringic acid, vanillin, ferulic acid, 3,4 dihydroxy-benzoic acid, catechol, p-hydroxy-benzoic acid, vanyllyl alcohol, 3,4 dihydroxy-benzalhyde, vanillic acid and isovanillic acid; and/or at least one exogenous aldose such as L-arabinose, D-xylose, D-glucose, D-mannose, D-idose, D-galactose and/or D-talose.
[0020] The cereal cells may be mature or immature embryonic cells.
[0021] The cereal cells may be stimulated to produce the active compound by wounding, centrifuging, sonicating, heat shocking, vortexing and/or chemically wounding the cells.
[0022] According to a second embodiment of the invention, there is provided an Agrobacterium -mediated method for transforming plant cereal cells, the method comprising the steps of:
[0023] stimulating cereal cells to produce at least one active compound; and
[0024] exposing the Agrobacterium to the cereal cells and the active compound(s) produced by the cereal cells, such that the active compound induces expression of at least one virulence gene of the Agrobacterium and effects T-DNA transfer from the Agrobacterium to the cereal cells, thereby transforming the cereal cells.
[0025] The cereal cells which are stimulated to produce the active compound(s) may be sorghum cells. Non-sorghum cereal cells (such as maize, wheat, barley, millet and rice) may also be exposed to the Agrobacterium and active compound(s) produced by the sorghum cells and thereby also transformed.
[0026] The method may be substantially as described above.
[0027] According to a third embodiment of the invention, there is provided the use of at least one active compound, which has previously been identified by stimulating sorghum cells, in an Agrobacterium -mediated method for transforming plant cereal cells, the method comprising the step of exposing the Agrobacterium to the cereal cells and the active compound(s), such that the active compound induces expression of at least one virulence gene of the Agrobacterium and effects T-DNA transfer from the Agrobacterium to the cereal cells, thereby transforming the cereal cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 : Schematic diagram of the plasmid PHP15303 used for Agrobacterium transformation. This plasmid contains the visual marker, gfp gene driven by the maize Ubiquitin promoter and the selectable marker, bar gene driven by the 35S promoter. UBI1ZMPRO=Maize Ubiquitin promoter; UBI1ZMINTRON=maize ubiquitin 1 intron; GFPM-EXON1 & 2=exon 1 or 2 for green fluorescence gene; PINII TERM=pin II terminator sequence; CAMV35S ENH=Cauliflower mosaic virus 35 S enhancer sequence; CAMV35S PROM=Cauliflower mosaic virus 35 S promoter; ADH1 INTRON1=Alcohol dehydrogenase intron 1 sequence; BAR=selectable marker bar gene for phosphinothricin (PPT) resistance. RB=right boarder sequence for Agrobacterium tumefaciens ; LB=left boarder sequence for Agrobacterium tumefaciens.
[0029] FIG. 2 : Effect of including or excluding synthetic acetosyringone on phenolic compound production by sorghum (P898012) and maize (GS3) immature embryos after 2-3 days of culture. “AS” or “NO-AS” indicates infection and co-cultivation in the presence or absence of acetosyringone respectively. “NOT INF.” Indicates embryos that have not been infected and are used as internal controls. P898012 and GS3 embryos in (B-C) and in (E-F) were isolated into the same tube, infected together and then only plated separately for co-cultivation.
[0030] FIG. 3 : Phenolic compound production in P898012 sorghum immature embryos infected with Agrobacterium vector PHP15303. (A). No acetosyringone was used in infection medium 700 and co-cultivation medium 710 B. (B). 100 μM acetosyringone was used in infection medium 700 and in co-cultivation medium 710 B. (C). 2000 μM of acetosyringone was used in infection medium 700 and 100 μM acetosyringone in 710 B. Time (hours) since infection is recorded on the left of the photographs.
[0031] FIG. 4 : Stable transformed sorghum calli were obtained following omission or inclusion of the synthetic acetosyringone. This is proof that sorghum phenolic compounds are capable of effecting permanent T-DNA transfer. White sectors and spots indicate stable GFP expression.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Disclosed is a method for regulating the expression of at least one virulence gene of the vir operon of Agrobacterium sp., in particular, the activation of the vir-operon of Agrobacterium tumefaciens and T-DNA transfer for the purpose of genetic transformation in plants.
[0033] Briefly, the present invention relates to a novel method for the activation of the vir-operon of Agrobacterium sp. The method comprises stimulating embryonic cereal cells to produce phenolic compounds and contacting the embryogenic cells with Agrobacterium sp.
[0034] The applicants have shown that sorghum cells can be stimulated to produce phenolic compounds or factors, such as by wounding immature embryos of sorghum. These phenolic compounds or factors were shown to influence T-DNA transfer, not only in sorghum, but also in other cereals such as maize (corn), as described below. The endogenous phenolic compounds or factors produced by the sorghum cells can be used to substitute for the exogenous phenolic compound, acetosyringone, which is usually added to the infection and co-cultivation medium used for Agrobacterium -mediated transformation of plants. Thus, it may not be necessary to add acetosyringone to the transformation medium. Alternatively, the phenolic compounds produced by the sorghum cells could be used in combination with exogenous acetosyringone to enhance the effect of the exogenous acetosyringone. The term “endogenous” is used herein to indicate that the compounds or factors are produced by the plant cells rather than being added to the transformation medium by an external source, whereas the term “exogenous” is intended to indicate that a compound is obtained from an external source and added to the transformation medium, rather than being produced by the plant cells.
[0035] Compared to the exogenous acetosyringone which is usually added to the transformation medium, the endogenous phenolic compounds or factors produced according to the method of the invention confer a T-DNA transfer frequency of about 15% higher than the exogenous acetosyringone at the transient level. Stably transformed callus and plants obtained in the absence of exogenous acetosyringone in the infection and co-cultivation medium indicated that endogenous phenolic compounds engendered permanent transmission of T-DNA into chromosomal/genomic DNA of plants. A broad application of this method of transformation and materials would be to use phenolic compounds or factors thus identified to broaden the scope for significantly improving the efficiency of Agrobacterium -mediated transformation, not only in sorghum, but in many other cereal crops, such as corn, wheat, barley and rice.
[0036] Materials, factors and methods for inducing vir operon (and hence vir gene) expression in Agrobacterium tumefaciens are described herein. The applicants have shown that phenolic compounds or factors exuded by cultured immature sorghum embryos are potent inducers of vir gene expression during the infection and co-cultivation phases when Agrobacterium is used to transform immature embryos of sorghum. This involved infecting sorghum immature embryos and co-cultivating them in the absence of the exogenous phenolic compound acetosyringone. Further, the applicants have shown that phenolic compounds and/or factors produced by wounded cultured embryos of sorghum can be used to induce and enhance vir gene expression, and effect efficient transient and stable T-DNA transfer in maize.
[0037] From these results, it is possible that phenolic compounds produced by wounded immature embryos of sorghum can be efficiently employed and used to enhance or substitute for acetosyringone or other transformation-inducing compounds when Agrobacterium is used for transforming other cereal crops such as corn, rice, wheat and barley. The current repertoire of known phenolic compounds which can be used to induce Agrobacterium transformation, albeit to different levels of efficiency, includes but is not limited to: acetosyringone, sinapinic acid, syringic acid, vanillin, ferulic acid, 3,4 dihydroxy-benzoic acid, catechol, p-hydroxy-benzoic acid, vanyllyl alcohol, 3,4 dihydroxy-benzalhyde, vanillic acid and isovanillic acid.
[0038] The method and compounds or factors described in the present invention are unique in that virulence-inducing acetophenones, such as acetosyringone, are thought to be restricted to families in, or close to Solanaceae, or that if present in monocotolydenous plants, they are produced to such low levels as not to have significant influence on transformation efficiency (Roy, et. al., 2000. Curr. Scie. 79: 954-960). This is the first time that compounds derived from sorghum have been used to substitute for, or to enhance, Agrobacterium vir gene expression and T-DNA transfer in crops or plants, as exemplified by sorghum and maize in the present disclosure.
[0039] The invention will now be described in more detail by way of the following non-limiting examples.
EXAMPLES
Plant Materials and Media Compositions
[0040] The sorghum public line, P898012 (originally supplied to Pioneer Hi-Bred International-USA by Dr. John Axtell, Purdue University; see Zhao et al., 2000) and the maize genotype denoted GS3 (developed by Pioneer Hi-Bred International-USA) were used for the isolation of immature zygotic embryos at 9-14 days after pollination. The two genotypes were grown in Pioneer greenhouses primarily as described in Zhao et al., 2000. Sterilization of sorghum panicles and corn ears was carried out with 50% Chlorox Bleech (3.075% (v/v) sodium hypochlorite) and 0.1% (v/v) Tween 20 for 20 minutes and then rinsed three times with sterile distilled water. This sterilization procedure was repeated with 10% Chlorox bleech (0.615% (v/v) sodium hypochlorite). Immature zygotic embryos ranging in size from 0.8 mm-1.8 mm were isolated and treated as indicated in the transformation procedures outlined below. The compositions of various media used in this study are outlined in Table 1.
[0000]
TABLE 1
Media compositions
Media and usage
Composition
700:
The following components were dissolved sequentially in
liquid media used
950 ml polished de-ionized water: 4.3 g MS basal salt
for
mixture; 0.1 g Myo-Inositol (10 000X); 0.5 ml Nicotinic
Agrobacterium
acid (1 mg/ml stock); 0.5 ml Pyridoxine (1 mg/ml stock);
infection of
2.5 ml Thiamine HCl. (4 mg/ml); 1 g Vitamin Casamino
immature
acids; 68.5 g Sucrose; 36 g glucose
embryos (GS3,
PH adjusted to 5.2 with 1M KOH.
P898012)
Final volume adjusted to 1 L with polished de-ionized
water
The media filter sterilized through a 0.22 μm filter and
aliquoted into 12 ml volumes and stored at 4° C.
Quality control tests carried out by streaking a few
microlitres of the media onto microbial plates to check for
contamination over 3 days.
710B:
The following components were dissolved sequentially in
Co-cultivation
950 ml polished de-ionized water: 4.3 g MS basal salt
medium
mixture; 0.1 g Myo-Inositol; 0.5 ml Nicotinic acid (1 mg/ml
stock); 0.5 ml Pyridoxine (1 mg/ml stock); 2.5 ml Thiamine
HCl. (4 mg/ml); 4 ml 2,4-D (0.5 mg/l stock); 20 g Sucrose;
10 g glucose; 0.7 g L-proline; 0.5 g MES buffer.
PH adjusted to 5.8 with 1M KOH.
Final volume adjusted to 1 L with polished de-ionized
water
4 g Sigma agar added
Autoclaved and cooled to 45-55° C.
Add 1 ml (100 mM stock) filter sterilized acetosyringone
Add 1 ml (10 mg/ml) Ascobic acid
Mix and pour plates
Quality control tests carried out by streaking a few
microlitres of the media onto microbial plates and
incubating at 28° C. to check for contamination over 3 days.
720J:
The following components were dissolved sequentially in
First two weeks
950 ml polished de-ionized water: 4.3 g MS basal salt
PPT selection (for
mixture; 0.5 ml Nicotinic acid (1 mg/ml stock); 0.5 ml
transformations
Pyridoxine (1 mg/ml stock); 2.5 ml Thiamine HCl.
carried out with
(4 mg/ml); 0.1 g Myo-Inositol; 3 ml 2,4-D (0.5 mg/l stock);
the bar gene)
20 g Sucrose; 0.7 g L-proline; 0.5 g MES buffer.
PH adjusted to 5.8 with 1M KOH.
Final volume adjusted to 1 L with polished de-ionized
water
4 g Sigma agar added
Autoclaved and cooled to 60° C.
1 ml added of Ascobic acid (10 mg/ml)
2 ml Agribio carbenicillin (50 mg/ml) added
5 ml PPT (10 mg/ml Glufosinate -NH 4 )
Mix and pour plates
Quality control carried out by streaking a few microlitres
of the media onto microbial plates and incubating at 28° C.
to check for contamination over 3 days.
720K
Essentially similar to 720J except that 10 ml PPT (10 mg/ml
Glufosinate -NH 4 ) was used instead of 5 mg/l PPT
289J
The following components were dissolved sequentially in
950 ml polished de-ionized water: 4.3 g MS basal salt
mixture; 1.0 g Myo-Inositol; 5 ml of MS Vitamin stock
solution; 1 ml zeatin (of stock 0.5 mg/ml); 0.7 g L-Proline;
60 g sucrose;
PH adjusted to 5.6 with 1M KOH.
Final volume adjusted to 1 L with polished de-ionized
water
4 g Sigma agar added
Autoclaved and cooled to 60° C.
After autoclaving add; 2.0 ml of IAA (0.5 mg/ml stock);
1.0 ml ABD (0.1 mM stock); 0.1 ml of Thidiazuron
(1.0 mg/ml stock); 2.0 ml carbenicillin (50 mg/ml stock);
5.0 ml PPT (1.0 mg/ml stock of Glufosinate-NH4).
Mix and pour plates
Quality control carried out by streaking a few microlitres
of the media onto microbial plates and incubating at 28° C.
to check for contamination over 3 days.
Transformation Procedures and Identification of Putative Positive Transformants
[0041]
Agrobacterium tumefaciens
[0042] Transformation was carried out in 6 distinctive but sequential phases. The medium used at each phase is given in Table 1 above.
1. Freshly isolated embryos of P898012 or GS3 were mixed together or separated into 1.5 mL of medium 700 either lacking or containing 100 mM or 200 mM acetosyringone. The concentration of A. tumefaciens harbouring the vector PHP15303 ( FIG. 5 ) in the suspension was adjusted to 0.857×10 9 cfu/mL [Optical Density (OD) approximately 0.6 at 550 nm]. The infection suspension was vortexed gently for 15 seconds, poured into 1 cm-diameter microplates and vacuumed for 5 minutes with gentle rocking for mixing. 2. The Agrobacterium suspension was then aspirated and the embryos plated on co-cultivation medium 710 B either lacking or containing 100 mM and 200 mM acetosyringone for 3 days (co-cultivation) and cultured in the dark at 25° C. 3. After the 3-day co-cultivation, the embryos were transferred onto resting medium 710 B containing 100 mg/mL carbenicillin, an antibiotic to kill off the Agrobacterium . This medium did not contain acetosyringone. The embryos were cultured in the dark for 4 days at 28° C. during this phase. 4. The embryos were then transferred onto medium 720 J for two weeks in the dark at 28° C. 5. The proliferating embryos were then subjected to a second phase of selection on medium 720 K until putative transgenic callus units averaging about 1 cm in diameter were observed. 6. Putative transgenic calli were regenerated on medium 289 J.
[0049] The transformation process is summarised below:
[0000]
[0050] Imaging for green fluorescent protein (GFP) expression (contained as a visual marker within vector PHP15303 ( FIG. 1 ) to enable confirmation of integration of the gene of interest into the genome of the host and expression of the gene in the host cell) was carried out starting at two days post infection until stable integration was achieved (normally over 30 days post infection). Fresh subcultures were conducted at 1-2 week intervals depending on the amount of observable phenolic compounds or other compounds on the medium. Putative transgenic calli from one embryo were kept separate and tentatively treated as one event until proven through analysis (PCR and Southern blot analysis) to contain more than one event.
[0051] Transformation of GS3 maize embryos was carried out in a similar manner to sorghum and cultured on medium identical to that for sorghum for the period of the experiment. In cases where sorghum and maize embryos were infected together the procedure followed was to isolate embryos of both crops into the same tube, infect them together and either plate/spread the maize embryos and sorghum embryos separately on different plates during the co-cultivation phase, or alternatively the two types of embryos were plated adjacent and touching each other on the same plate. These groups of embryos were only separated after two days post infection or at the end of the co-cultivation period (3 days post infection). Before assaying for GFP expression sorghum embryos were separated from maize embryos.
[0052] Cultured immature zygotic embryos of the sorghum genotype P898012 produce phenolic compounds which can be visually identified as black/dark brown exudates within the proximity of the embryos on tissue culture medium ( FIG. 2 (I) and FIG. 1 (J)). When these immature embryos are infected with A. tumefaciens , higher quantities of these phenolic compounds are produced, especially when the medium on which the embryos are cultured is not supplemented with the synthetic acetosyringone (contrast FIGS. 2 (A & B) vs. FIGS. 2 (D & E)).
[0053] Immature zygotic embryos of the GS3 maize genotype used in this research do not produce visible phenolic compounds in tissue culture, whether they have been infected with Agrobacterium or not ( FIG. 2 (C, F, G, H, K, L)).
[0054] The use of synthetic acetosyringone depresses the production of phenolic compounds in infected and cultured immature zygotic embryos of sorghum ( FIG. 3 ). In the absence of synthetic acetosyringone, the onset of heavy phenolic compound production or other compound production is as early as 48 hours post infection (compare FIG. 3 (panel A) vs. FIG. 3 (panel B and C)).
[0055] Phenolic compounds or other compounds produced by infected immature zygotic embryos of sorghum positively influence T-DNA transfer during the infection phase of A. tumefactions . Furthermore, the effect of these sorghum phenolic compounds or other compounds is additive to that of acetosyringone in promoting T-DNA transfer particularly in maize. The fact that T-DNA transfer was achieved in the absence of synthetic acetosyringone is proof that sorghum phenolic compounds or other compounds are capable of activating the vir genes of Agrobacterium and are a sufficient signal for the processing and transfer of T-DNA. The T-DNA transfer induced by sorghum phenolic compounds or other compounds is equivalent in intensity to that effected by the exogenous acetosyringone.
[0056] Sorghum phenolic compounds are capable of effecting permanent T-DNA transfer and hence stable foreign DNA integration ( FIG. 4 ). In order for T-DNA transfer to occur, there must be a transducer and activator of the vir genes of Agrobacterium in the manner of the two-component system involving virA/virG. These results indicate that sorghum phenolic compounds or other compounds can be used as potent signals for the transcriptional activation of the vir genes of Agrobacterium . This effectively means that these phenolic compounds or other compounds can be used to extend the current repertoire of compounds that can be used across many different crop species to improve the process of Agrobacterium -mediated transformation.
[0057] It was also shown that the effect of sorghum phenolic compounds or other compounds is synergistic to the synthetic acetosyringone ( FIG. 3 (C)).
[0058] The results obtained in this research indicate that it is possible that phenolic compounds or other compounds produced by wounded immature embryos of sorghum can be efficiently employed to enhance or substitute for acetosyringone or other transformation-inducing compounds when Agrobacterium is used for transforming cereals such as sorghum, corn, rice, wheat and barley.
REFERENCES
[0059] The following references are included herein by reference:
Roy, M. Jain, R. K., Rohila, J. S. and Wu. R. 2000. Production of agronomically superior transgenic rice plants using agrobacterium transformation methods: present status and future perspectives. Curr. Scie. 79 (9): 954-960. Shimoda, N., Akiko, T-Y., Nagamine, J., Usami, S. Katayama, M., Sakagami, Y. and Machida, Y. 1990. Control of expression of Agrobacterium vir genes by synergistic actions of phenolic signal molecules and monosaccharides. PNAS 87: 6684-6688. Spencer, P. A. and Towers, G. H. N. 1991. Restricted occurrence of acetophenone signal compounds. Phytochem. 27: 2781-2785. Zhao, Z. Y., Cai, T., Tagliani, L., Miller, M., Wang, N., Pang, H., Rudert, M., Schroeder, S., Hondred, D., Seltzer, J. and Pierce, D. 2000. Agrobacterium -mediated sorghum transformation. Plant Mol. Biol. 44: 789-798. Zhu, J., Oger, P. M., Schrammeijer, Hooykaas, P. J. J, Farrand, S. and Winans, S. C. 2000. The bases of crown gall tumorigenesis. J. Bacteriol. 182: 3885-3895. | A method for regulating expression of a virulence gene of Agrobacterium is described. The method comprises the steps of stimulating cereal cells, such as sorghum, so as to produce an active, typically phenolic, compound and exposing the Agrobacterium to this compound. The compound induces expression of the virulence gene of the Agrobacterium , effecting T-DNA transfer from the Agrobacterium to the cereal cells, which are thereby transformed. | 2 |
[0001] This application is a continuation patent application of U.S. patent application Ser. No. 12/526,194 filed Aug. 6, 2009 which is the national stage of international patent application no. PCT/GB2008/000393 filed on Feb. 26, 2008, which in turn claims priority from British Patent Application Ser. No. 0702401.1 filed on Feb. 8, 2007, the disclosures of each of which are incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The invention relates to a novel human stem cell and in particular an articular cartilage stem cell; a population of cells derived therefrom; a method for the production of said stem cell and said population of stem cells; the use of said stem cell and population of cells in tissue repair, and particularly connective tissue repair and more specifically joint repair; and an implant comprising or including said stem cell or said population of cells.
BACKGROUND OF THE INVENTION
[0003] Articular cartilage is avascular, aneural and contains no lymphatic vessels with a low level of metabolic activity compared with that of other connective tissues such as muscle but can be considered active for a cell that relies largely on glycolysis for energy. It also has an extensive extracellular matrix, which it relies upon to provide cartilage with its characteristic properties of low friction pain-free articulation. The two main constituents of articular cartilage are the highly specialised chondrocyte, which is unique to cartilage and the matrix, composed of a complex, interconnecting arrangement of proteoglycans, collagens and non-collagenous proteins (Buckwalter and Hunziker, 1999).
[0004] Articular cartilage can be divided into four main zones through its depth. These are the superficial; transitional; upper and lower radial; and calcified cartilage zones running from the outer articular surface to the deep subchondral bone, respectively. Although named zones are present, there are no ‘actual’ boundaries, which can be visualised between the zones. In each zone there are biomechanical and morphological variations (Dowthwaite et al, 2004), which include differences in cell morphology (size and shape), cell packing, metabolic activity and the thickness of the layers. Differences in matrix composition also exist between zones, with variations in the types and quantities of various collagens, proteoglycans, and non-collagenous proteins.
[0005] At most, articular cartilage is only a few millimetres thick, but it can reach up to 7 mm in large joints such as the hip. In spite of being only a few millimetres thick, it still manages to provide resistance to compression and displays the ability to distribute loads, thus in turn, reducing high stresses placed upon subchondral bone (Buckwalter and Hunziker, 1999).
Chondrocytes
[0006] Normal articular cartilage contains one cell type, the highly specialised chondrocyte surrounded by extracellular matrix (Buckwalter, 1998). In the majority of cases, the chondrocyte is “cytoplasmically isolated” (Archer and Francis-West, 2003) from its adjacent cells, seldom forming cell-cell contacts except in the most superficial part of the tissue. Each chondrocyte, therefore, is completely surrounded by matrix with which it freely interacts. Chondrocytes differ in their morphology and metabolic activities between the zones of articular cartilage. Generally the chondrocyte has a rounded or polygonal morphology, except at tissue boundaries where it may appear flattened or discoid, i.e. at the articular surface of joints (Archer and Francis-West, 2003). The principal role of the chondrocyte is in the maintenance of the intricate extracellular matrix of cartilage in particular the soluble, hydrophilic structures such as hyaluronan and aggrecan (Knudson, 2003). Intracellularly, the chondrocyte contains organelles that are typical of that of a metabolically active cell (Archer and Francis-West, 2003) that play a pivotal role in matrix synthesis, continually working to synthesise and turnover a large matrix to volume ratio, primarily composed of proteoglycans, glycosaminoglycans and collagens (Buckwalter and Hunziker, 1999). Some chondrocytes also contain short processes or microvilli, which can detect mechanical alterations in the matrix. This is achieved as they extend from the cell directly into the matrix. Intracytoplastic filaments, lipid, glycogen and secretory vesicles enable chondrocytes to interact with the matrix. Mature chondrocytes are easily distinguished from other cells as they have a spheroidal morphology. They also have abundant amounts of type II collagen, large aggregating proteoglycans and specific non-collagenous proteins interwoven within a meshwork, which forms a cartilaginous matrix that covers and binds to their cell membranes (Buckwalter and Hunziker, 1999).
Zones
[0007] Superficial zone
[0008] The superficial zone ( FIG. 2 ) is extremely thin and consists of two layers. The most superficial layer is acellular and consists of a thin, clear film of amorphous material known as the lamina splendens which overlies a sheet of fine, densely packed collagen type II microfibrils (Buckwalter and Hunziker, 1999) and comprises largely lubricin. The deeper cellular layer is composed of flattened, discoid chondrocytes enclosed within a collagen-rich matrix, which lie parallel to the articular surface (Dowthwaite et al, 2003). These cells synthesise matrix, which is abundant in collagen, fibronectin and water, and low in proteoglycans content compared to that of the deeper zones.
[0009] The dense layer of collagen fibrils have an orientation parallel to that of the surface and provide cartilage with its characteristic mechanical properties which include having high tensile strength and being able to resist shear force put upon it (Buckwalter and Hunziker, 1999). The meshwork of collagen fibrils also permits the movement of molecules into and out of cartilage such as antibodies and large cartilage molecules respectively.
[0010] Various studies have shown that the surface zone of articular cartilage is involved in the regulation of tissue development and growth. Developmental studies in our laboratory have identified that articular cartilage grows by appositional growth from the articular surface (Hayes et al 2001) and that this method of growth allows for the distinct zonal architecture of this heterogeneous tissue to be established. These studies also showed that growth is driven by a slowly dividing population of chondrocytes in the surface zone of articular cartilage and a more rapidly dividing population of cells in the transitional zone (Hayes et al 2001). Not only do these observations account for the appositional nature of articular cartilage growth and zonal variation, they also suggest the presence of a specific articular chondrocyte progenitor cell population in the surface zone and a population of transit amplifying cells in the transitional zone. Further, the surface zone has been found to be a signalling centre due to the expression of various growth factors and their receptors, which play a pivotal role in the morphogenesis of the diarthrodial joint via differential matrix synthesis (Dowthwaite et al, 2003). The surface zone has also been shown in vivo to be responsible for the appositional growth of articular cartilage (Hayes et al, 2001) and recent in vitro studies have shown that the surface zone of articular cartilage contains a progenitor cell population (Dowthwaite et al, 2004).
[0011] Additionally, US published patent application 2006/0239980 teaches that articular cartilage obtained from the surface zone of human cartilage tissue can be enzymatically digested to produce a population of chondrocytes which, through culturing, can be dedifferentiated into chondroprogenitor tissue. However, there is no data in this document concerning the phenotypic stability of this tissue and there is no assertion or indication that the tissue represents isolated stem cells and therefore the use of this dedifferentiated tissue as a reliable source of material for tissue repair is questionable.
[0012] In the past we have identified a population of chondroprogenitor cells within the surface zone of bovine articular cartilage (Dowthwaite et al 2004). This population was obtained by exploiting the differential adhesion of bovine chondrocytes to fibronectin. The chondroprogenitors, as well as being characterised by their increased adhesion to fibronectin, also had increased colony-forming efficiency. Further, this chondroprogenitor population exhibited plasticity in terms of its differentiation pathway when assayed in ovo. The bovine chondroprogenitor cells engrafted into various chick connective tissue lineages such as tendon and bone, in addition to cartilage, and the engrafted cells expressed characteristic tissue markers such as type I collagen and, further, orientated in a functional manner.
[0013] Recently, we have extended the afore studies and discovered, to our surprise, that it is possible to isolate a population of human stem cells, from the entire depth of human cartilage tissue. This goes against conventional wisdom which teaches that it is the superficial, or surface, zone of cartilage that is responsible for tissue growth and development.
[0014] Indeed, our experiments have shown that it is possible to isolate a population of human stem cells from the mid as well as the surface zone of cartilage tissue.
[0015] A further surprising aspect to our work is the fact that our stem cells were derived from aged human tissue. Aged human cartilage tends to be thinner than normal cartilage and is metabolically less active.
[0016] Moreover, we have discovered that our isolated human stem cells appear immortal in that they have now exceeded 80 population doublings and remain viable. This is in contrast to the above bovine chondroprogenitors that we previously isolated which were characterised by a population doubling of approximately 50 when a number of characteristics of telomerase-dependant senescence were evident. These facts indicate that our bovine chondroprogenitors were not stem cells.
[0017] In contrast, our stem cells show self-renewal; as evidenced by the continual population doublings. In order to put our current figure of 80 population doublings into context, one must bear in mind that the Hayflick figure for population doubling is 52. Leonard Hayflick, in 1965, observed that cells dividing in cell culture divide about 50 times before dying. Stem cells which have the ability to continually regenerate new cells survive the entire life span of the endogenous organism.
[0018] Furthermore, we have shown that our human stem cells can still produce cartilage when cultured in permissive pellet culture conditions after 70 population doublings.
[0019] It follows that our isolated human stem cells have the capacity to undergo massive expansion with a view to providing new connective tissue and, indeed, the amount of expansion is such that one can replace an entire piece or section of human tissue, such as, cartilage using this single stem cell resource.
[0020] Additionally, our novel stem cells exhibit phenotypic plasticity in that these cells can be functionally engrafted into various connective tissue types in order to produce different sorts of connective tissue.
[0021] The isolation of our novel tissue involves the exploitation of a unique tissue characteristic. That being the expression of a protein sequence which selectively binds with exceptionally high affinity to an RGD sequence in fibronectin. The RGD sequence in fibronectin comprises the amino acids Arginine, Glycine and Aspartic Acid. A number of cells have the ability to bind to this sequence if cultured for a sufficient length of time (typically hours). In contrast, our stem cells, even after fairly aggressive enzyme isolation, bind the sequence within minutes and, indeed, after 20 minutes, it is possible to isolate a colony comprising our human stem cells.
[0022] Finally, the differentiated tissue from this stem cell source expresses at least one structurally relevant protein, namely Type I collagen when engrafted into developing chick connective tissue.
[0023] Reference herein to the term stem cell includes reference to a cell that can continuously produce unaltered daughters and also has the ability to produce daughter cells that have different more restricted properties.
[0024] Reference herein to a progenitor cell includes reference to a dividing cell with the capacity to differentiate, and includes putative stem cells in which self-renewal has not yet been demonstrated.
[0025] As will be apparent to those skilled in the art, cartilage tissue has a limited capacity for self-repair. There are several limitations on the ability of cartilage to repair itself in terms of restoring a long-term functional diarthrodial joint. Chondral repair tissue has an intermediate structure and composition between hyaline cartilage and fibrocartilage, rarely, if ever replicating the actual structure of articular cartilage. There is disruption to the orientation and organisation of the collagen fibrils, failure to make important interactions between macromolecules, in particular the proteoglycans and the collagen fibrillar network, thus resulting in a decrease in stiffness and in the ability to resist compressive loads. A major factor contributing to the low reparative capacities of articular cartilage is that the tissue is avascular and aneural.
[0026] Treatments are being developed to try and overcome the problems that are faced when trying to treat articular cartilage defects. Potential treatments need to successfully integrate a tissue into a defect that has the same mechanical and structural properties as articular cartilage. Current cell based transplantation treatments involve the use of expanded autologous chondrocytes for transplantation into the defect to generate a repair tissue hopefully similar to that of the native articular cartilage. This cell based transplantation treatment is known as Autologous Chondrocyte Implantation (ACI) and was described by Brittberg et al (1994) for the treatment of full-thickness cartilage defects. The problem with this technique is that it involves the extraction of healthy articular cartilage from a non-injured, non-weight bearing region of the joint. Contemporary research is looking into the potential use of mesenchymal stem cells (MSCs) as a cell source for use in tissue engineering and their infiltration into biodegradable scaffolds. Bone marrow derived MSCs have been focused on extensively but many other tissue types are now being considered as MSC sources such as cartilage and synovium.
[0027] It follows that our stem cells have significant use in cartilage repair. However, our stem cells could be used for the repair of other forms of connective tissue such as ligament, skin or bone.
[0028] Further, although our stem cells are suited to autologous repair, particularly cartilage repair, these cells also could be used allogeneically since many other stem cells have been shown to be immunosuppressive.
BRIEF SUMMARY OF THE INVENTION
[0029] According to a first aspect of the invention there is provided a human stem cell isolated from aged human cartilage.
[0030] Reference herein to aged human cartilage includes reference to cartilage from an adult and most preferably either a mature adult or an adult whose cartilage tends to be thinner than normal cartilage and/or is metabolically less active.
[0031] According to a further aspect of the invention there is provided a homogenous population of human stem cells isolated from the full depth of cartilage tissue.
[0032] In a preferred embodiment of the invention said human stem cell is isolated from either the surface or mid zone of cartilage tissue or both.
[0033] Reference herein to the ‘full depth of cartilage tissue’ means the whole of the tissue depth from surface to base is used as a source for the stem cell.
[0034] According to a yet further aspect of the invention there is provided a homogenous population of human stem cells which are characterised by any one or more of the following traits:
[0035] 1. isolation from the full depth of human articular cartilage;
[0036] 2. isolation by high affinity adhesion to fibronectin or a fragment thereof containing the RGD sequence;
[0037] 3. a population doubling in excess of 52;
[0038] 4. the ability to differentiate into any connective tissue type;
[0039] 5. the expression of any one or more of the following stem cell markers: STRO1, MSX1 or notch 1;
[0040] 6. isolation from human aged cartilage.
[0041] According to a further aspect of the invention there is provided a homogenous human stem population as deposited at the National Institute for Biological Standards and Control (NIBSC) at Blanche Lane, South Mimms, Potters Bar, Hertfordshire EN6 3QG under Accession No. P-08-016.
[0042] According to a yet further aspect of the invention there is provided a population of human connective tissue cells derived from the aforementioned stem cell.
[0043] According to a further aspect of the invention there is provided the use of the aforementioned described stem cell in tissue repair.
[0044] According to a further aspect of the invention there is provided the use of a population of human connective tissue cells derived from the stem cell described herein in tissue repair.
[0045] According to a further aspect of the invention there is provided an implant for use in tissue repair comprising a stem cell, or a population of cells derived therefrom, as described herein.
[0046] According to a further aspect of the invention there is provided a method for isolating a human stem cell comprising:
[0047] a) obtaining human articular cartilage tissue from the full depth of the cartilage tissue;
[0048] b) digesting the tissue to release chondrocytes, by using enzymes;
[0049] c) exposing the isolated chondrocytes to fibronectin and/or a fragment thereof containing RGD sequence; and
[0050] d) isolating those cells that bind fibronectin or said fragment.
[0051] In a preferred method of the invention said released chondrocytes are cultured on fibronectin or a RGD sequence, such as a fragment of fibronectin containing same.
[0052] In a further preferred method of the invention said articular cartilage is digested with a combination of pronase and collagenase and more preferably the articular cartilage is exposed to 70 units/ml of pronase for 3 hours at 37° C. followed by exposure to 300 units/ml of collagenase for a longer period, typically overnight, at 37° C.
[0053] In yet a further aspect of the invention the digested chondrocytes are either filtered or centrifuged in order to isolate the chondrocytic tissue.
[0054] Where centrifugation takes place it is undertaken at 2000 rpm for 5 minutes.
[0055] Isolated chondrocytes, preferably, are then seeded into wells coated with fibronectin.
[0056] In a preferred method of the invention the articular cartilage tissue is aged tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] The invention will now be described with reference to the following figures wherein:
[0058] FIG. 1 shows a section through cartilage tissue
[0059] FIG. 2A shows the initial adhesion of human chondrocytes to fibronectin. It was noted that a cohort of chondrocytes adhered to fibronectin within 20 minutes compared to controls (p<0.05);
[0060] FIG. 2B shows chondrocytes that adhere to fibronectin within 20 minutes can form colonies consisting of more than 32 cells by 8 days and, further the number of colonies increases with time in culture compared with controls (p<0.05);
[0061] FIG. 2C shows clonally derived human stem cells or chondroprogenitors can be extensively sub-cultured and undergo more than 80 population doublings;
[0062] FIG. 3 shows views of clonal cells derived from differential adhesion to fibronectin and unselected cells from the same patient which were immunolabelled with antibodies to the cell surface signalling molecule Notch 1, the stem cell marker STRO1 and the transcription factor MSX1. In clonal cell lines, every cell labelled with antibody to Notch 1 and Stro 1 and the majority of cells labelled with antibody to MSX1. In contrast, monolayer cultures contained fewer cells labelled with antibodies to stem cell markers STRO1, Notch 1 and MSX1 ( FIG. 3A-C );
[0063] FIG. 4 shows that using an in ovo assay, clonally derived cartilage stem cells were shown to engraft into various chick tissues including, bone, tendon and cartilage and such engrafted stem cells were shown to synthesise a structurally relevant protein, namely human type I collagen ( FIG. 4 ); and
[0064] FIG. 5 shows wax sections of aged human tissue were labelled with antibody to the transcription factor MSX1 (N20, Santa Cruz Biotechnology; 5 ug ml −1 in PBS for 1 hour) and detected with anti-rabbit FITC conjugated secondary antibody (Sigma; 1:100 in PBS for 1 hour). MSX 1 positive cells were present in the surface and middle zones of the tissue suggesting that this is where the stem cells reside within the tissue. Arrows indicate positive intracellular labelling.
DETAILED DESCRIPTION OF THE INVENTION
Materials and Methods
[0065] 12 well plates were coated with 10 μg ml −1 plasma fibronectin (Sigma, UK) in PBS containing 1 mM MgCl 2 and 1 mM CaCl 2 (PBS+) overnight at 4° C. Dishes were blocked with 1% BSA (Sigma) in PBS+ before chondrocytes were added. Control dishes were treated with PBS+ overnight at 4° C.
[0066] Tissue was obtained from patients undergoing hemiarthrotomy with full institutional ethical approval. Full depth cartilage was removed from the grossly normal femoral condyle and incubated in 1:1 DMEM/F12 (Gibco) containing 10% FCS (Gibco) overnight. Chondrocytes were then isolated by sequential pronase (Roche)/collagenase (Sigma) digestion as previously described (Dowthwaite et al 2004). Briefly cartilage chips were incubated with pronase (70 units ml −1 in DMEM/F12 containing 5% FCS) for 3 hours at 37° C. Pronase was removed and cartilage incubated with collagenase (300 units ml −1 in DMEM/F12 containing 5% FCS) overnight at 37° C. Chondrocytes were centrifuged at 2000 rpm for 5 minutes, supernatant removed and resuspended in serum free DMEM/F12 and counted. After isolation, chondrocytes (1,000 ml −1 ) were seeded into individual wells of 12 well plates and incubated at 37° C. for 20 minutes in 1:1 DMEM/F12 containing 0.1% Gentamycin (DMEM/F12−). After 20 minutes, media (and non-adherent cells) was removed and placed in a second dish for 40 minutes at 37° C. before this media (and non-adherent cells) was removed and placed in a third dish. After removal of media at 20 and 40 minutes, fresh 1:1 DMEM/F12 containing 0.1% Gentamycin and 10% FCS (DMEM/F12+) was added to the remaining adherent cells which were maintained in culture for up to 17 days. Controls comprised cells subjected to differential adhesion on dishes coated with 1% BSA in PBS+.
[0067] Within 3 hours of plating, initial chondrocyte adhesion was assayed by counting the total number of cells adhering to the bottom of the dish using an inverted microscope equipped with phase contrast optics and expressed as a percentage of the initial seeding density. Colonies of chondrocytes consisting of more than 32 cells were counted using the same microscope at 8, 12, 14 and 17 days. Colony forming efficiency (CFE) was calculated by dividing the number of colonies by the initial number of adherent cells.
[0068] Once colonies consisting of more than 32 cells had formed, they were identified under a light microscope. Clones were trypsinised (0.25%; Gibco) and extensively subcultured in DMEM/F12 +10% FCS. Cell numbers were calculated at each passage and population dynamics plotted.
[0069] Clonal cell lines were immunolabelled with antibodies to Notch 1 (C20, 5 ug ml −1 ; Santa Cruz Biotechnology), STRO1 (neat TC supernatant, gift from R Oreffo, Southampton University) and MSX1 (N20, 5 ug ml −1 ; Santa Cruz Biotechnology) after fixing for 5 minutes in either 95% EtOH (Notch 1, STRO1) or 10% NBFS (MSX1). Primary antibodies were localised using relevant fluorescently conjugated antibodies and observed under a fluorescent microscope.
[0070] Clonal cell lines were labelled with 10 uM cell tracker green (Invitrogen) following the manufacturers instructions and injected into the wing bud of 3 day old (HH St 12-14) chick embryos which had been previously windowed. Embryos were resealed with sellotape and incubated for various times up to day 10 (HH St 36-37) and wings were fixed in 10% NBFS and processed for wax embedding. Samples were sectioned at 10 μm, dewaxed and mounted in DPX before being examined under a fluorescent microscope. Additional sections were immunolabelled with antibody 5D8 (anti human type I collagen; Abcam) and observed under a fluorescence microscope.
[0071] As shown in FIG. 5 , wax sections of aged human tissue that have been labelled with antibody to the transcription factor MSX 1, a marker for stem cells, showed that stem cells were present in both the surface and middle zones of cartilage tissue. This goes against conventional wisdom which presumed that stem cells were only present in the surface of cartilage tissue.
REFERENCES
[0072] Archer C and Francis-West P (2003) The chondrocyte. Int. J Biochem Cell Biol. 35, 401-404.
[0073] Brittberg, M, Lindahl, A, Nilsson, A, Ohlsson, C, Isakssin, O, Peterson, L. (1994) Treatment of deep cartilage defects in the knee with autologous chondrocyte transplantation. N Engl J Med. 331, 889-895.
[0074] Dowthwaite, G P, Flannery, C R, Lewthwaite, J, Flannelly, J, Archer, C W and Pitsillides A A. (2003) A mechanism underlying the movement requirement for synovial joint cavitation. Matrix Biol. 22, 311-322.
[0075] Dowthwaite, G P, Bishop J C, Redman S N, Khan I M, Rooney P, Evans D J, Haughton L, Bayram Z, Boyer S, Thomson B, Wolfe M S, Archer C W. (2004). The surface of articular cartilage contains a progenitor cell population. J Cell Sci. 117,889-897
[0076] Flannery C R, Hughes C E, Schumacher B L, Tudor D, Aydelotte M B, Kuettner K E, Caterson B. (1999) Articular cartilage superficial zone protein (SZP) is homologous to megakaryocyte stimulating factor precursor and Is a multifunctional proteoglycan with potential growth-promoting, cytoprotective, and lubricating properties in cartilage metabolism. Biochem Biophys Res Commun. 254, 535-41.
[0077] Hayes, A J, MacPherson, S, Morrison, H, Dowthwaite, G P and Archer, C W (2001). The development of articular cartilage: evidence for an appositional growth mechanism. Anat Embryol. 203, 469-79.
[0078] Knudson C B (2003). Hyaluronan and CD44: strategic players for cell-matrix interactions during chondrogenesis and matrix assembly. Birth Defects Res C Embryo Today. 69, 174-96. | The invention concerns a homogenous population of human stem cells isolated from the full depth of human cartilage tissue and/or isolated from aged human cartilage; and uses thereof. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an apparatus for wetting fibrous material, in particular wood, woodchips and waste paper.
[0002] Woodchips with a size of about 4 cm×2 cm×1 cm are decomposed into their fiber constituents by refiner grinding. This gives rise to the TMP fibrous substance required for papermaking (TMP=thermomechanical pulp). The higher the moisture content of the woodchips is, the more elastic, the softer and the more pliable is the composite fibrous structure within the woodchips and the individual fibers contained in the woodchip. Since, with an increasing length of the fibers, their strength increases, and such fibers are suitable for making high-grade papers, the aim is for the fibers to have as high moisture and elasticity as possible during the refiner grinding.
[0003] EP 1 051 551 discloses a method for wetting fibrous material composed of waste paper having a multilayer coating, such as, for example, beverage pasteboard. In beverage pasteboard, as it is known, both sides of the paper are coated with plastic and/or aluminum.
[0004] An apparatus and a method for the recovery of cellulose fibers from waste paper are known from U.S. Pat. No. 5,496,439. Here, the waste paper surrounded by a liquid is exposed in succession to underpressure and to overpressure.
SUMMARY OF THE INVENTION
[0005] The object on which the invention is based is to provide apparatuses, with the aid of which the wetting of woodchips or waste paper in bale form is possible in a simple and effective way.
[0006] In this context, wetting is understood to mean not only the moistening of the woodchips on their surface, but also the introduction of liquid, in particular water, in the overall volume of the woodchips. This means that not only the interspaces between the fibers of the woodchips, but also the interior of the fibers, are filled with a liquid.
[0007] This object is achieved, according to the invention, by means of an apparatus having the features of patent claim 1 .
[0008] With the aid of the apparatus according to the invention, it is possible to wet fibrous material, whether in the form of woodchips or in the form of waste paper in bales, quickly and effectively with a liquid. In this case, the elasticity of the fibers and the change in volume of the fiber cavities on account of alternating pressures are utilized.
[0009] In pulp manufacture, the following principle applies: the moister the woodchips injected into the pulp digester are, the higher are the filling density and therefore the throughput capacity of the pulp digester. Moreover, using the apparatus according to the invention, it is possible to start filling the digester with digesting liquor at a markedly earlier stage, since the woodchips, if their moisture is sufficiently high, do not float when the digesting liquor is pumped in.
[0010] If hot digesting liquor is used for wetting the woodchips by the method according to the invention, the digesting time is additionally also shortened markedly, since hot digesting liquor is not only located between the fibers, but also within the fibers (Luumen=fiber cavity).
[0011] When round timber (grinding wood) is used for the production of mechanical wood pulp, as high a moisture content of the wood as possible is critical so as to keep the fraction of splinters and fines low. In this method, the wood fragments with a length of up to 2 meters are pressed with high pressure against a large rough grindstone and are thereby defibrated and pulverized. The moister the round timber is during this processing, the more elastic, the softer and the more pliable is the composite fiber structure in the overall wood fragment and each of its individual fibers and the lower is the fraction of splinters and fines. With such wood fragments, too, considerable quantities of energy and time can be saved, using an apparatus according to the invention.
[0012] However, it has arisen that dried foodstuffs, such as, for example, mushrooms, beans or apples, can be moistened in dried form quickly, cost-effectively and efficiently.
[0013] By means of the ventilation line according to the invention, it is possible to execute the alternation between underpressure and ambient pressure or overpressure more quickly and thereby further increase the effectiveness of moistening.
[0014] By means of the at least one closable orifice provided according to the invention, the apparatus can be operated in batch mode or, in the case of two or more orifices, continuously, so that this improved method flow also markedly increases the effectiveness and the throughput rate of the apparatus according to the invention.
[0015] In all fiber-containing materials which are to be wetted, according to the present invention the wetting liquid can be used in liquid form (liquid) or gaseous form (vapor) or in a combination of both. The wetting liquid may be water, solvent, an individual chemical or a chemical mixture. The wetting liquids may also be in vaporous form.
[0016] Also, all these wetting liquids, when employed and used in the present invention, may have a temperature ranging from very cold to boiling point.
[0017] The wetting agents employed may have a coloring, hydrophobic, hydrophilic, bleaching, resin and lignin-decomposing, impregnating, preserving and/or surface tension-lowering or surface tension-increasing character of inorganic or organic type.
[0018] It has proved to be especially advantageous if the housing has a closable first orifice for loading the housing and a closable second orifice for unloading the latter, because the effectiveness and throughput of fibrous material to be moistened can thereby be increased even further.
[0019] Depending on the preferred intended use and local conditions, the at least one orifice may be closed by means of a door, a flap, a slide, a valve, a plug screw, a sluice and/or a drain trap.
[0020] Doors and flaps are suitable especially for the introduction of large fibrous material fragments to be moistened, such as, for example, a bale of pressed waste paper, while a slide or valve is especially suitable when the fibrous material is in small fragments and is to be delivered continuously. The advantage of a door, flap, slide and valve is that the orifice can be closed in a defined way and therefore controlled and reproducible pressure conditions inside the housing always prevail. Closing off the orifice in a pressure-tight or gas-tight manner increases the rate of pressure alternation or the rate of pressure change, this having a positive influence upon the effectiveness of moistening.
[0021] The advantage of a plug screw is to be seen in that it can convey fibrous material, which is already wetted with the liquid, such as, for example, water or digesting liquor, into the housing continuously or intermittently and at the same time affords an airtight and vapor tight closure of the housing orifice. The plug screw is therefore suitable especially for continuous or quasi-continuous operation of a plant and may, for example, be coupled to a valve or a slide.
[0022] Furthermore, it is possible to close the orifices by means of a drain trap which is filled with a barrier liquid. It is thereby possible, without moved parts, to close off the orifices of the housing in an airtight and vapor tight manner. At the same time, it is possible, by means of this drain trap, to introduce the fibrous material into the housing and also convey it out of the housing. Since this drain trap is a passive closure element, the control of the apparatus according to the invention is also simplified.
[0023] So that the liquid quantity absorbed by the fibrous material and transported out of the housing together with the fibrous material can be compensated, in a further advantageous refinement of the invention a supply line for the medium with which the fibrous material is moistened is provided. Further, a regulating valve is provided in this supply line, so that the quantity of medium contained in the housing can be regulated according to a stipulated desired value.
[0024] In order further to accelerate moistening and the penetration of the liquid into the woodchips or into the waste paper stacks, a pressure line with a second directional valve may be provided. It is thereby possible not only to carry out a lowering of pressure, but, in alternation with this lowering of pressure, also to carry out a rise in pressure within the housing. By the amplitude of between the pressure maximum and pressure minimum being increased, moistening and the penetration of the liquid into the fibrous material to be moistened are further intensified.
[0025] The pressure line is advantageously connected to a compressed air generator and/or to a pressure vessel. It is thereby possible to build up the overpressure quickly, and at the same time, if a pressure vessel is used, the compressed air generator can be of smaller design and run continuously.
[0026] The same applies accordingly to the vacuum line which is connected to a vacuum generator and/or to a vacuum vessel.
[0027] In order to convey the fibrous material into the apparatus and out of the apparatus fully automatically, a conveying device is provided which is preferably designed as a conveyor worm, transport belt and/or chain conveyor. The conveying device may, however, even be dispensed with if the apparatus is placed sufficiently obliquely.
[0028] Depending on the required performance and the space conditions, it is possible to set up one or more housings so as to be connected in parallel and/or in series to one another. On the basis of standard modules, therefore, the performance of the apparatus can be adapted within broad limits to the requirements of an individual case.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Further advantages and advantageous refinements of the invention may be gathered from the following drawing, its description and the patent claims. All the features disclosed in the drawing, its description and the patent claims may be essential to the invention both individually and in any combination with one another.
[0030] In the drawing:
[0031] FIG. 1 shows a circuit diagram of the first exemplary embodiment of an apparatus according to the invention,
[0032] FIG. 2 shows circuit diagrams of further exemplary embodiments of the apparatus according to the invention with two plug screws and with a conveyor worm,
[0033] FIG. 3 shows exemplary embodiments of apparatuses according to the invention with drain traps and with a conveyor belt as a transport device or with a tubular chain conveyor,
[0034] FIG. 4 shows an exemplary embodiment of an apparatus according to the invention which combines the functions of a pulper and of an apparatus according to the invention for the moistening of fibrous material.
DETAILED DESCRIPTION
[0035] In the exemplary embodiment illustrated in FIG. 1 , the housing is given the reference symbol 1 . The housing 1 illustrated has a parallelepipedal geometry. A sidewall of the housing 1 is designed as a door 2 and can be closed, airtight and vapor tight, with the aid of a closure 3 .
[0036] The apparatus according to the invention for wetting is illustrated diagrammatically, and greatly simplified, in FIG. 1 . The structural details are not clear from this illustration, but are within the manual ability of a person skilled in the art.
[0037] To load the housing 1 , the door 2 is opened and, for example, woodchips or a bale of waste paper, not illustrated, can be transported into the housing 1 . The door 2 is subsequently closed and locked, so that the housing interior is sealed off, airtight and vapor tight, from the surroundings.
[0038] The path along which the paper bale, not illustrated, can be loaded into the apparatus and unloaded from it is indicated by a double arrow 10 .
[0039] It is, of course, advantageous if the housing interior can be negotiated by a lift truck or another transport appliance, so that one or more bales of waste paper which are located, for example, on a Europallet can be introduced into the housing interior quickly and simply with the aid of a lift truck.
[0040] Various lines, with the aid of which the moistening of the woodchips or of the wastepaper (not illustrated) can take place, issue into the housing 1 .
[0041] A supply line is designated by reference symbol 4 . The supply line contains a regulating valve 5 .
[0042] The liquid with which the fibrous material is to be moistened can be introduced in liquid and/or vaporous form through the supply line into the interior of the housing 1 according to demand. As a rule, water is used for moistening. However, it is also possible to provide the water with various additives or to employ another liquid, such as, for example, digesting liquor.
[0043] It goes without saying that a conveying device, not illustrated, such as, for example, a pump, and/or a storage tank, is located upstream of the regulating valve.
[0044] A vacuum line is designated by reference symbol 6 . This vacuum line 6 has a first directional valve 7 which is usually designed as a switchable 2/2-way valve, a vacuum vessel 19 and a vacuum generator 20 . The vacuum vessel 19 is merely optional. If such a vacuum vessel 19 is present, the vacuum generator 20 can have relatively small dimensioning and can suck air or vapor out of the vessel 19 continuously. When the directional valve 7 is opened, a lowering of pressure can be carried out very quickly and effectively in the inner space of the housing 1 , even though the vacuum generator 20 has relatively small dimensioning. It goes without saying that the volume of the vacuum vessel 19 and the volume of the housing 1 and also the power of the vacuum generator 10 must be coordinated with one another.
[0045] Reference symbol 8 identifies a pressure line into which a second 2/2-way valve 9 is integrated.
[0046] This pressure line 8 is connected to a compressor 15 and to a pressure vessel 16 . Here, too, the pressure vessel 16 serves for increasing the running time of the compressor 15 and at the same time for reducing the required power of the compressor 15 .
[0047] The pressure line 8 is necessary only when an overpressure is to be generated after the lowering of the pressure in the inner space of the housing 1 .
[0048] Optionally, air, vapor or a liquid can be conducted into the housing 1 via the pressure line 8 .
[0049] A ventilation line is designated by reference symbol 11 . A third directional valve 12 is provided in this ventilation line 11 .
[0050] The apparatus according to the invention operates as follows:
[0051] With a door 2 open, the fibrous material to be moistened is conveyed into the housing 1 . The door 2 is subsequently closed in an airtight and vapor tight manner.
[0052] The first directional valve 7 , second directional valve 9 and third directional valve 12 are first closed. With the regulating valve at least partially open, the medium required for moistening the paper (not illustrated) containing the housing 1 is conveyed in a vaporous and/or liquid state through the supply line 4 into the interior of the housing 1 .
[0053] The regulating valve 5 is subsequently closed, and the first directional valve 7 is quickly opened. The interior of the housing 1 is thereby connected to the vacuum vessel 19 , and pressure compensation takes place between the two vessels. The pressure inside the housing 1 consequently falls abruptly to values of between 0.9 bar and 0.1 bar, preferably to values of between 0.7 bar and 0.3 bar.
[0054] As soon as the desired underpressure has been reached in the housing 1 , the first directional valve 7 is closed and, immediately thereafter, the third directional valve 12 is opened, so that pressure compensation between the surroundings and the inside of the housing can take place. The “abrupt” compensation is in this case especially important. It must take place as quickly as the fibers and cavities, which have collapsed due to the vacuum, also endeavor to recover their original form.
[0055] If desired, after a few seconds, the third directional valve 12 can be closed again and the second directional valve 9 opened. A few seconds or even only less than one second may elapse between the closing of the third directional valve 12 and the opening of the second directional valve 9 . Since the pressure line 8 is connected to the pressure vessel 16 , pressure compensation between the pressure vessel 16 and the inside of the housing 1 takes place immediately after the opening of the second directional valve 9 . Consequently, the pressure inside the housing rises to values above the ambient pressure. Overpressures of between 0.1 bar and 1 bar are preferred.
[0056] When a desired overpressure inside the housing 1 has been reached, the second directional valve 9 is closed, and this overpressure is maintained for several seconds, for example 5 seconds, but preferably for less than two seconds. The cycle then commences from the outset. So that the overpressure does not have to be broken down by the vacuum generator 20 , the third directional valve 12 can be opened briefly beforehand, so that the overpressure breaks down via the ventilation pressure compensation line 11 .
[0057] FIG. 2.1 shows a second exemplary embodiment of an apparatus according to the invention which is preferably operated continuously, but may also be used batchwise.
[0058] The housing 1 is designed as a cylindrical tube.
[0059] A first orifice 21 is provided at the end, on the left in FIG. 2.1 of the housing 1 . This first orifice 21 is preceded by a first plug screw 23 and a filling funnel 25 . Between the first orifice 21 and the plug screw 23 is arranged a valve 27 which can be actuated via an actuator 29 , for example in the form of a pneumatic cylinder. FIG. 2.1 illustrates the first closing valve 27 in the closed position. The position of the open valve 27 is illustrated by dashes.
[0060] As is clear from FIG. 2.1 , the supply line 4 is branched so that one branch of the supply line 4 issues directly in the housing 1 via the regulating valve 5 . 1 , while further branches 4 . 1 and 4 . 2 issue respectively into the filling funnel 25 and into the plug screw 23 .
[0061] Upstream of the branches 4 . 1 and 4 . 2 , a second regulating valve 5 . 2 is provided, which likewise serves for controlling the liquid quantity flowing into the apparatus according to the invention.
[0062] The plug screw 23 is constructed in a similar way to a conventional conveyor worm. The essential difference is that the pitch of the conveyor worm decreases in the conveying direction, so that, in addition to the conveying movement, compression of the conveyed material is also carried out. However, the plug screw may also additionally taper conically.
[0063] The fibrous material to be moistened, preferably in the form of woodchips, together with, for example, water, is administered into the filling funnel 25 and is subsequently conveyed by the first plug screw 23 in the direction of the housing 1 . Simultaneously with a conveying movement, compression of the conveyed woodchips takes place, so that a pressure-tight plug is formed in the first plug screw 23 . Sealing off of the housing interior from the surroundings is thereby achieved. As a rule, it is sufficient to seal off the orifice 21 by means of the plug screw 23 or the woodchips compressed by it. However, as illustrated in FIG. 2.1 , a closing valve 27 may also additionally be provided.
[0064] When the first plug screw 23 has conveyed the woodchips and the water through the first orifice 21 into the housing, this mixture of woodchips and water is conveyed slowly through the housing 1 via conveyor worm 31 which is arranged inside the housing 1 . While the material is being conveyed through the housing 1 , the pressure alternation described in connection with the exemplary embodiment according to FIG. 1 takes place. The woodchips are thereby moistened. After the woodchips have been conveyed through the housing 1 by the conveyor worm 31 , they fall through the second orifice 33 into a second plug screw 35 . A closing valve 27 and an actuator 29 actuating the closing valve 27 are likewise arranged at the end of the second plug screw 35 . It is thereby possible also to close off the second orifice 33 of the housing in a pressure tight and vapor tight manner at any time. The conveyor worm 31 may even be dispensed with if the housing 1 is suitably placed obliquely.
[0065] When the closing valve 27 at the end of the second plug screw 35 is opened or when the pressure of the plug screw 35 is higher than the pressure of the actuator 29 , the moistened woodchips and any excess water present can fall downward out of the apparatus according to the invention.
[0066] The exemplary embodiment of an apparatus according to the invention, as described with reference to FIG. 2 , may selectively be operated continuously or batchwise, since woodchips can be conveyed at any time into the housing 1 by the first plug screw 23 and the moistened woodchips can be conveyed out of the housing 1 with the aid of the second plug screw 35 .
[0067] It is also possible to dispense with the second plug screw 35 and to close the second orifice 33 solely by means of the closing valve 27 . Such an embodiment is illustrated in FIG. 2.2 .
[0068] In the exemplary embodiment illustrated in FIG. 3.1 , the first orifice 21 and the second orifice 33 of the housing 1 are closed by means of a drain trap 36 . The drain traps 36 contain water or another suitable barrier liquid. The filling level of the barrier liquid is set via the supply lines 37 and the regulating valve 38 such that there is no direct connection between the atmosphere inside the housing 1 and the ambient air. For this purpose, it is advantageous if the first orifice 21 and the second orifice 33 are arranged on a vertical wall of the housing 1 .
[0069] A conveyor belt 40 is led through the first orifice 21 and the second orifice 33 and the drain traps 36 and guides the fibrous material (not illustrated) to be moistened into the interior of the housing 1 . The deflecting rollers belonging to the conveyor belt 40 have been given the reference symbol 34 . Teeth 42 are arranged on the conveyor belt 40 and also make it possible to transport the fibrous material in a vertical direction and counter to gravitational force. The supply line 4 , the vacuum line 6 and the pressure line 8 issue into the housing 1 . The inflow and outflow through these lines are controlled with the aid of the valves 5 , 7 and 9 in the way already described above.
[0070] FIG. 3.2 shows a further exemplary embodiment of an apparatus according to the invention with a drain trap and a conveyor belt, here a tubular chain conveyor.
[0071] FIG. 4 illustrates a further exemplary embodiment of an apparatus according to the invention for wetting fibrous material, which is suitable especially for wetting individual or several waste paper or pulp bales, paper in sheets and split paper rolls.
[0072] This apparatus can be produced by converting a conventional pulper is also suitable for retrofitting such pulpers. The pulper, and also the cowl mounted on top, must be adapted to or designed for the pressure conditions prevailing in the invention.
[0073] The fibrous material is administered into the housing 1 by means of a conveying device 42 through the open orifice 21 . A slide 48 is subsequently moved down and the orifice 21 is thereby closed.
[0074] The regulating valve 5 of the supply line 4 is opened, and wetting liquid, in particular water, is added to the desired level. When the level is reached, the regulating valve 5 is closed again.
[0075] A motor 46 is subsequently switched on in that a rotor 44 is set in rotation. Intermixing of the waste paper or pulp bales contained in the housing 1 and of the wetting liquid thereby takes place.
[0076] As regards the lines 4 , 6 and 8 , reference is made to what was said regarding these lines in connection with the preceding exemplary embodiments.
[0077] After the fibrous material has been moistened, a pump 48 is switched on and the moistened fibrous material is pumped away via a perforated plate 50 . The charging of the pulper and moistening then commence anew.
[0078] Since the complete moistening of the fibrous material takes place in a very short time (<2 minutes) and completely moistened fibrous material can immediately be comminuted very effectively at little outlay in terms of energy, it can even be pumped away continuously via the perforated plate 50 . Nonfibrous material (for example, films, wires) can be removed periodically, as already happens now, through a large outward transfer orifice (not illustrated) or by means of grab crane apparatus through orifices, not illustrated, in the pulper cowl.
[0079] Owing to the wetting times, which are very short on account of this apparatus, and therefore very short degrading and residence time of the waste paper in the pulper, the paper fibers can be detached very quickly from plastic films or other coatings and pumped away via the perforated plate 50 . These nonfibrous materials can thereby be removed from the pulper housing 1 in markedly larger fragments. Moreover, the currently customary outlay for resorting the fibrous material which has been pumped away via the perforated plate 50 can thereby be reduced very sharply. | Apparatus for dampening fibrous material using the alternating pressure process with an airtight and vapour-tight housing ( 1 ), with a vacuum line ( 6 ), wherein a first directional valve ( 7 ) is provided in the vacuum line ( 6 ), the housing ( 1 ) has at least one closable opening ( 2, 21, 23 ) for loading and unloading the housing ( 1 ) and a ventilating line ( 11 ), and wherein a third directional valve ( 12 ) is provided in the ventilating line ( 11 ). | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to support structures and more particularly pertains to an playing card holder for supporting a plurality of playing cards in a desired orientation.
2. Description of the Prior Art
The use of support structures is known in the prior art. More specifically, support structures heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
Known prior art support structures include U.S. Pat. Nos. 4,927,149; 4,630,824; 4,538,813; 4,073,494 and 3,791,651.
While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a playing card holder for supporting a plurality of playing cards in a desired orientation which includes a support for positioning on a horizontal surface, and a plurality of engaging means secured to the support and each being operable for receiving and supporting an individual playing card therein.
In these respects, the playing card holder according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of supporting a plurality of playing cards in a desired orientation.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of support structures now present in the prior art, the present invention provides a new playing card holder construction wherein the same can be utilized for supporting a plurality of playing cards. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new playing card holder apparatus and method which has many of the advantages of the support structures mentioned heretofore and many novel features that result in a playing card holder which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art support structures, either alone or in any combination thereof.
To attain this, the present invention generally comprises a holder for supporting a plurality of playing cards in a desired orientation. The inventive device includes a support for positioning on a horizontal surface. A plurality of engaging assemblies are secured to the support and are each operable for receiving and supporting an individual playing card thereon.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
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.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new playing card holder apparatus and method which has many of the advantages of the support structures mentioned heretofore and many novel features that result in a playing card holder which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art support structures, either alone or in any combination thereof.
It is another object of the present invention to provide a new playing card holder which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new playing card holder which is of a durable and reliable construction.
An even further object of the present invention is to provide a new playing card holder which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such playing card holders economically available to the buying public.
Still yet another object of the present invention is to provide a new playing card holder which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new playing card holder for supporting a plurality of playing cards in a desired orientation for playing of a card game.
Yet another object of the present invention is to provide a new playing card holder which includes a support for positioning on a horizontal surface, and a plurality of engaging means secured to the support and each being operable for receiving and supporting an individual playing card therein.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of a prior art support structure.
FIG. 2 is a top plan view of a further prior art support structure.
FIG. 3 is an isometric illustration of a playing card holder according to the present invention.
FIG. 4 is a bottom plan view thereof.
FIG. 5 is a front elevation view of the playing card holder.
FIG. 6 is a top plan view thereof.
FIG. 7 is an end elevation view as seen from line 7--7 of FIG. 5.
FIG. 8 is a cross sectional view taken along line 8--8 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 3-8 thereof, a new playing card holder embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
Turning initially to FIGS. 1 and 2 wherein prior arts support structures are illustrated, it can be shown that the prior art teaches a simple rack structure, as shown in FIG. 1, or a planar member having a plurality of slots directed thereinto, as shown in FIG. 2.
Turning now to FIGS. 3 through 8 wherein the playing card holder 10 according to the present invention is illustrated in detail, it can be shown that the playing holder comprises a support means 12 for positioning upon a horizontal support surface, and a plurality of engaging means 14 coupled to the support means 12 for engaging a plurality of cards 16 to support the cards relative to the support means. As shown in FIG. 3, each of the engaging means 14 is operable to receive and support an individual playing card 16 to support the playing card in a substantially vertical orientation projecting orthogonally relative to the support means 12.
As best illustrated in FIG. 6, it can be shown that the support means 12 according to the present invention 10 comprises a substantially rectangular base plate 18 having a front edge 20 spaced from and oriented substantially parallel to a rear edge 22, with a pair of lateral edges 24 extending substantially orthogonally between the front and rear edges so as to define a substantially rectangular shape of the base plate 18. If desired and as shown in FIG. 4, a plurality of support feet 26 can be secured to a bottom surface of the base plate 18 to support base plate in a spaced orientation relative to a horizontal support surface upon which the support means 12 is positioned.
With continuing reference to FIG. 6, it can be shown that the engaging means 14 of the present invention 10 are arranged in a specific pattern and project from an upper surface of the base plate 18 of the support means 12. To this end, a first plurality of the engaging means 14 are arranged in an arcuate array 28 across the base plate 18. Further, a first lateral pair 30 of the engaging means 14 are positioned proximal to an intersection of a first one of the lateral edges 24 with the front edge 20. Similarly, a second lateral pair 32 of engaging means 14 is positioned proximal to an intersection of a second one of the lateral edges 24 with the front edge 20. By this structure, a first plurality of cards can be positioned within the arcuate array 28, with a further plurality of cards being positioned in the first lateral pair 30, and another further plurality of cards being positioned in the second lateral pair 32 as desired. Such configuration of the engaging means 14 permits for organization of the playing cards 16 into a desired orientation for a particular game being played.
Referring now to FIGS. 7 and 8, it can be shown that the engaging means 14 each project into an unlabeled cylindrical bore extending into the base plate 18. The engaging means 14 can be adhesively secured within the respective bores of the base plate 18, or alternatively, the engaging means may simply be gravitationally and frictionally retained within the respective bores so as to permit at least a slight rotation of the engaging means 14 relative to the base plate 18 such that the playing cards 14 positioned within the engaging means can be selectively oriented towards an unillustrated player. Preferably and as illustrated in FIG. 6, the engaging means are angled slightly such that the cards will be oriented towards the player.
Each of the engaging means 14, as best shown in FIG. 8, comprises a substantially cylindrical clamp member 36 having a longitudinal slot 38 directed thereinto separating the clamp member 36 into a first clamp leg 40 spaced from a second clamp leg 42. Thus, a playing card 16 can be positioned between the clamp legs 40 and 42 so as to be secured relative to the clamp member 36. To this end, the longitudinal slot 38 is preferably of a first transverse dimension at an upper end 44 thereof and tapers to a second transverse dimension proximal to a medial portion 46 thereof, wherein the first transverse dimension is substantially greater than the second transverse dimension such that a playing card 16 positioned between the clamp legs 40 and 42 will be frictionally engaged thereby. The longitudinal slot 38 continues from the medial portion 46 thereof to terminate in a lower end 48 of a third transverse dimension, wherein the third transverse dimension is substantially greater than the second transverse dimension. Preferably, the lower end 48 of the slot extends slightly below the top surface of the base plate 18. By this structure, playing cards 16 of various sizes can be captured within the clamp member 36, while still projecting above the upper end 44 of the longitudinal slot 38 for viewing thereof.
In use, the playing card holder 10 according to the present invention can be easily utilized to support a plurality of playing cards 16 in a descried orientation for viewing by a card player during an associated game. The playing card holder 10 is particularly useful by handicapped people who may only have one hand with which to manipulate the cards 16.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A holder for supporting a plurality of playing cards in a desired orientation. The inventive device includes a support for positioning on a horizontal surface. A plurality of engaging assemblies are secured to the support and are each operable for receiving and supporting an individual playing card thereon. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional application 60/377,155 filed May 1, 2002 and U.S. provisional application 60/384,755 filed May 31, 2002.
FIELD OF THE INVENTION
[0002] This invention relates to a technique for estimating the characteristics of the seabed from the amplitudes of echoes received from sound waves transmitted at the seabed. More particularly the invention specifies a method for compensating the amplitudes received from multibeam and sidescan sounders by removing the effects of range and angle of incidence thus providing improved classifications of seabed characteristics such as sediment composition.
BACKGROUND OF THE INVENTION
[0003] The estimation of seabed characteristics is made using multibeam and sidescan sounders. Typical of the sounding equipment used is that supplied by the Norwegian company Kongsberg Simrad. For example, the EM 1002 echo sounder records echoes over a 3.3° wide arc (measured fore to aft) and over a 150° sector (measured athwartships) at 95 kHz. For shallow water operations, a pulse of duration 0.2 ms is used and the amplitude of the backscattered echo is sampled at a suitable selected frequency in the range of about 5-15 kHz.
[0004] Conventionally, a multibeam sounder is mounted on the hull of a vessel or on a towfish travelling with a forward motion of up to 10 knots. The swath swept out by the sounder has a typical useful size of approximately 5 times the water depth. This wide swath is a considerable advantage as the resulting seabed maps provide greater detail and ensure that there are no uncharted shoals. Further, seabed maps can be produced more quickly, thus reducing ship survey time.
[0005] Frequently, multibeam echo sounders are connected to positioning equipment, heading and motion sensing instruments, as well as sound velocity sensors, in order to track the sounder's path and orientation over the seabed. The raw data collected are stored in digital form aboard ship, and receive subsequent processing on shore for “cleaning” (the elimination of unreasonable values) and enhancement.
[0006] The amplitude of echoes backscattered from the seabed varies with the type of material present on the seabed as well as factors such as the distance travelled by the pulse to the seabed (the “range”) and the angle at which the pulse is incident at the seabed (the “angle of incidence”). By measuring the amplitude of backscattered echoes, it is possible to estimate the composition of the seabed. The angle of incidence at the point from which a given detected sonar signal has been reflected is the angle made at the seabed by the arriving wavefront with a vector normal to the surface of the seabed.
[0007] The attenuation of the amplitude signal due to the range of the sound waves through seawater is caused both by the spherical spreading of the wave front as it expands out from its source and by absorption of sound energy in water. The absorption of sound in water depends on the temperature as well as the salinity. A technique, known as time-varying gain (“TVG”), is widely used to compensate for the attenuation caused by different ranges through seawater. This does no more than make a rough adjustment by multiplying the amplitude of the received signal by a factor depending on the range. TVG does not always correct precisely for both spreading loss and absorption of sound by water. Further, TVG does not adjust for the angle of incidence at all. To remove artifacts in the image that remain after applying an estimated TVG, it is popular to apply an adaptive gain based on recently recorded amplitudes. This is inappropriate for sediment classification as it makes the recorded backscatter from a sediment type dependent on adjacent areas and the survey direction.
[0008] In “ A real Seabed Classification using Backscatter Angular Response at 95 kHz ” [J. E. Hughes Clarke, B. W. Danforth and P. Valentine published in “ High Frequency Acoustics in Shallow Water ”, NATO SACLANTCEN, Lerici, Italy, July 1997], the authors describe a proposal for seabed classification based on the shape of the angular response curve (“AR”). The AR curve plots the amplitude of the backscatter signal against the angle of depression towards the seabed. The shape of the AR curve is considered in three domains, the length and slope of which are suggested as being determinative of the nature of the seabed. This research offers some insight into the classification problem but does not offer a means or methodology for determining the sediment type, nor any proposal for generating processed data that would adequately represent seabed classification by sediment type or otherwise.
[0009] In “ Seabed Classification of Multibeam Sonar Images ” [J. M. Preston, A. C. Christney, S. F. Bloomer and I. L. Beaudet published in the proceedings of the IEEE Ocean's 2001 Conference, Honolulu, November 2001] the authors, who include the inventors named in this present patent application, outline the context in which the present invention is described. They point out that a division of the seabed echo data and corresponding seabed sediment data into acoustic classes is useful because substrate characteristics for any given sediment class are relatively constant throughout such class and are distinct from those of other classes. This makes it possible to considerably reduce the amount of real sampling of the seabed that needs to be done in order to convert the acoustic classification into a classification by sediment type. The technique proposed by the authors relies on computing measures (“features”) that are used, alone or in combination, to infer an appropriate acoustic classification from the recorded data by conventional statistical techniques. Further detail of the techniques employed is provided below. As the processing performed makes use of the entire survey data set, the classification is conveniently done after the survey is complete. In general, this technique can be applied to backscatter data from any multibeam system, provided it is operated consistently during the survey.
[0010] Preston et al. in the foregoing paper suggest the computation of more than 130 features that can be used in a principal components analysis to determine the most effective combination of features to act as the predictor of sediment type. Examples suggested are mean, standard deviation, higher-order moments, histogram, quantile, power spectra and fractal dimension. As a final step, cluster analysis is suggested to optimally assign classifications to collected data.
[0011] In “ HIPS: Hydrographic Information Processing System ” [M. Gourley and D. Dodd, White Paper #21, CARIS, Fredericton, New Brunswick, 1998] the authors describe a Hydrographic Data Cleaning System (“HDCS”) that provides a set of interactive software tools for detecting and cleaning up raw swath data. A number of these tools rely on having a human being available to identify and correct (or remove) bad data through personal inspection of the data.
[0012] Among the published United States patent literature, there are two patents that have some relevance to the normalization technique of the invention. U.S. Pat. No. 5,493,619 describes a normalization technique for eliminating false detections in a mine detection process. U.S. Pat. No. 6,052,485 describes a method for automatically identifying clutter in a sonar image. Neither of these issued patents attempts to deal with the enhancement of sonar data for seabed classification.
[0013] There are a number of United States patents which disclose inventions of apparatus or methods related to multibeam sounders. U.S. Pat. Nos. 4,024,490, 5,177,710, 5,579,010 and 5,663,930 are representative and provide further details of the equipment and methods used in echo sounding.
[0014] In U.S. Pat. No. 6,549,853 Chakraborty et al. describe a technique for measuring seafloor roughness using a multibeam sounder. The method described there relies on fitting survey data to predictions from theoretical backscatter models combined with geometrical corrections and detailed knowledge of particular sonar systems. However, such a technique does not have the advantages of statistical approaches, which are intuitive and give useful results with a wide range of sonar systems that do not have to be calibrated.
[0015] The data used to estimate the character of the seabed are echoes recorded from sound pulses transmitted towards the seabed. Each echo measured is a time series of the amplitude of sound received from a point on the seabed by a detector and is a sequence of digital values sampled from the analog signal at equal time intervals. Each time series has a “dead” period corresponding to the round-trip of the pulse to the nearest survey point on the seabed, followed by a spike corresponding to the backscattered echo of the pulse from the seabed. The essence of the classification procedure is to compare features (statistical measures, particularly defined below) derived from the amplitudes measured at survey points within rectangular patches on the seabed and where the features are judged to be sufficiently “similar”, assign those patches to the same acoustic classification. Subsequently, the acoustic classifications are related to real attributes of the seabed by actual observation of the seabed at representative points.
[0016] However, the echo amplitudes are affected by a number of factors, each of which must be compensated for if a useful comparison is to be made between echoes received from different survey points:
[0017] (1) The best multibeam transmitters produce a wave approximately resembling a fan—having a broad arc shape transverse to the motion of the vessel (typically 150 degrees) and a narrow uniform angle along the vessel's path (typically 1-3 degrees). The pulse advances on the surface of a sphere and its intensity falls off according to an inverse square law.
[0018] (2) The transmitter does not produce a beam of uniform intensity across all angles. Typical transmitter elements: produce pulses varying considerably in amplitude according to the angle of depression.
[0019] (3) Seawater absorbs energy non-uniformly, typically dependent on both temperature and frequency. This causes a reduction in the amplitude of echoes detected.
[0020] (4) Because the backscatter is from a wide swath, and because the bottom is often irregular, the echo received varies substantially with the angle of incidence at the seabed.
[0021] In practice, items 2 and 3 above are dealt with by the manufacturers of multibeam sonar systems. In particular, such manufacturers are able, to some extent, to incorporate adjustments internally to compensate the echo signal for the non-uniformity of angular transmission and to generate frequencies in a narrow range.
[0022] Thus there remain two important factors, range (item 1) and angle of incidence (item 4), which require compensation before valid comparisons can be made between echoes received from different points on the seabed.
SUMMARY OF THE INVENTION
[0023] This invention relates to the enhancement of sonar image data, especially seabed echo data. In the context of a seabed survey, the present invention adjusts the amplitude of echoes detected from the backscattering of sonar pulses at survey points on the seabed for the attenuating effects of range and angle of incidence. The resulting compensated echo amplitudes are used to display enhanced images and to classify seabed sediments.
[0024] In the preferred embodiment of the invention a compensation table is used. The compensation table has two dimensions: one corresponding to range and the other to angle of incidence. The cells correspond to partitions of range and angle of incidence data, selected so that every pair of range and angle of incidence occurring in the survey dataset as a whole, can be found in a single cell of the compensation table. Each cell contains summary data for the count, sum and sum of squares of associated echo amplitudes. The amplitude of each echo recorded in the survey is adjusted as a function of the summary data stored in the relevant compensation table cell. The population of resulting echo amplitudes associated with each cell has zero mean and unit variance.
[0025] In a first aspect of the invention, echo amplitudes are adjusted to compensate for the attenuating effects of range and angle of incidence and are displayed in a variety of styles and in a variety of media.
[0026] In a second aspect of the invention, the echo amplitudes, adjusted to compensate for the attenuating effects of range and angle of incidence, are processed further to produce classifications of the seabed according to the acoustic nature estimated at a number of patches which substantially cover the survey area. These results, alone or in combination with other data, are suitable for display in a variety of styles and in a variety of media.
[0027] Although the present invention is particularly useful for and is described principally in the context of sediment classification, the compensation technique according to the invention has wider application. For example, the invention can also enhance images of the seabed for the improved identification of shipwrecks or aircraft debris. In principle, the invention can be used to enhance the processing of echo amplitudes from any exposed stratum or object capable of providing an echo amplitude from the reflection or backscattering of a transmitted sonar pulse.
[0028] The invention is adaptable for use with multibeam or sidescan echo sounders available commercially from a number of suppliers. The detailed operation of the apparatus required to practice the inventive methodology varies from supplier to supplier. The preferred embodiment describes the use of the invention with a multibeam echo sounder. An alternative embodiment describes the invention in use with a sidescan echo sounder.
[0029] Other features and advantages of the invention will become apparent from the detailed description and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] [0030]FIG. 1 is a schematic drawing of a vessel projecting a sonar pulse onto a representative portion of the seabed. The figure includes an enlarged area showing the angle of incidence of a selected portion of the fan. The methodology illustrated for the sonar projection and detection is previously known.
[0031] [0031]FIG. 2 is a schematic flowchart of the typical steps in the processing of raw sonar data according to the invention to produce output digital data representing sediment classification.
[0032] [0032]FIG. 3 shows a plot of the results of a typical cluster analysis to classify sediments.
[0033] [0033]FIG. 4 shows an exploded view of layers, each layer showing the location of one type of sediment plotted against latitude and longitude.
[0034] [0034]FIG. 5 shows a plot of the layers of FIG. 4 superimposed to provide a visual representation of an exemplary sediment classification.
DETAILED DESCRIPTION
[0035] [0035]FIG. 1 shows schematically a cross-section athwartships of a vessel 104 , travelling in a direction into the plane of FIG. 1 and emitting a repeated series of pings from a transmitter (not shown) located in the vicinity of the keel of the vessel 104 . Each ping is made up of a short pulse of sound waves that propagate approximately spherically out towards the seabed 108 . The surrounding water level is shown as 102 .
[0036] The transmitter transmits a ping lasting typically between 0.2 and 15 ms. To avoid interference between successive pings, it is not possible to transmit a second ping until the echo from a first ping has returned to the vessel 104 . In water of a depth requiring a sound wave to traverse a range of 250 metres, the round-trip time is approximately one third of a second. Typically, soundings are made twice per second.
[0037] A detector (not shown), including complementary sampling and data-processing equipment, is located in the vicinity of the transmitter. The analog signals of sound energy scattered back from the seabed 108 are sampled at 300 Hz to 25 kHz to produce digital echo amplitudes. The detector is designed only to receive energy arriving from a solid angle having a fan shape indicated generally in the plane transverse to the motion of the vessel as 106 . The fan 106 extends across an arc (typically greater than 150°) transverse to the motion of the vessel and is oriented downwards towards the seabed 108 . The fan 106 has a uniform angular size in the direction of the motion of the vessel 104 , typically 1-3°.
[0038] In a multibeam echo sounder, the detector measures the amplitude of the sound energy received at a number of uniformly spaced solid angles within the fan 106 , each of which is referred to as a beam. Usually there are more than one hundred beams, shown generally as 111 within the fan 106 . Beams 110 and 112 are representative. Each beam 111 corresponds to a known depression angle relative to the horizontal θ. Typically, multibeam echo sounders provide digitized values for the amplitude of the echo as time series, one time series for each beam. The values at individual points within each time series correspond to the amplitudes of echoes received as the ping's wavefront passes across the beam's footprint on the seabed. For the purposes of image enhancement and sediment classification according to the invention, the time series separately recorded for each beam are combined together into a single set of observations for each ping.
[0039] In a sidescan echo sounder, the detector (usually a pair, one for port and one for starboard) records the digitized values of echo amplitudes scattered back from the seabed at known ranges for each ping but without any record of the corresponding angles of depression. In the absence of measured angles of depression, values for the angle of depression are calculated assuming that the seabed is flat. The angle of depression for a particular echo amplitude is calculated as the inverse cosine of the range to the nadir divided by the range to the survey point in question.
[0040] The resulting data captured for a single ping from either a multibeam or sidescan sounder are (usually several thousand) digital echo amplitudes each having an associated, known range and angle of depression.
[0041] A portion 116 of the upper view of FIG. 1 is shown as an enlarged detail view 118 in the lower part of the drawing to illustrate the definition of the angle of incidence. The seabed 108 is generally not flat and its topography is described by a set of normal vectors each orthogonal to a small element at a survey point on the seabed 108 . The angle of incidence θ at any survey point on the seabed 108 is the angle in three dimensions between a line from the transmitter to that survey point 112 and the normal vector 126 at that survey point.
[0042] Other shipboard instrumentation, all conventional, provide data for several variables pertaining not only to the ping and its echo but also to the motion of the vessel or the towfish. These variables include the course, velocity, roll, pitch and heave of the vessel. This information is used to relate the survey data to a geographic position on the surface of the Earth and to adjust all angles measured relative to the axes of the vessel for the vessel's movement along its course, with due correction for wind, current and wave buffeting, relative to the Earth's surface.
[0043] [0043]FIG. 2 shows a flowchart of the typical processing steps taken in the preparation of sediment classification data according to the preferred embodiment of the invention from the raw data 252 supplied by a multibeam or sidescan echo sounder. At suitable points in the processing, data are stored in files of a particular format. The names of these formats (.SONAR, .NAV, .RECT, .CTABLE, .FFV and .DAT) refer to particular formats used within the QTC Multiview product supplied by Quester Tangent Corporation of Sidney, British Columbia. The particular details of these formats are not of significance in the description of the invention.
[0044] The method to be described in steps (1) to (12) below includes the methodology of the invention in the context of other typical and well-known data processing steps. Steps (1) to (3), (4)(a), (4)(b), and (6) to (12) are well-known methods relying on standard techniques. Steps (4)(c) and (5) are novel and descriptive of the preferred embodiment of the present invention.
[0045] (1) With reference to FIG. 2, the steps involving ping transmission 244 , echo detection 246 , digital sampling 248 and the storage of the resulting digital data 250 have been described above with reference to FIG. 1.
[0046] Raw data 252 initially obtained in digital form from a detector are stored on a suitable storage medium, such as a hard disk, and are converted (step 254 ) from one of a variety of formats established by the manufacturers of echo sounder hardware to a standard format. The steps in the process of FIG. 2 beginning with step 254 are typically performed ashore on the raw data 252 after the survey is complete. In the preferred embodiment, the raw survey data 252 are converted to a .SONAR file format and the additional data supplied about the vessel's position and instantaneous orientation are converted into a .NAV file format. The results are stored (step 256 ) typically as files on a hard disk.
[0047] The .SONAR data includes the travel time from the transmitter to the seabed for each detected survey point, and the corresponding fore-aft and athwartship angles of depression. These allow the depth to be calculated at each survey point. The .NAV file contains ship position and orientation data which can be combined with data from the .SONAR file to give the geographic position of each survey point.
[0048] The data resulting from one ping contains values of range, depression angle and echo amplitude at each of the survey points within the fan measured transverse to the course of the vessel. Typically, this amounts to data at each of several thousand points. These data are stored on a hard disk.
[0049] (2) Invariably some of the echoes detected are of no utility. They may be misleading reflections from an intervening object, or spurious values caused by the measuring equipment.
[0050] In the Quality Control step 258 , the range to each survey point is computed and values that do not appear to be reliable are marked to be ignored in the subsequent processing.
[0051] There are a variety of standard techniques available to identify data that do not meet appropriate quality criteria.
[0052] This step does not delete any data. The .SONAR file obtained by step 256 is augmented with a mask that indicates which sample values are to be included and is rewritten (step 260 ) as a file to the hard disk.
[0053] (3) The description of sediment types requires that the surface of the seabed be broken down conceptually and for purposes of measurement into a quilt of rectangular patches each of which will finally be assigned a sediment classification. This step 264 draws on data from the .NAV file, known echo sounder properties and suitable parameters indicating the desired rectangle size, to determine rectangular patches in which groups of .SONAR records appear. These data are stored (step 268 ) as a file on the hard drive in .RECT format.
[0054] The choice of the size of the rectangular patches is a parameter determined to satisfy objective criteria determined at each survey site. In the preferred embodiment, the following criteria have been found to be suitable:
[0055] (a) The rectangular patches should be small enough to provide a spatial resolution sufficient for the purposes of the survey;
[0056] (b) The rectangular patches should not be in numbers so great that they make the subsequent processing of the data unreasonably time-consuming;
[0057] (c) The shape of each rectangular patch should be approximately square as measured on the seabed. As the recorded resolution transverse to the motion of the vessel is usually considerably finer than that along the track of the vessel, the rectangular patches are suitably chosen to include many more points transverse to the vessel's motion than along the track of the vessel.
[0058] (d) The rectangular patches should be large enough to include a sufficient number of points to provide a statistically significant sample.
[0059] In the preferred embodiment, a suitable size for a rectangular patch is 16 pings along the track of the vessel by 128 points transverse to the motion of the vessel, containing data for 2048 points in total.
[0060] (4) To compensate for the effects of range and angle of incidence on the recorded amplitude values, a first pass through the survey dataset is used to construct a set of summary data that are stored in a compensation table. In a subsequent pass through the survey dataset (step (5) below) the recorded echo amplitudes are adjusted based on the summary data stored in the compensation table.
[0061] The construction of the compensation table 262 takes place in three substeps as follows:
[0062] (a) Knowing the depression angle (θ in FIG. 1) and the range (calculated from the time elapsed between the transmission of the ping and the return of its echo and the speed of sound in sea water) at each survey point detected, the depth from the surface to that point can be calculated by trigonometry.
[0063] (b) By observing how the depth changes across the survey area, it is possible, with one of several well-known techniques, to calculate the normal vectors at survey points. A review of suitable methods for this calculation is presented in “A comparison of local surface geometry estimation methods” [Alan M. McIvor and Robert J. Valkenburg, Machine Vision and Applications (1997) 10: 17-26]. Then, knowing in three dimensions both the depression angle for each survey point (the angle θ in FIG. 1) and the direction of the normal vector at the point of incidence 126 , it is straightforward to calculate the angle of incidence (the angle φ in FIG. 1) as the angle between the two.
[0064] (c) If the survey records data for n pings and the detector provides data at m survey points for each ping, then the entire survey dataset holds m×n echo amplitudes, Ampl. The echo amplitude corresponding to the j'th survey point (j between 1 and m) within the i'th ping (i between 1 and n) is referred to as Ampl ij ; the range to that survey point is Range ij ; and the angle of incidence φ at that survey point is Angle ij .
[0065] The compensation table is built as follows:
[0066] (i) the maximum value of the Range ij values is found, MaxRange;
[0067] (ii) a selection is made of a size parameter SR for the range so that the values for range can be partitioned into NR equal partitions each of size SR such that (NR×SR) is at least MaxRange.
[0068] A preferred selection for SR is made so that when the range values Range ij are classified into the NR partitions, each partition holds a sufficient number of values so that features calculated subsequently from the populations contained in those partitions are statistically significant.
[0069] In practice, a choice of SR of between 75 cm (1 ms, in shallow water) to 7.5 metres (10 ms, in deep water) is generally found to be suitable.
[0070] (iii) a selection is made of a size parameter SA for the angle of incidence φ (measured in degrees) so that the values for the angle of incidence Angle ij can be partitioned into NA equal partitions each of size SA such that (NA×SA) is at least 90 degrees.
[0071] A preferred selection for SA is made so that when the angle of incidence values Angle ij are classified into the NA partitions, each partition holds a sufficient number of values so that features calculated subsequently from the populations contained in those partitions are statistically significant. In practice, a choice of SA in the range about 0.5 degrees to about 1.5 degrees is generally found to be suitable.
[0072] (iv) A compensation table Comp is constructed with (NR×NA) cells arranged conceptually as NR rows and NA columns. The cell in row u and column v, Comp uv , corresponds to the uth partition of range values and the vth partition of angle of incidence values. Each cell entry holds summary data as three numeric values: N uv is a count of the number of echo amplitudes associated with the Comp uv cell; S uv holds the corresponding sum of the echo amplitudes; and SSQ uv holds the corresponding sum of squares of the echo amplitudes.
[0073] The cells in the compensation table are filled by reviewing the entire survey dataset. Any data which has been marked as bad in the quality control step are ignored. For the j'th survey point within the i'th ping, the values of Range ij and Angle ij are examined and the corresponding partitions of range and angle of incidence in which the Range ij and Angle ij values fall (as specified by the indices u and v respectively) are identified. The three numeric values associated with the Comp uv cell are incremented as follows:
N uv =N uv +1
S
uv
=S
uv
+Ampl
ij
SSQ uv =SSQ uv +( Ampl ij ×Ampl ij )
[0074] (These three statements use a common convention to describe the updating of items by an assignment statement. For example, the statement N uv =N uv +1 should be read as “take the present value stored for N uv , add 1 to it, and store the result again for N uv ”.)
[0075] The results of building the compensation table are stored (step 266 ) in a file on the hard disk in a .CTABLE format.
[0076] (5) The echo amplitudes are adjusted (step 270 ) using the summary data stored in the compensation table as follows:
[0077] (a) The mean amplitude and mean square amplitude are calculated for each cell in the compensation table:
[0078] M uv =S uv /N uv the mean amplitude
[0079] MSQ uv =SSQ uv /N uv the mean square amplitude
[0080] (b) The echo amplitudes are adjusted in a second pass through the entire survey dataset. As was described above for the construction of the compensation table, the values of Range ij and Angle ij for the j'th point within the i'th ping are examined and the corresponding cell (u, v) is identified. Each echo amplitude, Ampl ij , is adjusted as follows:
Ampl ij =( Ampl ij −M uv )/ sqrt ( MSQ uv −( M uv ×M uv ))
[0081] This transformation maps those echo amplitudes associated with each compensation table cell into a population with zero mean and unit variance. The values for mean and variance are chosen for convenience in the preferred embodiment, but the technique can equally well be applied to the data to produce populations each having the same value for the mean and variance, but for which the mean is not zero and the variance is not unity.
[0082] The compensated echo amplitudes thus produced are an enhanced image of the survey area, free of artifacts introduced either by inadequate adjustment for range (TVG) or variation due to angle of incidence. After compensation, the amplitudes are usually linearly mapped to [0:255] so they can be displayed as 8-bit images and for convenience in feature generation. It is usually effective to map from [−k:k] to [0:255], where k is a number of standard deviations. Choosing k=4 is suitable for many data sets, while other choices are also effective, including non-symmetrical selections. The resulting data are suitable at this point for a number of uses, one of which, sediment classification, is described in more detail below.
[0083] (6) The compensated echo amplitudes are used to calculate a feature vector 271 for each rectangular patch of the survey area. Each feature vector comprises 100 or more features. Each feature is calculated from those echo amplitudes associated with a particular rectangular patch after compensation. These feature vectors are stored on the hard disk in a file with an .FFV format 276 and are used subsequently in a principal components analysis and cluster analysis described in more detail below.
[0084] The features selected for this analysis are well-known in the art and are discussed in the following publications:
[0085] “Textual Features for Image Classification”, R. M. Haralick, K. Shanmugam and I. Dinstein, IEEE Transactions on Systems, Man and Cybernetics, Volume SMC-3, (1973) pp 610-621.
[0086] “Seabed classification from sonar data: report for 1993.” Milvang, O., K. W. Bjerde, R. B. Huseby and A. S. Solberg, 1994 Norsk Regnesentral/Norwegian Computing Centre, Oslo, Norway.
[0087] “Pattern Recognition for SAR Thematic Mapping: Co-occurrence Matrices” Huber R., 1999 http://www.cosy.sbg.ac.at/˜reini/diss/node90.html
[0088] “The use of image processing techniques for the automated detection of blue-green algae” Thiel S. U. 1994 http://www.cs.cf.ac.uk/user/S.U. Thiel/thesis/thesis.html
[0089] Pace, N. G. and Gao, H., “Swathe Seabed Classification”, IEEE Journal of Oceanic Engineering, Vol 13, 83-90, 1988.
[0090] “Estimating the fractal dimension from digitized images” Kraft R, Munich University of technology http://www.edv.agrar.tu-muenchen.de/ane/algorithms/algorithms.html
[0091] For example, the table below includes the features commonly used for the principal component analysis. (The value x pq used below refers to the echo amplitude appearing in column q of row p within a selected rectangular patch. Each rectangular patch is assumed to have P rows and Q columns.)
Mean μ = 1 PQ ∑ p = 1 P ∑ q = 1 Q x pq Standard Deviation σ = 1 PQ ∑ p = 1 P ∑ q = 1 Q ( x pq - μ ) 2 Skewness 1 PQ σ 3 ∑ p = 1 P ∑ q = 1 Q ( x pq - μ ) 3 Kurtosis 1 PQ σ 4 ∑ p = 1 P ∑ q = 1 Q ( x pq - μ ) 4 Quantiles The times at which 10%, 20% . . . 90% of the energy of the echo has been received. Normalized to make the largest value 1. Histogram Fraction of the echo's energy falling in each of 8 equally spaced ranges. Pace features As described in Pace et al. supra. Haralick features derived from Correlation, prominence, homogeneity and gray-level co-occurrence other Haralick features with several matrices step sizes and directions. Fractal dimension Calculated with the conventional triangular prism surface area algorithm.
[0092] (7) A principal components analysis 274 derives from the feature vectors of all patches a matrix of factors. This is square with as many rows and columns as there are features. Each column holds a vector of factors which can be applied as a weighted sum to a feature vector to produce a single number, a “component”. When a feature vector is applied as an inner product with the entire matrix of factors, the result is a revised feature vector transformed to a new basis (representing linear combinations of the original features). There are many possible choices for such a matrix of factors. Of particular utility is the choice where the matrix of factors is chosen to optimize the ability of a small number of the components to accurately represent the feature vectors—a principal components analysis.
[0093] The principal component analysis 274 is entirely conventional and follows the accepted methodology described in any standard statistical reference (for example: “Multivariate statistical methods: a primer” B. F. Manly, Chapman and Hall, 1994)
[0094] (8) The final computational step is a conventional cluster analysis 272 . To reduce the dimensionality of the task of searching for clusters, only the first three of the factors calculated in the principal components analysis are used. These are usually referred to as Q-factors, Q1, Q2 and Q3 and typically explain more than 90% of the variability in the feature vectors. They can be conveniently displayed as a graph in three dimensions.
[0095] The cluster analysis determines a relatively small number (usually between 5 and 10) of clusters which are identified by the coordinates of their centroids as measured in the space spanned by Q-vectors {Q1, Q2, Q3}. Each patch, as represented by its Q-vector is assigned by the technique to a cluster using a Bayesian metric. A confidence value can be derived from the record to the closest cluster and to other clusters and by comparison to the cluster covariance in that direction.
[0096] Cluster analysis is a well-known technique and more detail of the theoretical basis for the computations described herein may be found in “Numerical Ecology”, P. Legendre and L. Legendre, second English edition, Elsevier Science BV, 1998.
[0097] [0097]FIG. 3 shows the typical results of the cluster analysis as a set of points arranged in three dimensions. The three coordinate axes ( 304 , 306 and 308 ) of the graph of FIG. 4 correspond to the values of the three most significant components calculated from the principal component analysis step (Q1, Q2 and Q3). The feature vector associated with each rectangular patch produces one point in the graph, calculated by standard means from the principal component weights and the set of features for each rectangular patch. FIG. 4 shows eight clusters of such points, labelled as 310 to 324 .
[0098] (9) By way of example, FIG. 4 shows a computer screen display 402 of the results of a sediment classification from a multibeam survey. Each cluster identified in the cluster analysis is displayed as a separate layer 404 to 412 . Each layer shows the location of points on the seabed, related to axes for latitude 414 and longitude 416 , that fall into the same cluster. On a computer screen, the points in each layer have a distinct colour as an aid to viewing (displayed as grey scales in FIG. 5). Of special note, in the uppermost layer 404 (corresponding to cobbles and boulders) are two approximately straight lines highlighted within ellipses 418 and 420 . These correspond to the known locations of sewage outfalls along the coast of Parksville, British Columbia, Canada.
[0099] (10) FIG. 5 shows the five layers 404 to 412 of FIG. 4 superimposed. This display clearly shows the tracks of the survey vessel which appear as a band structure 504 throughout the image. The two sewage outfalls are shown as 418 and 420 .
[0100] The vessel's course is established during the survey by latitude (for example 414 ) and longitude (for example 416 ) coordinates obtained from a Global Positioning System.
[0101] (11) The data displayed in FIGS. 4 and 5 show portions of the seabed classified according to their acoustic nature. However, in order to make the seabed classification more useful as a description of conditions on the seabed, each cluster is related to the actual conditions on the seabed. This is done by selecting suitable points on the seabed representative of each cluster and returning with a survey vessel to either view actual conditions on the seabed (with a camera) or to bring sediments to the surface (with a “grab”).
[0102] (12) The final result of the computer program's operation is a compilation of refined data stored in a dataset on a computer-readable medium. The data records are conveniently provided in an ordinary tabular format (“.DAT”) within an ASCII text file, readily usable by a variety of other off-the-shelf software applications.
[0103] Note that while the invention has been described with particular reference to a system and methodology associated with seabed sonar surveying, and that the description has been focused on a multibeam sonar system, those skilled in the technology will recognize that variants and modifications can readily be made to enable the principles of the invention to be applied to other terrain and objects to be surveyed, including adaptation to other types of sonar system. | The composition of the seabed can be estimated by measuring the amplitude of echoes back-scattered from the seabed. However, the amplitude measured varies not only with the type of material present on the seabed but also with the range travelled to and the angle of incidence of the transmitted pulse at the seabed. This invention is a method for adjusting the amplitudes of backscattered echoes to compensate for the attenuation due to range and angle of incidence. A compensation table is created, each cell of which is associated with a unique combination of a partition of range and a partition of angle of incidence values. Each cell contains summary data for all echo amplitudes associated with that cell. The echo amplitude values are then adjusted using the summary data held in the compensation table. | 6 |
BACKGROUND
[0001] This relates generally to graphics processing and, particularly, to three-dimensional rendering.
[0002] Graphics processing involves synthesizing an image from a description of a scene. It may be used in connection with medical imaging, video games, and animations, to mention a few examples. A scene contains the geometric primitives to be viewed, as well as description of the lighting, reflections, and the viewer's position and orientation.
[0003] Rasterization involves determining which visible screen space triangles overlap certain display pixels. Pixels may be rasterized in parallel. Rasterization may also involve interpolating barycentric coordinates across a triangle face.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a depiction of a graphics pipeline in accordance with one embodiment of the present invention;
[0005] FIG. 2 is a flow chart in accordance with one embodiment of the present invention; and
[0006] FIG. 3 is a flow chart for a pixel shader shown in FIG. 1 according to one embodiment.
DETAILED DESCRIPTION
[0007] Referring to FIG. 1 , a graphics pipeline 10 may include a plurality of stages. It may be implemented in a graphics processor or as a standalone, dedicated, integrated circuit, in software, through software implemented general purpose processors or by combinations of software and hardware.
[0008] The input assembler 12 reads vertices out of the memories in fixed function operations, forming geometry, and creating pipeline work items. Auto generated identifiers enable identifier-specific processing, as indicated by the dotted line on the right side in FIG. 1 . Vertex identifiers and instance identifiers are available from the vertex shader 14 onward. Primitive identifiers are available from the hull shader 16 onward. The control point identifiers are available only in the hull shader 16 .
[0009] The vertex shader 14 may be perform operations such as transformation, skinning, or lighting. It may input one vertex and output one vertex. In the control point phase, invoked per output control point and each identified by a control point identifier, the vertex shader has the ability to read all the input control points for a patch independent from output number. The hull shader 16 outputs the control point per invocation. The aggregate output is a shared input to the next hull shader phase into the domain shader 20 . Patch constant phases may be invoked once per patch with shared read input of all input and output control points. The hull shader 16 may output edge tessellation factors and other patch constant data.
[0010] The tessellator 18 may be implemented in hardware or software. The tessellator may input, from the hull shader, numbers to find out how much to tessellate. It generates primitives, such as triangles or quads, and topologies, such as points, lines, or triangles. The tessellator inputs one domain location per shaded read only input of all hull shader outputs for the patch in one embodiment. It may output one vertex.
[0011] The geometry shader 22 may input one primitive and output up to four streams, each independently receiving zero or more primitives. A stream arising at the output of the geometry shader can provide primitives to the rasterizer 24 , while up to four streams can be concatenated to buffers 30 . Clipping, perspective dividing, viewpoints, and scissor selection implementation in primitive setup may be implemented by the rasterizer 24 .
[0012] The pixel shader 26 inputs one pixel and outputs one pixel at the same position or no pixel. The output merger 28 provides fixed function target rendering, blending, depth, and stencil operations.
[0013] In accordance with one embodiment, the rasterizer 24 may avoid wasted interpolation and pixel shading caused by the occlusion of objects in the ultimate visible screen space depiction. The rasterizer 24 determines a transformed triangle's visible screen space position and compiles barycentric coordinates.
[0014] A typical rasterization pipeline takes object local space geometry and runs a vertex shader to determine screen space triangles. This basically involves transforming from object space coordinates to screen space coordinates. Wasted cycles arise from causing the rasterizer to interpolate unneeded attributes of occluded triangles. However, normally at initial stages of rasterization, the occluded triangles are not yet identified. Additional wasted cycles are the result of shading pixels that will be discarded later when rasterizing a triangle closer to the camera.
[0015] Only the positions of triangles may be submitted to the rasterizer, according to some embodiments. Referring to FIG. 2 , the rasterizer 24 may implement the sequence depicted. The sequence may be implemented in software, using instructions stored on a computer readable medium or hardware.
[0016] In one embodiment, the triangles may be pre-processed so that they only contain positions, as indicated at block 34 . Since positions are all that is needed, at this point, to figure out which triangles are in the camera's screen space view, only the position information is used. All other attributes may be handled later. The positions may be submitted in object space (block 36 ) using the rasterizer's vertex shading to move the vertices to post-projected screen space. Alternatively, transformed vertices may be submitted, relying on the rasterizer to do the perspective dividing and interpolation.
[0017] The pixel shader then directly writes out the barycentric weights (block 38 ). Barycentric weights indicate position relative to the corners of a triangle. In the case where the rasterizer cannot directly write out the barycentric weights, the barycentric weights may be set up in the geometry shader 22 and passed along directly to the pixel shader 26 (block 40 ). The pixel shader 26 then interpolates, using the barycentric weights, a triangle identifier, and a visible screen space depth. (As used herein, “depth” refers to the distance from the viewer.) In addition, an object identifier is stored per pixel.
[0018] The pixel shader then looks at the depth value, compares it to the nearest value (block 42 ) and, if the new value is closer to the camera (diamond 44 ), updates the barycentric coordinates that have been stored (block 46 ). Otherwise, the new value is ignored (block 48 ). If the pixel shader is unable to read and write the frame buffer, then the rasterizer's depth test may be used to get the closest fragment to the camera in one embodiment.
[0019] Once all of the triangles have been rasterized (diamond 49 ), a screen sized buffer contains barycentric weights, a triangle identifier, and an object identifier. Depending on the rasterizer, the pixel shading stage may be started ( FIG. 3 , block 50 ) either by running another pixel shader over the entire buffer or, in the case of a software rasterizer that works on chunks of the frame buffer, the threads that were used for rasterizing may be switched to pixel shading, keeping the weights and identifiers in a cache.
[0020] Actual pixel shading may be done using single instruction multiple data (SIMD) operations, such as streaming SIMD extensions (SSE). Doing pixel shading in this manner enables sharing memory and computations between pixels. The rasterizer need not compute all the attributes for shading, such as the texcoords, colors, or normals. Using the triangle identifier, the exact vertices may be found that cover the pixel (block 52 ). A group or tile of pixels may then be operated on in parallel, for example, using SIMD operations (block 54 ). The object identifier is loaded into a vector register (block 56 ) and vector comparison operations may be used to quickly determine all unique objects in the tile (block 58 ).
[0021] Looping over each unique object, the same operations may be done for unique triangles using the triangle identifier (block 60 ).
[0022] Finally, in an inner loop, a unique triangle and its attributes are developed. At this point, the vertex shader is used to compute the transformed vertices and to store the results in a per-thread or per-core local cache (block 62 ). This may avoid shading vertices more than once per thread or core.
[0023] Once the vertices have been transformed, interpolation may be done using the barycentric weights loaded into wide SIMD registers or interpolation may be differed until later, in the pixel shader, when the actual need for an attribute is known. In one embodiment, 16 pixels can be processed at a time using one pixel shader for all materials. The pixel shader may include branches and conditionals where different data is loaded, for example, for particular materials.
[0024] As an example, consider alpha tested geometry. A texcoord is interpolated right away to do the actual text or lookup to get the alpha, but there is no need to interpolate the normal until later. The vertex shader may be done earlier than needed to make the best use of the vertex cache.
[0025] Finally, the pixels are shaded using the interpolated attributes (block 64 ). Again, pixel shading may be done using wide SIMD instructions. Because attributes are only interpolated when they are needed, most of the context may be maintained in a cache. In general, the same pixel shader may be used for all pixels. This may be called an “Uber shader” because it is general enough to be used for all materials in the scene. This keeps the scheduling and texture latency, hiding fairly trivial because the exact layout of code and memory usage is known. To hide high latency memory accesses, C++ switch style co-routines may be used.
[0026] Because only barycentrics are stored, in some embodiments, with a couple of identifiers, several layers may be readily collected, enabling transparency to be done using order independent transparency (OIT), for example, using a k-buffer to achieve order independent transparency by storing multiple overlapping samples up to a maximum of k samples or, ideally, an anti-aliased, area-average accumulation buffer, or A-buffer, sorting the fragments in place.
[0027] In some embodiments, a highly optimized and flexible method for pixel shading uses a fixed function rasterizer to set up barycentric coordinates. The method may do everything in a single pass without wasting cycles and bandwidth computing unneeded values. There need be no special requirements, other than a rasterizer that can write out the barycentric coordinates and triangle identifiers.
[0028] The graphics processing techniques described herein may be implemented in various hardware architectures. For example, graphics functionality may be integrated within a chipset. Alternatively, a discrete graphics processor may be used. As still another embodiment, the graphics functions may be implemented by a general purpose processor, including a multicore processor.
[0029] References throughout this specification to “one embodiment” or “an embodiment” mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one implementation encompassed within the present invention. Thus, appearances of the phrase “one embodiment” or “in an embodiment” are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be instituted in other suitable forms other than the particular embodiment illustrated and all such forms may be encompassed within the claims of the present application.
[0030] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | A rasterizer may use only triangle position information. In this way, it is not necessary to rasterize objects that end up being culled in screen space. | 6 |
BACKGROUND
Hydrometallurgy is a process for separating valuable metallic species from other less valuable materials. The process involves the dissolution of the valuable metallic species into an aqueous solution, which is then separated from the insoluble residue. To enhance the rate of ion dissolution and to increase the loading of metal ions in the solution, it is common practice to use an acidic or basic solution. An example of a particularly useful basic solution is a mixture of sodium hydroxide in water. Other alkali materials can also be utilized, but the relatively low cost of sodium hydroxide usually makes it the most economical choice.
The aqueous solution loaded with dissolved metals is referred to as a “pregnant liquor.” Dissolved metals may be recovered from the pregnant liquor by one or more means, including: electrolysis, neutralization, and immiscible solvent extraction.
Hydrometallurgical methods for recovery of valuable metals have been practiced for decades. The following discussions and examples are based on recovery of zinc oxide from a mixed feedstock material. The basic-soluble zinc oxide is separated from non-basic soluble materials. The non-soluble materials include (but are not limited to) metals and metal oxides such as iron, iron oxide, nickel, cobalt, precious metals, and non-metal oxides such as silica.
There are several processes identified in the literature for recovery of zinc from zinc-containing feedstock mixtures. These processes typically involve three generic steps:
1. Contacting the zinc-containing feedstock with dilute base to selectively solubilize the zinc, usually at elevated temperatures
2. Separating the leach residue from the basic solution by filtration, centrifugation or other means
3. Recovering zinc from the basic solution (pregnant liquor) by electrowinning, neutralization, or other means.
The most difficult step in this process is usually the separation of the leach residue from the pregnant liquor. The fine particles suspended in the pregnant liquor are very difficult to completely remove. Relatively high pregnant liquor viscosity and surface tension make the removal of these fine particles by filtration or centrifugation exceedingly slow. However, if the particles are not essentially completely segregated from the pregnant liquor, then they will contaminate the zinc-rich product in the next step, rendering the entire purification process useless.
An article entitled “Recovery of Lead and Zinc from Electric Steelmaking Dust by the Cebedeau Process”, by J. Frenay et al. summarizes commercial and pilot scale attempts to separate zinc from basic-insoluble species. The high viscosity of highly concentrated basic solutions typically limits commercial operations to a maximum concentration of about 25-30 weight percent base.
The cost of hydrometallurgical processing is heavily dependent on the loading or concentration of the dissolved metal species in the pregnant liquor. As the loading is increased, the amount of liquor that must be processed to produce a given amount of product decreases, saving both capital and operating expense.
Higher concentrations of base permit higher loadings of base-soluble metals in solution. However, higher concentrations of base also produce a significantly more viscous solution. This higher viscosity hinders down-stream processing including the separation of the pregnant liquor from the leach residue.
A number of processes have been developed to recover zinc from various waste materials using hydrometallurgy, but few have been commercially successful. In large part, this is due to the high cost of recovering the dissolved metal species from the pregnant liquor. Typical metal recovery strategies include:
Electrolysis where a flowing electrical current reduces the metal ions to the metal and plates the metal atoms onto an electrode. Neutralization of the liquor to a near-neutral pH to precipitate various metallic salts, hydroxides, or oxides. Extraction of metallic ions or complexes with an immiscible solvent.
All of these methods of metal recovery are relatively expensive.
Electrolysis requires large amounts of electrical current to reduce the metal from a higher valence state to metal. Furthermore, if a metal oxide is the desired end-product, then the base metal must be subjected to an oxidation process to create the oxide form. Neutralization of the pregnant liquor requires large quantities of reagent. The neutralization process effectively destroys the liquor for further extraction, and creates a waste salt stream that must be disposed of Extraction with an immiscible solvent (such as kerosene doped with an organic amine) generally requires a large excess of extraction solvent, and costly post-processing to recover the metal from the immiscible solvent.
U.S. Pat. No. 4,005,061 to Lemaire discloses a method of removing zinc from spent battery zinc/air electrolyte using a miscible solvent. The single material referenced in the '061 patent is characterized as a “waste,” however, this chemical system is, in fact, a spent material containing potassium hydroxide and potassium zincate plus a few percent of potassium carbonate and trace impurities. The described system is directed to electrochemical storage cell batteries having a zinc negative electrode and is, therefore, different from and substantially less complex than the metallurgical waste and by-product materials that are the subject of the present application. The electrolyte is spent only because the metallic zinc powder has been oxidized by air to potassium zincate. It has not been mixed with other materials and only one, simple chemical reaction has occurred. Metallurgical wastes and by-products, spent catalysts, etc., on the other hand, are typically complex mixtures containing a number of different chemical elements in significant concentrations, and they often contain a number of different anions as well. The complexity of these materials requires additional process steps to separate the desired compound from impurities and undesirable compounds. Furthermore, there is no indication or suggestion that the described method would be useful in other types of systems, particularly more complex systems, or in the recovery of other amphoteric compounds. The solubilities of different compounds containing amphoteric metals can vary significantly. For example, lead sulfate is only soluble in hot, concentrated sodium hydroxide solution, while zinc sulfate is very soluble in 25% NaOH, even at room temperature. The solubility of halides decreases significantly above about 35% caustic at room temperature.
SUMMARY OF THE INVENTION
The present application relates to a method of recovering zinc and zinc oxide from a mixture of metals, metal oxides, and other materials. The process in accordance with certain embodiments comprises:
1. Dissolution of the zinc into a basic solution, typically of sufficient concentration to dissolve the zinc and yet suppress or prevent dissolution of halogens, salts and other undesirable species.
2. Separation of the basic solution containing the dissolved zinc from the undissolved materials.
3. Purification of the basic solution to remove undesirable non-zinc materials that are soluble in basic solution.
4. Precipitation of the zinc with a soluble anti-solvent such as methanol.
5. Regeneration of the basic solution and the anti-solvent by separation techniques such as distillation or crystallization to recover a basic solution and an anti-solvent suitable for recycling within the process.
A key advantage to this process is that the anti-solvent reduces the solubility of zinc oxide in basic solution without destroying the base. It does not chemically destroy it as would an acid. This makes it possible to easily regenerate both the basic solution and the antisolvent for recycle within the process. An additional advantage of this process is the ability to supersaturate the solution with zinc in the event dilution with water is necessary to enable the separation of solids from the pregnant liquor.
The hydrometallurgical process as disclosed herein can increase the loading of zinc in pregnant liquor streams, thereby increasing the capacity of a hydrometallurgical process, while avoiding large increases in viscosity so that down-stream operations can proceed unhindered.
Extraordinarily high concentrations of zinc can be achieved in relatively low viscosity basic solutions by first contacting the zinc or zinc oxide with a concentrated basic solution (if the zinc is metallic, an oxidizing agent must also be added to oxidize the zinc), and then diluting the solution with water to achieve the desired viscosity. In accordance with certain aspects, metal loadings can be obtained that are about 3 to 5 times the metal loading achieved by simply contacting the metal or metal oxide with dilute basic.
One would expect that by adding water to a solution of concentrated base and reducing the concentration of base, the system would become supersaturated in dissolved metallic ion, and precipitation would result. Applicants have demonstrated that quite unexpectedly, the desired metallic ions remain in solution and do not precipitate during subsequent processing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the experimentally determined solubility of zinc oxide in basic solution at varying concentrations of NaOH in water.
FIG. 2 is a flow chart illustrating a process for recovering zinc oxide in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
The following process is described for the recovery of zinc oxide from a mixed feedstock material. One skilled in the art could also apply these techniques to the separation of zinc oxide from other metals and metal oxides, including nickel, cobalt, manganese and copper, whose value would be substantially increased if separated from zinc. The described process may also be utilized to replace conventional purification of zinc during the production of zinc.
The feedstock material containing the zinc is admixed with a basic solution such as a sodium hydroxide solution. If the zinc is metallic, an appropriate oxidizing agent, such as air, must also be added to oxidize the zinc to Zn +2 . Higher loadings of dissolved metal are usually achieved by higher concentration of base. Bases useful in accordance with the present invention are inorganic bases that are highly soluble in water (at least 25% by weight) and produce an increase in OH but the cation does not form a complex with zinc. Specific examples of bases that can be used include, but are not limited to, alkali metal bases such as sodium hydroxide, lithium hydroxide and potassium hydroxide.
FIG. 1 is a graph illustrating the solubility of zinc oxide in basic solution at varying concentrations of NaOH in water.
The reaction of zinc oxide with sodium hydroxide solution can be written as:
ZnO+2NaOH+H 2 O Na 2 Zn(OH) 4
On a molar basis, two sodium cations are associated with each divalent zincate anion. Therefore, higher concentrations zinc can be dissolved in higher concentrations of base. This dramatically increases the efficiency of the solvent extraction process and results in significantly higher zinc loadings.
The solubility data shown in FIG. 1 clearly indicate the increase in zinc oxide loading that can be obtained by using a higher concentration of basic solution. About a six-fold increase is obtained by increasing the concentration of the basic solution from 25% to 50%. In accordance with certain embodiments, a concentrated sodium hydroxide is used wherein the solution may contain more than 30% wt % NaOH, more than 40 wt % in certain aspects of the invention and in yet other embodiments more than 50 wt % NaOH.
Unfortunately, a solution with 50 wt % base and over 200 grams of dissolved zinc oxide per liter of basic solution is extremely viscous—even at near-boiling temperatures. Removal of suspended fine particles from such a solution is extremely difficult. Although in some cases it is possible to flocculate and settle solids from 50% NaOH solutions containing greater than 200 g/L zinc.
In accordance with the certain aspects of the present invention, high concentrations of complex zinc ions can be achieved in a relatively dilute basic solution by following a specific path or sequence of steps. However, not all aspects of the present invention require a particular sequence of steps. The flow chart provided in FIG. 2 illustrates a process for recovering zinc oxide in accordance with one embodiment of the invention.
Normally, solid-liquid equilibria are path independent. The “end state” is important, and the route to achieve that end state is irrelevant. Unexpectedly, applicants have found that a specific path allows one to produce much higher zinc loadings than expected.
The process takes advantage of three phenomena:
1. Concentrated basic solutions dissolve more zinc than dilute basic solutions.
2. When water is added to a concentrated solution of zinc ions, diluting the basic, the zinc does not readily precipitate.
3. Dilute basic solutions are significantly less viscous and easier to handle and process than concentrated basic solutions.
Thus, by loading the basic solution with zinc at high basic concentrations and then diluting the solution with water to lower the base concentration, one can produce a solution with both high zinc loading and relatively low viscosity.
The relatively low viscosity allows for facile down stream processing, including solid-liquid separation (sedimentation, centrifugation, filtration, etc.).
A basic solution at 50 wt % NaOH is saturated with zinc at about 600 grams of zinc oxide per liter of basic solution. The solution may be diluted with water to an equivalent basic concentration of 35 wt % NaOH. The final solution created by following this path contains about 420 grams of zinc oxide per liter of basic solution. By comparison, initially dissolving the zinc oxide in a basic solution at 35 wt % NaOH, only about 220 grams of zinc oxide are dissolved per liter of basic solution. Dilution to 35% NaOH reduces the viscosity of the solution and improves the separation of solid residues from the pregnant liquor but does not significantly increase the solubility of impurities such as halide salts.
In accordance with one embodiment of the present invention, a zinc loading about three times greater than the zinc loading possible by simply starting with a caustic solution at 25 wt % base can be obtained. Even greater ultimate zinc loadings can be achieved by using a caustic solution with more than 50 wt % base. The maximum concentration of base and zinc is limited only by processing considerations, such as excessive viscosity.
There is also no specific requirement to dilute the concentrated solution to only 25 wt % basic concentration. Depending on the down stream processing equipment requirements, one must only add sufficient water to reduce the viscosity to the desired level. From a practical standpoint, the solution typically will be diluted to a concentration of from about 15-30 wt % basic concentration. In other cases, the solution may be diluted to a concentration of from about 30-35% basic concentration. This higher basic solution, for example, may be particularly useful if halogens are to be separated from zinc. Of course, concentrations outside the specified range are also within the scope of the present invention.
As disclosed herein, water can be added to a concentrated solution of sodium zincate providing dilution and a reduction in viscosity to occur without precipitating any zinc-bearing particulates. The zinc ions remain in solution at concentrations far greater than predicted by the solubility curve provided in FIG. 1 . This allows the more facile separation of suspended particles from the pregnant liquor while retaining a high zinc loading in solution.
In some aspects further processing may be accomplished without dilution of the pregnant liquor. In accordance with other embodiments, the pregnant liquor may be diluted by the addition of an amount of water up to 30% of the weight of the original NaOH solution to provide a low viscosity solution which facilitates further solid liquid separation. The pregnant liquor may be diluted with sufficient water to reduce the slurry viscosity by at least 10%, and in accordance with certain aspects of the invention by at least 50% and in yet other aspects by at least 75%.
High zinc loadings are important in the design of a hydrometallurgical plant. The rate of dissolution also generally increases with increasing solution temperature and increasing mixing intensity, both of which favor increased mass transfer from the solid to the liquid. The higher the zinc loading, the less the circulating basic rate required for recovery of a given quantity of zinc. A reduction in circulating basic rate has a major impact on both capital and operating cost.
The pregnant liquor (basic solution containing the dissolved zinc) can be separated from the residual material by any number of commercially available techniques including sedimentation, centrifugation, and filtration.
Although the pregnant liquor has been diluted, the resultant metal loading is still above the metal loading that could have been achieved if the solution had not previously been so highly concentrated during the extraction step of the process. In short, the solution is super-saturated. By creating such a super-saturated solution, one can increase processing efficiency by minimizing the amount of pregnant liquor that must be processed per unit of metal recovered.
To reduce the quantity of material that must be handled, the pregnant liquor may be reconstituted, after impurities have been removed, to a base concentration of at or near the initial concentration. As used herein, the term “reconstituted” means increasing the base concentration of the pregnant liquor to levels approaching those of the initial leaching solution. In accordance with certain embodiments, the pregnant solution is reconstituted to obtain a base concentration of greater than about 25%. In accordance with particular embodiments the base concentration is reconstituted to greater than about 30%, greater than about 35%, more particularly greater than about 40% and in certain embodiments about 50% to greater than 50% basic. By reconstituting the pregnant liquor to higher concentrations of base, the amount of solution that must be processed is reduced and the amount of anti-solvent required to precipitate the zinc oxide is also reduced. Reconstituting the solution to obtain a more concentrated solution can be accomplished in accordance with conventional methods, such as evaporation.
It should be noted that certain dissolved materials such as copper, lead, alumina, silica, some halogens and calcium can be removed from a sodium zincate solution prior to anti-solvent precipitation by known techniques such as precipitation, electrolysis or cementation. This results in the subsequent production of an extremely pure zinc oxide product. The exact purification procedures will depend upon the on the combination of the impurities and the particular properties of the composition. Precipitation with calcium oxide or other alkali metal oxides and cementation with zinc metal are particularly useful methods that may be employed with many common materials. It is not always necessary to filter the leachate before subjecting the composition to cementation and/or precipitation.
Zinc oxide can be precipitated from a pregnant liquor by adding a soluble anti-solvent. Anti-solvents are soluble in the pregnant liquor and effectively force the dissolved zinc to precipitate from the pregnant liquor. A soluble anti-solvent reduces the solubility of zinc in the basic solution, causing the dissolved species to precipitate—usually as the metal oxide, hydroxide, or a mixture of oxides and hydroxides.
Soluble anti-solvent molecules often have a non-polar hydrocarbon part and a polar part containing hetero atoms such as oxygen, nitrogen, or sulfur. It is this polar functionality that allows the anti-solvent to be soluble with the pregnant liquor. Specific examples of anti-solvents useful in the present invention include, but are not limited to, methanol, ethanol, propanol, etc. Methanol is particularly useful and produces precipitation of the dissolved species at relatively low quantities.
The soluble anti-solvent lowers the solubility of dissolved species in the pregnant liquor, causing them to precipitate. However, the soluble anti-solvent does not permanently neutralize or destroy the basic components of the solution. Rather, it forms a new solution that can easily be separated to regenerate both the basic solution and the anti-solvent.
The precipitation step is best carried out well below the boiling point of the anti-solvent to avoid excessive vaporization of the anti-solvent. Optimum temperature and pressure are a function of the physical properties of the anti-solvent.
The amount of metal precipitated (as a percentage of the total metal in solution) typically increases as the amount of anti-solvent increases. The amount of anti-solvent required will vary based on the particular processing conditions and anti-solvent used. Typically, about 1 to 5 volumes of anti-solvent per 1 volume of pregnant liquor will causes the precipitation of more than about 90% of the metal oxide in the pregnant liquor.
The actual ratio of soluble anti-solvent to pregnant liquor is a function of the concentration of zinc in solution, the concentration of base in solution, and the desired recovery in the process.
The precipitation begins immediately upon addition of the anti-solvent and is complete within a few minutes. The size of the zinc oxide particles initially formed is <2 μm. If the slurry is allowed to mix before the zinc oxide is separated from the liquid, the size of the particles will increase. This provides a method of producing zinc oxide products of varying particle sizes and specific surface areas. Particle size and specific surface area are important in some uses of zinc oxide.
Generally, the higher the initial concentration of zinc in basic solution and the higher the caustic concentration, the greater percentage of zinc is recovered for a given dosage of anti-solvent.
A simple distillation will generally recover anti-solvents with low to moderate boiling points from the spent pregnant liquor, regenerating both the anti-solvent and the basic solution. Recrystallization and other conventional means can be also used to regenerate the basic solution and anti-solvent. Both the basic solution and the anti-solvent can then be recycled within the process to treat the next batch of feedstock material.
Such a regeneration scheme is significantly less expensive than those involving the destruction of the basic solution through reaction with acid (forming a waste salt solution), followed by the purchase of fresh base to treat the next batch of feedstock material.
Crystallization and membrane separation are examples of regeneration methods that may be used in this step. Other methods of regeneration may also be used as could be determined by one of ordinary skill in the art.
Certain aspects of the present invention are illustrated in more detail by the following non-limiting example.
Specific Example for the Recovery of Zinc Oxide
The feedstock for this demonstration of the process was a baghouse dust from a brass ingot manufacturer. It was processed to recover a very pure zinc oxide as described in detail below.
The feedstock, referred to in the industry as “brass fume,” was formed during the production of brass alloys. It contained about 65 wt % zinc, along with lesser amounts of lead, copper, and other materials. The feedstock material was analyzed using ICP (Inductively Coupled Plasma) to determine the concentrations of various metallic species. An analysis of the feedstock can be found in Table 1.
TABLE 1
ZnO Feed Sample
Material
Results/Units
B
0.34%
Cd
0.18%
Cu
0.62%
K
0.41%
Na
2.14%
Pb
10.75%
Si
0.15%
Sn
0.69%
Zn
65.3%
Others Mg, Al, Cr, Mn, Fe, Bi 0.01-0.1%
Ti, Ni, As, Mo, Ag, Sb, W 0.001-0.01%
Elements looked for but not detected Be, Ca, Co, Ge, In, Nb, Sr, V, Zr
Step 1: Dissolution
Two hundred grams of this feedstock material was mixed with 650 grams of a basic solution that contained 50% sodium hydroxide by weight. The mixture of feedstock and basic solution was heated to 100° C. for about one hour with continuous stirring. A large portion of the feedstock material dissolved into the basic solution. The calculated zinc loading was in excess of 250 grams of zinc per liter of solution.
After one hour, the solution was cooled to about 50° C., and an additional 325 grams of water were added, reducing the effective basic strength to the equivalent of 33% base. No precipitate was observed. The zinc loading at this point in the process was in excess of 167 grams per liter. Note that the solubility of zinc in a 33% basic solution is only about 145 grams per liter, making this solution super-saturated as described above.
Step 2: Solid—Liquid Separation
The pregnant liquor was separated from the waste material by filtration through a glass fiber filter at room temperature, using a vacuum to enhance the filtration rate. Approximately 10 grams of fine black residue remained on the filter.
Cementation was then used to remove unwanted tin, cadmium, lead, and copper from the pregnant liquor. The slurry was heated to 80° C. for 30 minutes with constant stirring and then about 15 grams of finely powdered zinc metal were mixed into the pregnant liquor. The zinc powder reacted with the lead and copper ions in solution. After 30 minutes, the solids were separated from the pregnant liquor by vacuum filtration.
To insure purity, the cementation procedure above was repeated. Little change in the appearance of the zinc powder was noted during the second cementation, indicating that all metals below zinc in the electromotive series had reacted with the metallic zinc and were removed from the pregnant liquor.
Step 3: Precipitation of Zinc Oxide with Anti Solvent
The pregnant liquor was filtered as before, cooled to room temperature and treated with four volumes of methanol at ambient temperature and pressure. A white precipitate immediately formed upon the addition of the methanol to the pregnant liquor.
The precipitated solids were recovered from the mixture of spent basic solution and anti-solvent by vacuum filtration. The filtrate was first washed with methanol to remove caustic and then washed repeatedly with hot water to remove any residual basic solution or anti-solvent, and was then dried at 100° C. Approximately 150 grams of dry, brilliant white powder were recovered.
The product precipitate was analyzed using ICP (Inductively Coupled Plasma) to determine the concentrations of various metallic species. The sample was only partially washed. Typically, large scale operations that utilize complete washing and purification of the sample would provide samples of higher purity and fewer impurities. Impurities may be decreased to less than 10 ppm. The results for the ZnO product are shown in Table 2.
TABLE 2
ZnO Product Sample
Material
Results/Units
Ca
0.23%
Na
0.31%
Si
0.28%
Zn
79.1%
Others Mg, Cr, Sn 0.01-0.1%
B, Al, Mn, Fe, Ni, Cu, As, Sr, Sb, Pb 0.001-0.01%
Elements looked for but not detected
Ag, Be, Bi, Cd, Co, Ge, In, Mo, Nb, Ti, V, W, Zr
Step 4: Basic Solution and Anti-Solvent Regeneration
The mixture of anti-solvent and spent base was then regenerated by distillation. One stage of distillation resulted in a methanol purity of about 90%. Such a solution of methanol and water has been demonstrated to be an acceptable anti-solvent. If desired, further purification of the methanol can be achieved by rectification in a multi-stage distillation column.
The distillation “bottoms” or heavy liquid product was a basic solution containing about 35 wt % sodium hydroxide. Further heating would cause additional vaporization of water and the concentration of the sodium hydroxide could readily be increased up to 50% (or more) for use in leaching subsequent batches of raw material.
Increasing the net metal loading results in both capital equipment and operating cost savings. Less solution is required to recover the same amount of metal, leading to smaller tanks, pumps, filters, etc. Less thermal energy is also required resulting in lowered operating costs.
By not significantly increasing the viscosity of the pregnant liquor, one is able to continue to utilize the same equipment down-stream of the leaching process with no impediment to mass transfer. This results in a significant increase in production rate throughout the entire hydrometallurgical plant. | A process for separating zinc from a feedstock containing a mixture of metals and metal compounds. The process includes leaching a zinc-containing feedstock with a concentrated basic solution, optionally diluting the slurry with an amount of water sufficient to reduce the viscosity of the slurry thereby facilitating separation of a pregnant liquor containing dissolved zinc from insoluble materials, separating the insoluble materials from the pregnant liquor, and precipitating zinc oxide from the pregnant liquor by adding an anti-solvent to the pregnant liquor. The described process also provides for recycling of the basic solution and the anti-solvent. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority of U.S. provisional application Ser. No. 60/303,169, filed Jul. 5, 2001.
BACKGROUND OF THE INVENTION
This invention relates to heterocyclo-alkylsulfonyl pyrazoles, methods of treatment and pharmaceutical compositions for the treatment of cyclooxygenase mediated diseases, such as arthritis, neurodegeneration and colon cancer, in mammals, preferably humans, dogs, cats or livestock.
Nonsteroidal anti-inflammatory drugs (NSAIDs) are widely used in treating pain and the signs and symptoms of arthritis because of their analgesic and anti-inflammatory activity. Common NSAIDs work by blocking the activity of cyclooxygenase (COX), an enzyme that converts arachidonic acid into prostanoids. Two forms of COX are now known, a constitutive isoform (COX-1) and an inducible isoform (COX-2) of which expression is upregulated at sites of inflammation (Vane, J. R.; Mitchell, et. al., Proc. Natl. Acad. Sci. USA, 1994, 91, 2046). COX-1 appears to play a physiological role and to be responsible for gastrointestinal and renal protection. On the other hand, COX-2 appears to play a pathological role and is believed to be the predominant isoform present in inflammation conditions. The therapeutic use of conventional NSAIDs is, however, limited due to drug associated side effects, including life threatening ulceration and renal toxicity.
COX is also known as prostaglandin G/H synthase (PGHS). Prostaglandins, especially prostaglandin E 2 (PGE 2 ), a predominant eicosanoid detected in inflammation conditions, are mediators of pain, fever and other symptoms associated with inflammation. A pathological role for prostaglandins has been implicated in a number of human diseases including rheumatoid arthritis, osteoarthritis, pyrexia, asthma, bone resorption, cardiovascular diseases, dysmenorrhea, premature labour, nephritis, nephrosis, atherosclerosis, hypotension, shock, pain, cancer and Alzheimer. Compounds that selectively inhibit the biosynthesis of prostaglandins by intervention of the induction phase of the inducible enzyme COX-2 and/or by intervention of the activity of the enzyme COX-2 on arachidonic acid would provide alternate therapy to the use of NSAIDs or corticosteriods in that such compounds would exert anti-inflammatory effects without the adverse side effects associated with COX-1 inhibition.
A variety of sulfonylbenzene compounds which inhibit COX have been disclosed in patent publications (WO 97/11704, WO 97/16435, WO 97/14691, WO 96/19469, WO 96/36623, WO 96/03392, WO 96/03387, WO 96/19469, WO 96/08482, WO 95/00501, WO 95/15315, WO 95/15316, WO 95/15317, WO 95/15318, WO 97/13755, EP 0799523, EP 418845, EP 554829 and EP 1099695).
SUMMARY OF THE INVENTION
The present invention relates to compounds of the formula
wherein
is a heterocycle selected from the group consisting of
m is 0, 1 or 2, preferably m is 2;
X is CR 7 or N, preferably CR 7 wherein R 7 is hydrogen;
R 1 is hydrogen, halo, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, (C 1 -C 6 )alkylcarbonyl, formyl, formamidyl, cyano, nitro, hydroxycarbonyl, (C 1 C 6 )alkoxycarbonyl, (C 2 -C 9 )heteroarylcarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 1 -C 6 )alkylthio, (C 6 -C 10 )arylthio, (C 2 -C 9 )heteroarylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, or (C 1 -C 6 )alkylcarbonyl-N(R 2 )—;
wherein each of said R 1 (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy;
R 2 is hydrogen or (C 1 -C 6 )alkyl;
R 3 is (C 1 -C 6 )alkylthio, (C 3 -C 7 )carbocyclylthio, C 6 -C 10 )arylthio, (C 2 -C 9 )heteroarylthio, (C 1 -C 6 )alkyl-S(═O), (C 6 -C 10 )aryl-S(═O), (C 2 -C 9 )heteroaryl-S(═O), (C 1 -C 6 )alkyl-SO 2 -, (C 6 -C 10 )aryl-SO 2 —, (C 2 -C 9 )heteroaryl-SO 2 —, (C 1 -C 6 )alkyl-SO 2 -amino, (C 3 -C 7 )carbocyclyl-SO 2 -amino, (C 6 -C 10 )aryl-SO 2 -amino, (C 2 -C 9 )heteroaryl-SO 2 -amino, amino-SO 2 —, N—(C 1 -C 6 )alkylamino-SO 2 —, N,N—[(C 1 -C 6 )alkyl] 2 amino-SO 2 —, N—(C 3 -C 7 )carbocyclylamino-SO 2 —, N—(C 6 -C 10 )arylamino-SO 2 —, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino-SO 2 —, N—(C 2 -C 9 )heteroarylamino-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, or N—(C 2 -C 9 )heteroarylamino;
wherein each of said R 3 (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy;
R 4 is (C 1 -C 6 )alkyl optionally substituted by hydroxy or one to three halo atoms, such as fluoro atoms;
R 5 is hydrogen, halo, hydroxy, mercapto, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy optionally substituted with one to three halo (such as fluoro) atoms, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, cyano, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkylcarbonyloxy, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6) alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, or (C 1 -C 6 )alkylthio;
wherein each of said R 5 (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 8 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy;
R 6 is selected from the group consisting of:
(a) phenyl optionally substituted by one to three, preferably one, substituents independently selected from the group consisting of halo (preferably fluoro), hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl (preferably methyl), (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl; preferably halo, most preferably one fluoro atom, or (C 1 -C 6 )alkyl, most preferably methyl;
(b) phenyl fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring;
wherein either of said phenyl or said fused saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring is optionally substituted by one to two substituents per ring, wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
(c) phenyl fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein either of said phenyl or said fused saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is optionally substituted with one to two substituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N-—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
(d) (3- to 7-membered)-carbocyclic optionally containing one or two double bonds, preferably the (3- to 7-membered)-carbocyclic contains no double bonds;
wherein said (3- to 7-membered)-carbocyclic may also be optionally substituted by one to three substituents independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
(e) (5- to 7-membered)-carbocyclic fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring;
wherein said (5- to 7-membered)-carbocyclic may optionally contain one or two double bonds;
wherein either of said (5- to 7-membered)-carbocyclic or said fused saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring is optionally substituted by one to two substituents per ring, wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
(f) (5- to 7-membered)-carbocyclic fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein said (5- to 7-membered)-carbocyclic may optionally contain one or two double bonds;
wherein either of said (5- to 7-membered)-carbocyclic or said fused saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is optionally substituted with one to two substituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
(g) saturated, partially saturated or aromatic, preferably aromatic, (5- to 6-membered)-heterocyclyl containing one to four, preferably one, ring heteroatom(s) independently selected from the groups consisting of —N═, —NR 2 —, —O—, and —S—, preferably selected from the group consisting of —O—, and —S—;
wherein said (5- to 6-membered)-heterocyclyl is optionally substituted by one to three substituents independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl; preferably said (5- to 6-membered)-heterocyclyl is unsubstituted;
(h) saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring;
wherein either of said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl ring or said fused saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring is optionally substituted by one to two substituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl; and
(i) saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S—, and —O—;
wherein said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein either of said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl or said fused saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is optionally substituted with one to twosubstituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 1 (a), (b), (c), (d), (e), (f), (g), (h), or (i) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy;
R 7 is hydrogen, halo, hydroxy, mercapto, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, optionally substituted with one to three halogen atoms, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, cyano, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkylcarbonyloxy, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, nitro, or (C 1 -C 6 )alkylthio;
wherein each of said R 7 (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy;
and the pharmaceutically acceptable salts thereof.
The present invention also relates to the pharmaceutically acceptable acid addition salts of compounds of the formula I. The acids which are used to prepare the pharmaceutically acceptable acid addition salts of the aforementioned base compounds of this invention are those which form non-toxic acid addition salts, i.e., salts containing pharmacologically acceptable anions, such as the hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate, bisulfate, phosphate, acid phosphate, acetate, lactate, citrate, acid citrate, tartrate, bitartrate, succinate, maleate, fumarate, gluconate, saccharate, benzoate, methanesulfonate, ethanesulfonate, benzenesulfonate, para-toluenesulfonate and pamoate [i.e., 1,1′-methylene-bis-(2-hydroxy-3-naphthoate)]salts.
The invention also relates to base addition salts of formula I. The chemical bases that may be used as reagents to prepare pharmaceutically acceptable base salts of those compounds of formula I that are acidic in nature are those that form non-toxic base salts with such compounds. Such non-toxic base salts include, but are not limited to those derived from such pharmacologically acceptable cations such as alkali metal cations (e.g., potassium and sodium) and alkaline earth metal cations (e.g., calcium and magnesium), ammonium or water-soluble amine addition salts such as N-methylglucamine (meglumine), and the lower alkanolammonium and other base salts of pharmaceutically acceptable organic amines.
The compounds of this invention include all stereoisomers (e.g., cis and trans isomers) and all optical isomers of compounds of the formula I (e.g., R and S enantiomers), as well as racemic, diastereomeric and other mixtures of such isomers.
The compounds of the invention also exist in different tautomeric forms. This invention relates to all tautomers of formula I.
The compounds of this invention may contain olefin-like double bonds. When such bonds are present, the compounds of the invention exist as cis and trans configurations and as mixtures thereof.
Unless otherwise indicated, the alkyl, referred to herein, as well as the alkyl moieties of other groups referred to herein (e.g., alkoxy), may be linear or branched (such as methyl, ethyl, n-propyl, isopropyl, n-butyl, iso-butyl, secondary-butyl, tertiary-butyl).
Unless otherwise indicated, halo includes fluoro, chloro, bromo or iodo.
As used herein, the term “alkenyl” means straight or branched chain unsaturated radicals of 2 to 6 carbon atoms, including, but not limited to ethenyl, 1-propenyl, 2-propenyl (allyl), iso-propenyl, 2-methyl-1-propenyl, 1-butenyl, or 2-butenyl.
As used herein, the term “alkynyl” is used herein to mean straight or branched hydrocarbon chain radicals of 2 to 6 carbon atoms having one triple bond including, but not limited to, ethynyl, propynyl, or butynyl.
As used herein, the term “alkoxy” refers to O-alkyl groups, wherein alkyl is as defined above.
As used herein, the term “alkoxycarbonyl” refers to an alkoxy radical as described above connected to a carbonyl group (>C═O), which, in turn, serves as the point of attachment.
As used herein, the term “carbocyclyl” refers to a mono or bicyclic carbocyclic ring (e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclopentenyl, cyclohexenyl, bicyclo[2.2.1]heptanyl, bicyclo[3.2.1]octanyl and bicyclo[5.2.0]nonanyl, etc.); optionally containing 1 or 2 double bonds.
As used herein, the term “amido” refers to aminocarbonyl- or carbamoyl- or NH 2 —(C═O)— moiety.
As used herein the term “aryl” means aromatic radicals such as phenyl, naphthyl, tetrahydronaphthyl, or indanyl.
As used herein the term “heteroaryl” refers to aromatic groups containing one or more heteroatoms (O, S, or N). A multicyclic group containing one or more heteroatoms wherein at least one ring of the group is aromatic is a s“heteroaryl” group. The heteroaryl groups of this invention can also include ring systems substituted with one or more oxo moieties. Examples of heteroaryl groups include, but are not limited to, pyridinyl, pyridazinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, quinolyl, isoquinolyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, oxazolyl, isothiazolyl, pyrrolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, cinnolinyl, indazolyl, indolizinyl, phthalazinyl, pyridazinyl, triazinyl, isoindolyl, purinyl, oxadiazolyl, thiazolyl, thiadiazolyl, furazanyl, benzofurazanyl, benzothiophenyl, benzotriazolyl, benzothiazolyl, benzoxazolyl, quinazolinyl, quinoxalinyl, naphthyridinyl, dihydroquinolyl, tetrahydroquinolyl, dihydroisoquinolyl, tetrahydroisoquinolyl, benzofuryl, furopyridinyl, pyrolopyrimidinyl, and azaindolyl.
The term “heterocyclic” as used herein refers to a cyclic group containing 2-9 carbon atoms and 1-4 hetero atoms selected from N, O, or S. Examples of such rings include furyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, triazolyl, tetrazolyl, isoxazolyl, oxazolyl, thiazolyl, isothiazolyl, oxadiazolyl, oxatriazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl, triazinyl, and the like. Examples of said monocyclic saturated or partially saturated ring systems are tetrahydrofuran-2-yl, tetrahydrofuran-3-yl, imidazolidin-1-yl, imidazolidin-2-yl, imidazolidin-4-yl, pyrrolidin-1-yl, pyrrolidin-2-yl, pyrrolidin-3-yl, piperidin-1-yl, piperidin-2-yl, piperidin-3-yl, piperazin-1-yl, piperazin-2-yl, piperazin-3-yl, 1,3-oxazolidin-3-yl, isothiazolidine, 1,3-thiazolidin-3-yl, 1,2-pyrazolidin-2-yl, 1,3-pyrazolidin-1-yl, thiomorpholine, 1,2-tetrahydrothiazin-2-yl, 1,3-tetrahydrothiazin-3-yl, tetrahydrothiadiazine, morpholine, 1,2-tetrahydrodiazin-2-yl, 1,3-tetrahydrodiazin-1-yl, 1,4-oxazin-2-yl, 1,2,5-oxathiazin-4-yl and the like; optionally substituted by 1 to 3 suitable substituents as defined below such as fluoro, chloro, trifluoromethyl, (C 1 -C 6 )alkoxy, (C 6 -C 10 )aryloxy, trifluoromethoxy, difluoromethoxy or (C 1 -C 6 )alkyl.
The term “phenyl fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring”, as used herein, unless otherwise indicated, means a bicyclic group having a first phenyl ring covalently bound to the pyrazole nucleus and wherein said first ring is fused to a second ring comprising a 5 to 7 membered carbocycle, wherein the 5 to 7 members include the carbon atoms common to both rings. Examples of such rings include tetralin-5-yl, tetralin-6-yl, 2,3-dihydro-inden-4-yl, 2,3-dihydro-inden-5-yl, inden-4-yl, inden-5-yl, 7,8-dihydro-naphthalen-1-yl, 7,8-dihydro-naphthalen-2-yl, 5,6-dihydro-naphthalen-1-yl, 5,6-dihydro-naphthalen-2-yl, 5,8-dihydro-naphthalen-1-yl, 5,8-dihydro-naphthalen-2-yl, naphthalen-1-yl, naphthalen-2-yl, 5-(6,7,8,9-tetrahydro-5H-benzocyclohepten-1-yl)-, 5-(8,9-dihydro-7H-benzocyclohepten-1-yl)-, 5-(6,7-dihydro-5H-benzocyclohepten-1-yl)-, 5-(7H-benzocyclohepten-1-yl)-, 5-(5H-benzocyclohepten-1-yl)-, 5-(9H-benzocyclohepten-1-yl)-, 5-(6,7,8,9-tetrahydro-5H-benzocyclohepten-2-yl)-, 5-(6,7-dihydro-5H-benzocyclohepten-2-yl)-, 5-(8,9-dihydro-7H-benzocyclohepten-2-yl)-, 5-(5H-benzocyclohepten-2-yl)-, 5-(9H-benzocyclohepten-2-yl )-, or 5-(7H-benzocyclohepten-2-yl )-.
The term “phenyl fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic ring”, as used herein, unless otherwise indicated, means a bicyclic group having a first phenyl ring covalently bound to the pyrazole nucleus and wherein said first ring is fused to a second ring comprising a (5- to 6-membered)-heterocyclic ring, wherein the 5 to 6 members include the carbon atoms common to both rings. Said second ring comprises a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic ring. Examples of such rings include quinolin-5-yl, quinolin-6-yl, quinolin-7-yl, quinolin-8-yl, isoquinolin-5-yl, isoquinolin-6-yl, isoquinolin-7-yl, isoquinolin-8-yl, quinazolin-5-yl, quinazolin-6-yl, quinazolin-7-yl, quinazolin-8-yl, cinnolin-5-yl, cinnolin-6-yl, cinnolin-7-yl, cinnolin-8-yl, 4H-1,4-benzoxazin-5-yl, 4H-1,4-benzoxazin-6-yl, 4H-1,4-benzoxazin-7-yl, 4H-1,4-benzoxazin-8-yl, 4H-1,4-benzthiazin-5-yl, 4H-1,4-benzthiazin-6-yl, 4H-1,4-benzthiazin-7-yl, 4H-1,4-benzthiazin-8-yl, 1,4H-1,4-benzdiazin-5-yl, 1,4H-1,4-benzdiazin-6-yl, 1,4H-1,4-benzdiazin-7-yl, 1,4H-1,4-benzdiazin-8-yl, indol-4-yl, indol-5-yl, indol-6-yl, indol-7-yl, benzo(b)thiophen-4yl, benzo(b)thiophen-5-yl, benzo(b)thiophen-6-yl, benzo(b)thiophen-7-yl, benzofuran-4-yl, benzofuran-5-yl, benzofuran-6-yl, benzofuran-7-yl, benzisoxazol-4-yl, benzisoxazol-5-yl, benzisoxazol-6-yl, benzisoxazol-7-yl, benzoxazol-4-yl, benzoxazol-4-yl, benzoxazol-5-yl, benzoxazol-6-yl and benzoxazol-7-yl. Preferred fused phenylheteroaryl rings include quinolinyl, isoquinolinyl, indolyl, benzo(b)thiophenyl, or benzofuranyl.
The term “(3- to 7-membered)-carbocyclic”, as used herein, unless otherwise indicated, means a monocyclic group containing 3 to 7 carbon atoms and optionally containing 1 or 2 double bonds. Examples of such rings include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptanyl, cyclopentenyl, cyclohexenyl or cycloheptenyl.
The term “(5- to 7-membered)-carbocyclic”, as used herein, unless otherwise indicated, means a monocyclic group containing 5 to 7 carbon atoms and optionally containing 1 or 2 double bonds. Examples of such rings include cyclopentyl, cyclohexyl, cycloheptanyl, cyclopentenyl, cyclohexenyl or cycloheptenyl.
The term “(5- to 7-membered)-carbocyclic fused to a saturated or partially saturated (5- to 7-membered)-carbocyclic ring”, as used herein, unless otherwise indicated, means a bicyclic group having a first carbocyclic ring covalently bound to the pyrazole nucleus and wherein said first ring is fused to a second ring comprising a 5 to 7 membered carbocycle, wherein the 5 to 7 members include the carbon atoms common to both rings and wherein said second ring may contain 1, 2 or 3 double bonds. Examples of such rings, wherein the fusion is so called ortho fused, include tetralin-1-yl, tetralin-2-yl, hexahydronaphthalen-1-yl, hexahydronaphthalen-2-yl, octahydronaphthalen-1-yl, octahydronaphthalen-2-yl, decalin-1-yl, decalin-2-yl, 4,5,6,7-tetrahydro-indan-4-yl, 4,5,6,7-tetrahydro-indan-5-yl, 4,5,6,7,8,9-hexahydro-indan-4-yl, 4,5,6,7,8,9-hexahydro-indan-5-yl, 4,5,6,7-tetrahydro-inden-4-yl, 4,5,6,7-tetrahydro-inden-5-yl, 4,5,6,7,8,9-hexahydro-inden-4-yl, 4,5,6,7,8,9-hexahydro-inden-5-yl, pentalan-1-yl, pentalan-2-yl , 4,5 dihydro-pentalan-1-yl, 4,5 dihydro-pentalan-2-yl, 4,5,6,7tetrahydro-pentalan-1-yl, 4,5,6,7 tetra-pentalan-2-yl, benzocycloheptan-5-yl, benzocycloheptan-6-yl and the like. Examples of such bicyclic rings that are not ortho fused include bicyclo[3.2.1]-octan-2-yl, bicyclo[3.2.1]-octan-3-yl, bicyclo [5.2.0]nonan-2-yl, bicyclo [5.2.0]nonan-3-yl, bicyclo [5.2.0]nonan-4-yl, bicyclo [4.3.2]undecan-7-yl, bicyclo [4.3.2]undecan-8-yl, bicyclo [4.3.2]undecan-9-yl, bicyclo[2.2.2]-octan-2-yl, bicyclo[2.2.2]-octan-3-yl, bicyclo[2.2.1]-heptan-2-yl, bicyclo[3.1.1]-heptan-2-yl, or borneol-2-yl.
The term “(5- to 7-membered)carbocyclic fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic”, as used herein, unless otherwise indicated, means a bicyclic group having a first carbocyclic ring covalently bound to the pyrazole nucleus and wherein said first ring is fused to a second ring comprising a 5 to 6 membered heterocyclic ring, wherein said second 5 to 6 members include the atoms common to both rings. Said second ring comprises a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic ring. Examples of said bicyclic ring systems are 5,6,7,8 tetrahydro-quinolin-5-yl, 5,6,7,8 tetrahydro-quinolin-6-yl, 5,6,7,8 tetrahydro-quinolin-7-yl, 5,6,7,8 tetrahydro-quinolin-8-yl, 5,6,7,8 tetrahydro-isoquinolin-5-yl, 5,6,7,8 tetrahydro-isoquinolin-6-yl, 5,6,7,8 tetrahydro-isoquinolin-7-yl, 5,6,7,8 tetrahydro-isoquinolin-8-yl, 5,6,7,8 tetrahydro-quinazolin-5-yl, 5,6,7,8 tetrahydro-quinazolin-6-yl, 5,6,7,8 tetrahydro-quinazolin-7-yl, 5,6,7,8 tetrahydro-quinazolin-8-yl, 5,6,7,8 tetrahydro-4H-1,4-benzoxazin-5-yl, 5,6,7,8 tetrahydro-4H-1,4-benzoxazin-6-yl, 5,6,7,8 tetrahydro-4H-1,4-benzoxazin-7-yl, 5,6,7,8 tetrahydro-4H-1,4-benzoxazin-8-yl, 5,6,7,8 tetrahydro-4H-1,4-benzthiazin-5-yl, 5,6,7,8 tetrahydro-4H-1,4-benzthiazin-6-yl, 5,6,7,8 tetrahydro-4H-1,4-benzthiazin-7-yl, 5,6,7,8 tetrahydro-4H-1,4-benzthiazin-8-yl, 5,6,7,8 tetrahydro-1,4H-1,4-benzdiazin-5-yl, 5,6,7,8 tetrahydro-1,4H-1,4-benzdiazin-6-yl, 5,6,7,8 tetrahydro-1,4H-1,4-benzdiazin-7-yl, 5,6,7,8 tetrahydro-1,4H-1,4-benzdiazin-8-yl, 4,5,6,7 tetrahydro-indol-4-yl, 4,5,6,7 tetrahydro indol-5-yl, 4,5,6,7 tetrahydro-indol-6-yl, 4,5,6,7 tetrahydro-indol-7-yl, 4,5,6,7 tetrahydro-benzo(b)thiophen-4-yl, 4,5,6,7 tetrahydro-benzo(b)thiophen-5-yl, 4,5,6,7 tetrahydro-benzo(b)thiophen-6-yl, 4,5,6,7 tetrahydro-benzo(b)thiophen-7-yl, 4,5,6,7 tetrahydro-benzofuran-4-yl, 4,5,6,7 tetrahydro-benzofuran-5-yl, 4,5,6,7 tetrahydro-benzofuran-6-yl, 4,5,6,7 tetrahydro-benzofuran-7-yl, 4,5,6,7 tetrahydro-benzisoxazol-4-yl, 4,5,6,7 tetrahydro-benzisoxazol-5-yl, 4,5,6,7 tetrahydro-benzisoxazol-6-yl, 4,5,6,7 tetrahydro-benzisoxazol-7-yl, 4,5,6,7 tetrahydro-benzoxazol-4-yl, 4,5,6,7 tetrahydro-benzoxazol-4-yl, 4,5,6,7 tetrahydro-benzoxazol-5-yl, 4,5,6,7 tetrahydro-benzoxazol-6-yl, or 4,5,6,7 tetrahydro-benzoxazol-7-yl.
The term “saturated, partially saturated or aromatic (5- to 6-membered)heterocyclic containing 1 to 4 ring heteroatoms independently selected from —N═, —NR 2 —, —O—, or —S—”, as used herein, unless otherwise indicated, means a monocyclic (5- to 6-membered)heterocyclic ring covalently bound to the pyrazole nucleus. Said ring may contain optional double bonds so as to include saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic rings. Examples of the monocyclic aromatic ring systems are furyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, triazolyl, tetrazolyl, isoxazolyl, oxazolyl, thiazolyl, isothiazolyl, oxadiazolyl, oxatriazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl, triazinyl, and the like. Examples of said monocyclic saturated or partially saturated ring systems are piperidin-1-yl, piperidin-2-yl, piperidin-3-yl, piperazin-1-yl, piperazin-2-yl, piperazin-3-yl, 1,3-oxazolidin-3-yl, isothiazolidine, 1,3-thiazolidin-3-yl, 1,2-pyrazolidin-2-yl, 1,3-pyrazolidin-1-yl, thiomorpholine, 1,2-tetrahydrothiazin-2-yl, 1,3-tetrahydrothiazin-3-yl, tetrahydrothiadiazine, morpholine, 1,2-tetrahydrodiazin-2-yl, 1,3-tetrahydrodiazin-1-yl, 1,4-oxazin-2-yl, or 1,2,5-oxathiazin-4-yl.
The term “saturated, partially saturated or aromatic (5- to 6-membered)heterocyclic fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring”, as used herein, unless otherwise indicated, means a bicyclic group having a first (5- to 6-membered)heterocyclic ring covalently bound to the pyrazole nucleus and wherein said first ring is fused to a second ring comprising a 5 to 6 membered heterocyclic ring, wherein said second 5 to 6 members include the atoms common to both rings. Said first and second rings comprise saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic rings. Examples of said bicyclic ring systems are indolidin-4-yl, indolidin-5-yl, quinolidin-5-yl, quinolidin-6-yl, quinolidin-7-yl, quinolidin-8-yl, isoquinolidin-5-yl, isoquinolidin-6-yl, isoquinolidin-7-yl, isoquinolidin-8-yl, quinazolidin-5-yl, quinazolidin-6-yl, quinazolidin-7-yl, quinazolidin-8-yl, benzofuran-2-yl, benzofuran-3-yl, isobenzofuran-1-yl, isobenzofuran-3-yl, benzothiophen-2-yl, benzothiophen-3-yl, indol-2-yl, indol-3-yl, isoindol-1-yl, isoindol-3-yl, cyclopentapyrid-2-yl, cyclopentapyrid-3-yl, benzoxazol-2-yl, or cinnolin-4-yl.
The term “saturated, partially saturated or aromatic (5- to 6-membered)heterocyclic fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic” as used herein, unless otherwise indicated, means a bicyclic heterocyclic group having a first ring covalently bound to the pyrazole nucleus and containing five to six ring atoms comprising one to two heteroatoms each independently selected from —N═, —NH—, —[N—(C 1 -C 4 )alkyl]-, —O— and —S—; wherein said first ring is fused to a second ring comprising a 5 to 6 membered heterocyclic ring, wherein said second 5 to 6 members include the atoms common to both rings. Said second ring comprises a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclic ring. Examples of said bicyclic ring systems are pyrano[3,4b]pyrrolyl, pyrano[3,2b]pyrrolyl, pyrano[4,3b]pyrrolyl, purin-2-yl, purin-6-yl, purin-7-yl, purin-8-yl, pteridin-2-yl, pyrido[3,4b]pyridyl, pyrido[3,2b]pyridyl, pyrido[4,3b]pyridyl, or naphthyridinyl.
An embodiment and a preferred group of compounds of the present invention includes compounds of formula 1, referred to as the IA1 group of compounds, wherein said compounds have the formula
wherein X is CR 7 or N, preferably CR 7 wherein R 7 is hydrogen; and wherein m is preferably 2.
A preferred group of compounds of the present invention includes compounds of formula I, referred to as the IA2 group of compounds, wherein said compounds have the formula
wherein X is CR 7 or N, wherein X is CR 7 or N, preferably CR 7 wherein R 7 is hydrogen hydrogen; and wherein m is preferably 2.
An embodiment of the present invention includes compounds of formula I, referred to as the IA3 group of compounds, wherein said compounds have the formula
wherein R 1 , R 3 , R 4 , R 5 and R 6 are as defined above hydrogen; and wherein m is preferably 2.
An embodiment of the present invention includes compounds of formula I, referred to as the IA4 group of compounds, wherein said compounds have the formula
wherein R 1 , R 3 , R 4 , R 5 and R 6 are as defined above hydrogen; and wherein m is preferably 2.
An embodiment of the present invention includes compounds of formula I, referred to as the IA5 group of compounds, wherein said compounds have the formula
wherein R 1 , R 3 , R 4 , R 5 and R 6 are as defined above hydrogen; and wherein m is preferably 2.
An embodiment of the present invention includes compounds of formula I, referred to as the IA6 group of compounds, wherein said compounds have the formula
wherein R 1 , R 3 , R 4 , R 5 and R 6 are as defined above hydrogen; and wherein m is preferably 2.
An embodiment and a preferred group of compounds of the present invention includes compounds of formula I, referred to as the R 6 (a) group of compounds, wherein R 6 is
(a) phenyl optionally substituted by one to three, preferably one, substituents independently selected from the group consisting of halo (preferably fluoro), hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl (preferably methyl), (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl; preferably halo, most preferably one fluoro atom, or (C 1 -C 6 )alkyl, most preferably methyl;
wherein each of said R 6 (a) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
A preferred embodiment of the R 6 (a) group of compounds includes compounds of formula I wherein R 6 is phenyl optionally substituted by one to three, preferably one, substituents independently selected from the group consisting of halo, most preferably chloro, or (C 1 -C 6 )alkyl, most preferably methyl;
wherein each of said R 6 (a) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 5 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Another preferred embodiment of the R 6 (a) group of compounds includes compounds of formula I wherein R 6 is phenyl optionally substituted with one to three, preferably one, halo, preferably chloro, or one to three, preferably one, (C 1 -C 6 )alkyl, preferably methyl.
Another preferred embodiment of the R 6 (a) group of compounds includes compounds of formula I wherein R 6 is unsubstituted phenyl.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (b) group of compounds, wherein R 6 is
(b) phenyl fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring;
wherein either of said phenyl or said fused saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring is optionally substituted by one to two substituents per ring, wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 6 (b) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (c) group of compounds, wherein R 6 is
(c) phenyl fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein either of said phenyl or said fused saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is optionally substituted with one to two substituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 ) alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 6 (c) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbony-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (d) group of compounds, wherein R 6 is
(d) (3- to 7-membered)-carbocyclic optionally containing one or two double bonds, preferably the (3- to 7-membered)-carbocyclic contains no double bonds;
wherein said (3- to 7-membered)-carbocyclic may also be optionally substituted by one to three substituents independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 6 (d) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Another embodiment of the R 6 (d) group of compounds includes compounds of formula I wherein R 6 is cyclohexyl optionally substituted by one substituent independently selected from the group consisting of halo, such as chloro, or (C 1 -C 6 )alkyl, such as methyl.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (e) group of compounds, wherein R 6 is
(e) (5- to 7-membered)-carbocyclic fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring;
wherein said (5- to 7-membered)-carbocyclic may optionally contain one or two double bonds;
wherein either of said (5- to 7-membered)-carbocyclic or said fused saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring is optionally substituted by one to two substituents per ring, wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 6 (e) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (f) group of compounds, wherein R 6 is
(f) (5- to 7-membered)-carbocyclic fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein said (5- to 7-membered)-carbocyclic may optionally contain one or two double bonds;
wherein either of said (5- to 7-membered)-carbocyclic or said fused saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is optionally substituted with one to two substituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 1 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 6 (f) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (g) group of compounds, wherein R 6 is
(g) saturated, partially saturated or aromatic, preferably aromatic, (5- to 6-membered)-heterocyclyl containing one to four, preferably one, ring heteroatom(s) independently selected from the groups consisting of —N═, —NR 2 —, —O—, and —S—, preferably selected from the group consisting of —O—, and —S—;
wherein said (5- to 6-membered)-heterocyclyl is optionally substituted by one to three substituents independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 ) alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl; preferably said (5- to 6-membered)-heterocyclyl is unsubstituted;
wherein each of said R 6 (g) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Another embodiment of the R 6 (g) group of compounds includes compounds of formula I wherein R 6 is saturated, partially unsaturated or aromatic, preferably aromatic, (5- to 6-membered), preferably 5-membered, heterocyclyl containing one to four preferably one, ring heteroatoms, independently selected from the groups consisting of —N═, —NR 2 —, —O—, and —S—, preferably selected from the group consisting of —O—, and —S—;
wherein said (5- to 6-membered)-heterocyclyl is optionally substituted by one to three substituents, preferably no substituents, independently selected from the group consisting of halo, such as chloro, or (C 1 -C 6 )alkyl, such as methyl;
wherein each of said R 6 (g) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C6)alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Another embodiment of the R 6 (g) group of compounds includes compounds of formula I wherein R 6 is aromatic (5- to 6-membered)-heterocyclyl containing one to two, preferably one, ring heteroatoms independently selected from the groups consisting of —N═, —NR 2 —, —O—, and —S—; preferably selected from the group consisting of —O—, and —S—;
wherein said (5- to 6-membered)-heterocyclyl is substituted by one to three, preferably one, halo, preferably chloro, or one to three, preferably one, (C 1 -C 6 )alkyl, preferably methyl.
Other preferred embodiment of the R 6 (g) group of compounds includes compounds of formula I wherein R 6 is unsubstituted aromatic (5- to 6-membered)-, more preferably (5-membered)-heterocyclyl, such as thienyl, most preferably 2-thienyl, or furanyl, most preferably 2-furanyl.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (h) group of compounds, wherein R 6 is
(h) saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is fused to a saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring;
wherein either of said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl ring or said fused saturated, partially saturated or aromatic (5- to 7-membered)-carbocyclic ring is optionally substituted by one to two substituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of R 6 (h) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryoxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
An embodiment of the present invention includes compounds of formula I, referred to as the R 6 (i) group of compounds, wherein R 6 is
(i) saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S—, and —O—;
wherein said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is fused to a saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl containing one to two ring heteroatoms independently selected from the group consisting of —N═, —NR 2 —, —S— and —O—;
wherein either of said saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl or said fused saturated, partially saturated or aromatic (5- to 6-membered)-heterocyclyl is optionally substituted with one to twosubstituents per ring;
wherein said substituents are independently selected from the group consisting of halo, hydroxy, cyano, mercapto, hydroxycarbonyl, nitro, (C 1 -C 6 )alkyl, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, —OCF 3 , (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, (C 1 -C 6 )alkylcarbonyloxy, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkoxycarbonyl, (C 6 -C 10 )aryl and (C 2 -C 9 )heterocyclyl;
wherein each of said R 6 (i) (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Subgeneric embodiments of the present invention of the “A” (i.e. A1, A2, A3, A4, A5, and A6) and R 6 (i.e. R 6 (a), R 6 (b), R 6 (c), R 6 (d), R 6 (e), R 6 (f), R 6 (g), R 6 (h), R 6 (i)) groups of compounds are expressly contemplated by the present invention. Such subgeneric embodiments within the A1 group of compounds include the A1 group in combination with each of the R 6 groups (i.e. A1-R 6 (a), A1-R 6 (b), A1-R 6 (c), A1-R 6 (d), A1-R 6 (e), A1-R 6 (f), A1-R 6 (g), A1-R 6 (h) and A1-R 6 (i)). Such subgeneric embodiments within the A2 group of compounds include the A2 group in combination with each of the R 6 groups (i.e. A2-R 6 (a), A2-R 6 (b), A2-R 6 (c), A2-R 6 (d), A2-R 6 (e), A2-R 6 (f), A2-R 6 (g), A2-R 6 (i)). Such subgeneric embodiments within the A3 group of compounds include the A3 group in combination with each of the R 6 groups (i.e. A3-R 6 (a), A3-R 6 (b), A3-R 6 (c), A3-R 6 (d), A3-R 6 (e), A3-R 6 (f), A3-R 6 (g), A3-R 6 (h) and A3-R 6 (i)). Such subgeneric embodiments within the A4 group of compounds include the A4 group in combination with each of the R 6 groups (i.e. A4-R 6 (a), A4-R 6 (b), A4-R 6 (c), A4-R 6 (d), A4-R 6 (e), A4-R 6 (f), A4-R 6 (g), A4-R 6 (h) and A4-R 6 (i)). Such subgeneric embodiments within the A5 group of compounds include the A5 group in combination with each of the R 6 groups (i.e. A5-R 6 (a), A5-R 6 (b), A5-R 6 (c), A5-R 6 (d), A5-R 6 (e), A5-R 6 (f), A5-R 6 (g), A5-R 6 (h) and A5-R 6 (i)). Such subgeneric embodiments within the A6 group of compounds include the A6 group in combination with each of the R 6 groups (i.e. A6-R 6 (a), A6-R 6 (b), A6-R 6 (c), A6-R 6 (d), A6-R 6 (e), A6-R 6 (f), A6-R 6 (h) and A6-R 6 (i)).
Preferred compounds of formula I are those compounds wherein the “A” ring is optionally substituted pyridin-2-yl or pyridin-3-yl; more preferably wherein m is 2.
Other compounds of this invention are those of the formula I wherein R 5 is hydrogen, halo(such as fluoro), hydroxy, mercapto, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy optionally substituted with one to three halogen atoms, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, cyano, formyl, (C 1 -C 6 )alkylcarbonyl, (C 1 -C 6 )alkylcarbonyloxy, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkoxyamido, or (C 1 -C 6 )alkylthio;
wherein each of said R 5 (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Other preferred compounds of this invention are those of the formula I wherein R 5 is hydrogen.
Other compounds of this invention are those of the formula I wherein R 4 is (C 1 -C 6 )alkyl, more preferably methyl, optionally substituted by one to three halo atoms, such as fluoro atoms.
Other preferred compounds of this invention are those of the formula I wherein R 4 is (C 1 -C 6 )alkyl, more preferably methyl.
Other compounds of this invention are those of the formula I wherein R 3 is (C 1 -C 6 )alkylthio (such as methylthio), (C 3 -C 7 )carbocyclylthio (such as cyclohexylthio), C 6 -C 10 )arylthio, (C 2 -C 9 )heteroarylthio, (C 1 -C 6 )alkyl-S(═O), (C 6 -C 10 )aryl-S(═O), (C 2 -C 9 )heteroaryl-S(═O), (C 1 -C 6 )alkyl-SO 2 —, (C 6 -C 10 )aryl-SO 2 —, (C 2 -C 9 )heteroaryl-SO 2 —, (C 1 -C 6 )alkyl-SO 2 -amino, (C 3 -C 7 )carbocyclyl-SO 2 -amino, (C 6 -C 10 )aryl-SO 2 -amino, (C 2 -C 9 )heteroaryl-SO 2 -amino, amino-SO 2 —, N—(C 1 -C 6 )alkylamino-SO 2 —, N,N—[(C 1 -C 6 )alkyl] 2 amino-SO 2 —, N—(C 3 -C 7 )carbocyclylamino-SO 2 —, N—(C 6 -C 10 )arylamino-SO 2 —, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino-SO 2 —, N—(C 2 -C 9 )heteroarylamino-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, or N—(C 2 -C 9 )heteroarylamino;
wherein each of said (C 1 -C 6 )alkyl group wherever they occur may optionally be substituted with one to three substituents independently selected from the group consisting of halo, hydroxy, (C 2 -C 6 )alkenyl, (C 2 -C 6 )alkynyl, (C 3 -C 7 )carbocyclyl, (C 1 -C 6 )alkoxy, carbonyl, formyl, formamidyl, (C 1 -C 6 )alkylcarbonyl, cyano, mercapto, nitro, hydroxycarbonyl, (C 1 -C 6 )alkoxycarbonyl, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, N—(C 2 -C 9 )heteroarylamino, amido, N—(C 1 -C 6 )alkylamido, N,N—[(C 1 -C 6 )alkyl] 2 amido, N—(C 6 -C 10 )arylamido, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamido, (C 1 -C 6 )alkoxyamido, (C 6 -C 10 )aryl, (C 6 -C 10 )aryloxy, (C 2 -C 9 )heteroaryl, (C 2 -C 9 )heteroaryloxy, (C 2 -C 9 )heteroarylcarbonyl, (C 1 -C 6 )alkylthio, (C 1 -C 6 )alkyl-S(═O)—, (C 1 -C 6 )alkyl-SO 2 —, (C 1 -C 6 )alkylcarbonyl-N(R 2 )—, and (C 1 -C 6 )alkylcarbonyloxy.
Other preferred compounds of this invention are those of the formula I wherein R 3 is (C 1 -C 6 )alkylthio (such as methylthio), (C 3 -C 7 )carbocyclylthio (such as cyclohexylthio), C 8 -C 10 )arylthio, (C 2 -C 9 )heteroarylthio, (C 1 -C 6 )alkyl-S(═O), (C 6 -C 10 )aryl-S(═O), (C 2 -C 9 )heteroaryl-S(═O), (C 1 -C 6 )alkyl-SO 2 —, (C 6 -C 10 )aryl-SO 2 —, (C 2 -C 9 )heteroaryl-SO 2 —, (C 1 -C 6 )alkyl-SO 2 -amino, (C 3 -C 7 )carbocyclyl-SO 2 -amino, (C 6 -C 10 )aryl-SO 2 -amino, (C 2 -C 9 )heteroaryl-SO 2 -amino, amino-SO 2 —, N—(C 1 -C 6 )alkylamino-SO 2 —, N,N—[(C 1 -C 6 )alkyl] 2 amino-SO 2 —, N—(C 3 -C 7 )carbocyclylamino-SO 2 —, N—(C 6 -C 10 )arylamino-SO 2 —, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino-SO 2 —, N—(C 2 -C 9 )heteroarylamino-SO 2 —, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, or N—(C 2 -C 9 )heteroarylamino.
Other preferred compounds of this invention are those of the formula I wherein R 3 is C 1 -C 6 )alkylthio (such as methylthio), (C 3 -C 7 )carbocyclylthio(such as cyclohexylthio), (C 6 -C 10 )arylthio, (C 2 -C 9 )heteroarylthio, amino, N—(C 1 -C 6 )alkylamino, N,N—[(C 1 -C 6 )alkyl] 2 amino, N—(C 3 -C 7 )carbocyclylamino, N—(C 6 -C 10 )arylamino, N—(C 1 -C 6 )alkyl-N—(C 6 -C 10 )arylamino, or N—(C 2 -C 9 )heteroarylamino.
Other preferred compounds of this invention are those of the formula I wherein R 3 is (C 1 -C 6 )alkylthio, more preferably methylthio, wherein each of said (C 1 -C 8 )alkyl group may optionally be substituted with one to three substituents independently selected from hydroxycarbonyl or (C 1 -C 6 )alkoxycarbonyl, such as methoxycarbonyl or ethoxycarbonyl.
Other preferred compounds of this invention are those of the formula I wherein R 3 is (C 1 -C 6 )alkylthio (more preferably methylthio), amino, alkylsulfonylamino, sulfamylamino, alkylamino and alkylcarbonylamino; more preferably wherein R 3 is (C 1 -C 6 )alkylthio or amino.
Other compounds of this invention are those of the formula I wherein R 2 is hydrogen, or (C 1 -C 6 )alkyl, such as methyl.
Other compounds of this invention are those of the formula I wherein R 1 is hydrogen, cyano, halo, (C 1 -C 6 )alkyl (such as methyl) optionally substituted with one to three halo (such as fluoro) atoms, (C 1 -C 6 )alkylcarbonyl, or formyl.
Other preferred compounds of this invention are those of the formula I wherein R 1 is hydrogen, halo, cyano, or (C 1 -C 6 )alkylcarbonyl, such as methylcarbonyl.
Most preferred compounds of this invention are those of the formula I wherein R 1 is cyano.
Other most preferred compounds of this invention are those of the formula I wherein the “A” ring is optionally substituted pyridin-2-yl or pyridin-3-yl; more preferably wherein m is 2; R 1 is cyano; R 3 is methylthio; R 4 is methyl; R 5 is hydrogen; and R 6 is phenyl optionally substituted by one to three, preferably one, substituents independently selected from the group consisting of halo, most preferably chloro, or (C 1 -C 6 )alkyl, most preferably methyl.
Other most preferred compounds of this invention are those of the formula I wherein the “A” ring is optionally substituted pyridin-2-yl or pyridin-3-yl; more preferably wherein m is 2; R 1 is cyano; R 3 is methylthio; R 4 is methyl; R 5 is hydrogen; and R 6 is phenyl optionally substituted with one to three, preferably one, halo, preferably chloro, or one to three, preferably one, (C 1 -C 6 )alkyl, preferably methyl.
Other most preferred compounds of this invention are those of the formula I wherein the “A” ring is optionally substituted pyridin-2-yl or pyridin-3-yl; more preferably wherein m is 2; R 1 is cyano; R 3 is methylthio; R 4 is methyl; R 5 is hydrogen; and R 6 is unsubstituted phenyl.
Other most preferred compounds of this invention are those of the formula I wherein the “A” ring is optionally substituted pyridin-2-yl or pyridin-3-yl; more preferably wherein m is 2; R 1 is cyano; R 3 is methylthio; R 4 is methyl; R 5 is hydrogen; and R 6 is unsubstituted aromatic (5- to 6-membered)-, more preferably (5-membered)-heterocyclyl, such as thienyl, most preferably 2-thienyl, or furanyl, most preferably 2-furanyl.
Examples of specific preferred compounds of the formula I are the following:
1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-phenyl-1H-pyrazole-4-carbonitrile; 5-(4-Chloro-phenyl)-1-(5-methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-1H-pyrazole-4-carbonitrile; 1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-p-tolyl-1H-pyrazole-4-carbonitrile; 1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-thiophen-2-yl-1H-pyrazole-4-carbonitrile; 1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-m-tolyl-1H-pyrazole-4-carbonitrile; 5-(3-Chloro-phenyl)-1-(5-methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-1H-pyrazole-4-carbonitrile; 3-Methanesulfonyl-1-(5-methanesulfonyl-pyridin-2-yl)-5-phenyl-1H-pyrazole-4-carbonitrile; 3-Azido-1-(5-methanesulfonyl-pyridin-2-yl)-5-phenyl-1H-pyrazole-4-carbonitrile; 3-Amino-1-(5-methanesulfonyl-pyridin-2-yl)-5-phenyl-1H-pyrazole-4-carbonitrile; N-[4-Cyano-1-(5-methanesulfonyl-pyridin-2-yl)-5-phenyl-1H-pyrazol-3-yl]-methanesulfonamide; [4-Cyano-1-(5-methanesulfonyl-pyridin-2-yl)-5-phenyl-1H-pyrazol-3-ylamino]-acetic acid; [4-Cyano-1-(5-methanesulfonyl-pyridin-2-yl)-5-phenyl-1H-pyrazol-3-ylamino]-acetic acid methyl ester; 1-(6-Methanesulfonyl-pyridin-3-yl)-3-methylsulfanyl-5-phenyl-1H-pyrazole-4-carbonitrile; 3-Methanesulfonyl-1-(6-methanesulfonyl-pyridin-3-yl)-5-phenyl-1H-pyrazole-4-carbonitrile; 3-Methanesulfonyl-1-(6-methanesulfonyl-pyridin-3-yl)-5-phenyl-1H-pyrazole-4-carbonitrile; and the pharmaceutically acceptable salts thereof.
The present invention also relates to a pharmaceutical composition for the treatment of a condition selected from the group consisting of arthritis (including osteoarthritis, degenerative joint disease, spondyloarthropathies, gouty arthritis, systemic lupus erythematosus, juvenile arthritis and rheumatoid arthritis), fever (including rheumatic fever and fever associated with influenza and other viral infections), common cold, dysmenorrhea, menstrual cramps, inflammatory bowel disease, Crohn's disease, emphysema, acute respiratory distress syndrome, asthma, bronchitis, chronic obstructive pulmonary disease, Alzheimer's disease, organ transplant toxicity, cachexia, allergic reactions, allergic contact hypersensitivity, cancer (such as solid tumor cancer including colon cancer, breast cancer, lung cancer and prostrate cancer; hematopoietic malignancies including leukemias and lymphomas; Hodgkin's disease; aplastic anemia, skin cancer and familiar adenomatous polyposis), tissue ulceration, peptic ulcers, gastritis, regional enteritis, ulcerative colitis, diverticulitis, recurrent gastrointestinal lesion, gastrointestinal bleeding, coagulation, anemia, synovitis, gout, ankylosing spondylitis, restenosis, periodontal disease, epidermolysis bullosa, osteoporosis, loosening of artificial joint implants, atherosclerosis (including atherosclerotic plaque rupture), aortic aneurysm (including abdominal aortic aneurysm and brain aortic aneurysm), periarteritis nodosa, congestive heart failure, myocardial infarction, stroke, cerebral ischemia, head trauma, spinal cord injury, neuralgia, neuro-degenerative disorders (acute and chronic), autoimmune disorders, Huntington's disease, Parkinson's disease, migraine, depression, peripheral neuropathy, pain (including low back and neck pain, headache and toothache), gingivitis, cerebral amyloid angiopathy, nootropic or cognition enhancement, amyotrophic lateral sclerosis, multiple sclerosis, ocular angiogenesis, corneal injury, macular degeneration, conjunctivitis, abnormal wound healing, muscle or joint sprains or strains, tendonitis, skin disorders (such as psoriasis, eczema, scleroderma and dermatitis), myasthenia gravis, polymyositis, myositis, bursitis, burns, diabetes (including types I and II diabetes, diabetic retinopathy, neuropathy and nephropathy), tumor invasion, tumor growth, tumor metastasis, corneal scarring, scleritis, immunodeficiency diseases (such as AIDS in humans and FLV, FIV in cats), sepsis, premature labor, hypoprothrombinemia, hemophilia, thyroiditis, sarcoidosis, Behcet's syndrome, hypersensitivity, kidney disease, Rickettsial infections (such as Lyme disease, Erlichiosis), Protozoan diseases (such as malaria, giardia, coccidia), reproductive disorders (preferably in livestock), and septic shock in a mammal, preferably a human, cat livestock or a dog, comprising an amount of a compound of formula I or a pharmaceutically acceptable salt thereof effective in such treatment and a pharmaceutically acceptable carrier.
The present invention also relates to a pharmaceutical composition for the treatment of a condition that can be treated by selectively inhibiting COX-2 in a mammal, preferably a human, cat, livestock or dog, comprising a COX-2 selective inhibiting effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof and a pharmaceutically acceptable carrier.
The present invention also relates to a pharmaceutical composition for the treatment of a condition selected from the group consisting of inflammatory diseases such as arthritis (including osteoarthritis, degenerative joint disease, spondyloarthropathies, gouty arthritis, systemic lupus erythematosus, juvenile arthritis and rheumatoid arthritis), or fever (including rheumatic fever and fever associated with influenza).
The present invention also relates to a method for treating a condition selected from the group consisting of arthritis (including osteoarthritis, degenerative joint disease, spondyloarthropathies, gouty arthritis, systemic lupus erythematosus, juvenile arthritis and rheumatoid arthritis), fever (including rheumatic fever and fever associated with influenza and other viral infections), common cold, dysmenorrhea, menstrual cramps, inflammatory bowel disease, Crohn's disease, emphysema, acute respiratory distress syndrome, asthma, bronchitis, chronic obstructive pulmonary disease, Alzheimer's disease, organ transplant toxicity, cachexia, allergic reactions, allergic contact hypersensitivity, cancer (such as solid tumor cancer including colon cancer, breast cancer, lung cancer and prostrate cancer; hematopoietic malignancies including leukemias and lymphomas; Hodgkin's disease; aplastic anemia, skin cancer and familiar adenomatous polyposis), tissue ulceration, peptic ulcers, gastritis, regional enteritis, ulcerative colitis, diverticulitis, recurrent gastrointestinal lesion, gastrointestinal bleeding, coagulation, anemia, synovitis, gout, ankylosing spondylitis, restenosis, periodontal disease, epidermolysis bullosa, osteoporosis, loosening of artificial joint implants, atherosclerosis (including atherosclerotic plaque rupture), aortic aneurysm (including abdominal aortic aneurysm and brain aortic aneurysm), periarteritis nodosa, congestive heart failure, myocardial infarction, stroke, cerebral ischemia, head trauma, spinal cord injury, neuralgia, neuro-degenerative disorders (acute and chronic), autoimmune disorders, Huntington's disease, Parkinson's disease, migraine, depression, peripheral neuropathy, pain (including low back and neck pain, headache and toothache), gingivitis, cerebral amyloid angiopathy, nootropic or cognition enhancement, amyotrophic lateral sclerosis, multiple sclerosis, ocular angiogenesis, corneal injury, macular degeneration, conjunctivitis, abnormal wound healing, muscle or joint sprains or strains, tendonitis, skin disorders (such as psoriasis, eczema, scleroderma and dermatitis), myasthenia gravis, polymyositis, myositis, bursitis, burns, diabetes (including types I and II diabetes, diabetic retinopathy, neuropathy and nephropathy), tumor invasion, tumor growth, tumor metastasis, corneal scarring, scleritis, immunodeficiency diseases (such as AIDS in humans and FLV, FIV in cats), sepsis, premature labor, hypoprothrombinemia, hemophilia, thyroiditis, sarcoidosis, Behcet's syndrome, hypersensitivity, kidney disease, Rickettsial infections (such as Lyme disease, Erlichiosis), Protozoan diseases (such as malaria, giardia, coccidia), reproductive disorders (preferably in livestock) and septic shock in a mammal, preferably a human, cat livestock or a dog, comprising administering to said mammal an amount of a compound of formula I or a pharmaceutically acceptable salt thereof effective in treating such a condition.
The present invention also relates to a method for treating a disorder or condition that can be treated by selectively inhibiting COX-2 in a mammal, preferably a human, cat livestock or a dog, comprising administering to a mammal requiring such treatment a COX-2 selective inhibiting effective amount of a compound of formula I or a pharmaceutically acceptable salt thereof.
The present invention also relates to a method for treating a condition selected from the group consisting of inflammatory diseases such as arthritis (including osteoarthritis, degenerative joint disease, spondyloarthropathies, gouty arthritis, systemic lupus erythematosus, juvenile arthritis and rheumatoid arthritis), or fever (including rheumatic fever and fever associated with influenza).
This invention also relates to a method of or a pharmaceutical composition for treating inflammatory processes and diseases comprising administering a compound of formula I of this invention or its salt to a mammal including a human, cat, livestock or dog, wherein said inflammatory processes and diseases are defined as above, and said inhibitory compound is used in combination with one or more other therapeutically active agents under the following conditions:
A.) where a joint has become seriously inflammed as well as infected at the same time by bacteria, fungi, protozoa, and/or virus, said inhibitory compound is administered in combination with one or more antibiotic, antifungal, antiprotozoal, and/or antiviral therapeutic agents;
B.) where a multi-fold treatment of pain and inflammation is desired, said inhibitory compound is administered in combination with inhibitors of other mediators of inflammation, comprising one or more members independently selected from the group consisting essentially of:
(1) NSAIDs; (2) H 1 -receptor antagonists; (3) kinin-B 1 - and B 2 -receptor antagonists; (4) prostaglandin inhibitors selected from the group consisting of PGD-, PGF-PGI 2 -, and PGE-receptor antagonists; (5) thromboxane A 2 (TXA 2 -) inhibitors; (6) 5-, 12- and 15-lipoxygenase inhibitors; (7) leukotriene LTC 4 -, LTD 4 /LTE 4 -, and LTB 4 -inhibitors; (8) PAF-receptor antagonists; (9) gold in the form of an aurothio group together with one or more hydrophilic groups; (10) immunosuppressive agents selected from the group consisting of cyclosporine, azathioprine, and methotrexate; (11) anti-inflammatory glucocorticoids; (12) penicillamine; (13) hydroxychloroquine; (14) anti-gout agents including colchicine; xanthine oxidase inhibitors including allopurinol; and uricosuric agents selected from probenecid, sulfinpyrazone, and benzbromarone;
C.) where older mammals are being treated for disease conditions, syndromes and symptoms found in geriatric mammals, said inhibitory compound is administered in combination with one or more members independently selected from the group consisting essentially of:
(1) cognitive therapeutics to counteract memory loss and impairment; (2) anti-hypertensives and other cardiovascular drugs intended to offset the consequences of atherosclerosis, hypertension, myocardial ischemia, angina, congestive heart failure, and myocardial infarction, selected from the group consisting of:
a. diuretics; b. vasodilators; c. β-adrenergic receptor antagonists; d. angiotensin-II converting enzyme inhibitors (ACE-inhibitors), alone or optionally together with neutral endopeptidase inhibitors; e. angiotensin II receptor antagonists; f. renin inhibitors; g. calcium channel blockers; h. sympatholytic agents; i. α 2 -adrenergic agonists; j. α-adrenergic receptor antagonists; and k. HMG-CoA-reductase inhibitors (anti-hypercholesterolemics);
(3) antineoplastic agents selected from:
a. antimitotic drugs selected from:
i. vinca alkaloids selected from:
[1] vinblastine, and [2] vincristine;
(4) growth hormone secretagogues; (5) strong analgesics; (6) local and systemic anesthetics; and (7) H 2 -receptor antagonists, proton pump inhibitors, and other gastroprotective agents.
The term “treating”, as used herein, refers to reversing, alleviating, inhibiting the progress of, or preventing the disorder or condition to which such term applies, or one or more symptoms of such disorder or condition. The term “treatment”, as used herein, refers to the act of treating, as “treating” is defined immediately above.
The term “livestock animals” as used herein refers to domesticated quadrupeds, which includes those being raised for meat and various byproducts, e.g., a bovine animal including cattle and other members of the genus Bos , a porcine animal including domestic swine and other members of the genus Sus , an ovine animal including sheep and other members of the genus Ovis , domestic goats and other members of the genus Capra; domesticated quadrupeds being raised for specialized tasks such as use as a beast of burden, e.g., an equine animal including domestic horses and other members of the family Equidae, genus Equus , or for searching and sentinel duty, e.g., a canine animal including domestic dogs and other members of the genus Canis ; and domesticated quadrupeds being raised primarily for recreational purposes, e.g., members of Equus and Canis , as well as a feline animal including domestic cats and other members of the family Felidae, genus Felis.
“Companion animals” as used herein refers to cats, dogs and horses. As used herein, the term “dog(s)” denotes any member of the species Canis familiaris , of which there are a large number of different breeds. While laboratory determinations of biological activity may have been carried out using a particular breed, it is contemplated that the inhibitory compounds of the present invention will be found to be useful for treating pain and inflammation in any of these numerous breeds. Dogs represent a particularly preferred class of patients in that they are well known as being very susceptible to chronic inflammatory processes such as osteoarthritis and degenerative joint disease, which in dogs often results from a variety of developmental diseases, e.g., hip dysplasia and osteochondrosis, as well as from traumatic injuries to joints. Conventional NSAIDs, if used in canine therapy, have the potential for serious adverse gastrointestinal reactions and other adverse reactions including kidney and liver toxicity. Gastrointestinal effects such as single or multiple ulcerations, including perforation and hemorrhage of the esophagus, stomach, duodenum or small and large intestine, are usually debilitating, but can often be severe or even fatal.
The term “treating reproductive disorders (preferably in livestock)” as used herein refers to the use of the COX-2 inhibitors of the invention in mammals, preferably livestock animals (cattle, pigs, sheep, goats or horses), during the estrus cycle to control the time of onset of estrus by blocking the uterine signal for lysis of the corpus luteum, i.e. F-series prostaglandins, then removing the inhibition when the onset of estrus is desired. There are settings where it is useful to control or synchronize the time of estrus, especially when artificial insemination or embryo transfer are to be performed. Such use also includes enhancing the rate of embryo survival in pregnant livestock animals. Blocking F-series prostaglandin release can have several beneficial actions including reducing uterine contractions, enhancing uteroplacental bloodflow, supporting recognition of pregnancy, and postponing lysis of the corpus luteum at the time when estrus would have occurred had the animal not become pregnant (around Day 21 of pregnancy). Such treatment also abrogates the effects of stress on reproduction. For example reductions in fertility caused by excessive heat, negative energy balance and other stresses which have a COX-2 mediated component, as does abortion induced by stress such as heat, transportation, co-mingling, palpation, infection, etc. Such treatment is also useful to control the time of parturition, which is accompanied by release of F-series prostaglandins that lead to lysis of the corpus luteum. Inhibition of COX-2 would block the onset of premature labor in livestock animals, allowing the offspring time to mature before birth. Also there are settings where controlling the time of parturition is a useful tool for management of pregnant animals.
The subject invention also includes isotopically-labelled compounds, which are identical to those recited in Formula I, but for the fact that one or more atoms are replaced by an atom having an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Examples of isotopes that can be incorporated into compounds of the invention include isotopes of hydrogen, carbon, nitrogen, oxygen, phosphorous, fluorine and chlorine,. such as 2 H, 3 H, 13 C, 14 C, 15 N, 18 O, 17 O, 31 P, 32 P, 35 S, 18 F, and 36 Cl, respectively. Compounds of the present invention, prodrugs thereof, and pharmaceutically acceptable salts of said compounds or of said prodrugs which contain the aforementioned isotopes and/or other isotopes of other atoms are within the scope of this invention. Certain isotopically-labelled compounds of the present invention, for example those into which radioactive isotopes such as 3 H and 14 C are incorporated, are useful in drug and/or substrate tissue distribution assays. Tritiated, i.e., 3 H, and carbon-14, i.e., 14 C, isotopes are particularly preferred for their ease of preparation and detectability. Further, substitution with heavier isotopes such as deuterium, ie., 2 H, can afford certain therapeutic advantages resulting from greater metabolic stability, for example increased in vivo half-life or reduced dosage requirements and, hence, may be preferred in some circumstances. Isotopically labelled compounds of Formula I of this invention and prodrugs thereof can generally be prepared by carrying out the procedures disclosed in the Schemes and/or in the Examples and Preparations below, by substituting a readily available isotopically labelled reagent for a non-isotopically labelled reagent.
This invention also encompasses pharmaceutical compositions containing prodrugs of compounds of the formula I. This invention also encompasses methods of treating disorders that can be treated by the selective inhibition of COX-2 comprising administering prodrugs of compounds of the formula I. Compounds of formula I having free amino, amido, hydroxy, carboxylic acid ester, sulfonamide or carboxylic groups (especially alkyl-S— and alkyl-(S═O)—) can be converted into prodrugs. Prodrugs include compounds wherein an amino acid residue, or a polypeptide chain of two or more (e.g., two, three or four) amino acid residues which are covalently joined through peptide bonds to free amino, hydroxy or carboxylic acid groups of compounds of formula I. The amino acid residues include the 20 naturally occurring amino acids commonly designated by three letter symbols and also include, 4-hydroxyproline, hydroxylysine, demosine, isodemosine, 3-methylhistidine, norvalin, beta-alanine, gamma-aminobutyric acid, citrulline, homocysteine, homoserine, ornithine and methionine sulfone. Prodrugs also include compounds wherein carbonates, carbamates, amides and alkyl esters are covalently bonded to the above substituents of formula I through the carbonyl carbon prodrug sidechain. Prodrugs also include metabolically labile groups such as ethers, acetates, mercaptans and sulfoxides.
One of ordinary skill in the art will appreciate that the compounds of the invention are useful in treating a diverse array of diseases. One of ordinary skill in the art will also appreciate that when using the compounds of the invention in the treatment of a specific disease that the compounds of the invention may be combined with various existing therapeutic agents used for that disease.
For the treatment of rheumatoid arthritis, the compounds of the invention may be combined with agents such as TNF-α inhibitors such as anti-TNF monoclonal antibodies and TNF receptor immunoglobulin molecules (such as Enbrel®), low dose methotrexate, lefunimide, hydroxychloroquine, d-penicilamine, auranofin or parenteral or oral gold.
The compounds of the invention can also be used in combination with existing therapeutic agents for the treatment of osteoarthritis. Suitable agents to be used in combination include standard non-steroidal anti-inflammatory agents (hereinafter NSAID's) such as piroxicam, diclofenac, propionic acids such as naproxen, flurbiprofen, fenoprofen, ketoprofen and ibuprofen, fenamates such as mefenamic acid, indomethacin, sulindac, apazone, pyrazolones such as phenylbutazone, salicylates such as aspirin, COX-2 inhibitors such as celecoxib and rofecoxib, analgesics and intraarticular therapies such as corticosteroids and hyaluronic acids such as hyalgan and synvisc.
The active ingredient of the present invention may be administered in combination with inhibitors of other mediators of inflammation, comprising one or more members selected from the group consisting essentially of the classes of such inhibitors and examples thereof which include, matrix metalloproteinase inhibitors, aggrecanase inhibitors, TACE inhibitors, leucotriene receptor antagonists, IL-1 processing and release inhibitors, ILra, H 1 -receptor antagonists; kinin-B 1 - and B 2 -receptor antagonists; prostaglandin inhibitors such as PGD-, PGF-PGI 2 -, and PGE-receptor antagonists; thromboxane A 2 (TXA2-) inhibitors; 5- and 12-lipoxygenase inhibitors; leukotriene LTC 4 -, LTD 4 /LTE 4 -, and LTB 4 -inhibitors; PAF-receptor antagonists; gold in the form of an aurothio group together with various hydrophilic groups; immunosuppressive agents, e.g., cyclosporine, azathioprine, and methotrexate; anti-inflammatory glucocorticoids; penicillamine; hydroxychloroquine; anti-gout agents, e.g., coichicine, xanthine oxidase inhibitors, e.g., allopurinol, and uricosuric agents, e.g., probenecid, sulfinpyrazone, and benzbromarone.
The compounds of the present invention may also be used in combination with anticancer agents such as endostatin and angiostatin or cytotoxic drugs such as adriamycin, daunomycin, cis-platinum, etoposide, taxol, taxotere and alkaloids, such as vincristine, and antimetabolites such as methotrexate.
The compounds of the present invention may also be used in combination with anti-hypertensives and other cardiovascular drugs intended to offset the consequences of atherosclerosis, including hypertension, myocardial ischemia including angina, congestive heart failure, and myocardial infarction, selected from vasodilators such as hydralazine, β-adrenergic receptor antagonists such as propranolol, calcium channel blockers such as nifedipine, α 2 -adrenergic agonists such as clonidine, α-adrenergic receptor antagonists such as prazosin, and HMG-CoA-reductase inhibitors (anti-hypercholesterolemics) such as lovastatin or atorvastatin.
The active ingredient of the present invention may also be administered in combination with one or more antibiotic, antifungal, antiprotozoal, antiviral or similar therapeutic agents.
The compounds of the present invention may also be used in combination with CNS agents such as antidepressants (such as sertraline), anti-Parkinsonian drugs (such as L-dopa, requip, mirapex, MAOB inhibitors such as selegine and rasagiline, comP inhibitors such as Tasmar, A-2 inhibitors, dopamine reuptake inhibitors, NMDA antagonists, nicotine agonists, dopamine agonists and inhibitors of neuronal nitric oxide synthase), and anti-Alzheimer's drugs such as donepezil, tacrine, COX-2 inhibitors, propentofylline or metryfonate.
The compounds of the present invention may also be used in combination with osteoporosis agents such as roloxifene, lasofoxifene, droloxifene or fosomax and immunosuppressant agents such as FK-506 and rapamycin.
The present invention also relates to the formulation of the active agents of the present invention alone or with one or more other therapeutic agents which are to form the intended combination, including wherein said different drugs have varying half-lives, by creating controlled-release forms of said drugs with different release times which achieves relatively uniform dosing; or, in the case of non-human patients, a medicated feed dosage form in which said drugs used in the combination are present together in admixture in said feed composition. There is further provided in accordance with the present invention co-administration in which the combination of drugs is achieved by the simultaneous administration of said drugs to be given in combination; including co-administration by means of different dosage forms and routes of administration; the use of combinations in accordance with different but regular and continuous dosing schedules whereby desired plasma levels of said drugs involved are maintained in the patient being treated, even though the individual drugs making up said combination are not being administered to said patient simultaneously.
DETAILED DESCRIPTION OF THE INVENTION
The following reaction Schemes illustrate the preparation of the compounds of the present invention. Unless otherwise indicated, R 1 through R 7 , A, X and m in the reaction schemes and discussion that follow are as defined above.
Scheme 1 illustrates methods of synthesizing compounds of the formula I. Referring to Scheme 1, a compound of the formula I,
wherein the heterocyclic
has a general formula
wherein each of X, Y, or Z can independently be CR 7 or N and at least one of X, Y, or Z must be N (ie., compounds of general formulae A1 (wherein X is CR 7 or N, Y is CH, and Z is N), A2 (wherein X is CR 7 or N, Y is CH, and Z is N), A3 (wherein X is CH, Y is N, and Z is N), A4 (wherein X is N, Y is N, and Z is N), A5 (wherein X is N, Y is N, and Z is N), and A6 (wherein X is N, Y is N, and Z is CH)). Specifically, the compounds of formula I (ie., a compound of the formulae IA1-IA6, respectively):
can be prepared by reacting a compound of formula II, wherein L 1 is a leaving group, with a a compound of formula M-R 3 , wherein M is a cation such as sodium, in a solvent. In the aforesaid reaction, said L 1 is displaced with said R 3 . Suitable leaving group L 1 includes halo, such as bromo or chloro, or (C 1 -C 6 )alkylsulfonate, such as methylsulfonate. The aforesaid reaction can be performed in neutral or basic conditions by methods familiar to those in the art. Suitable solvents include alcohol (such as methanol or ethanol), di(C 1 -C 6 )alkylethers (such as diethylether), halogenated solvents (such as methylene chloride), or dimethylformamide (DMF). This reaction can be carried out at a temperature of from about −20° C. to about 120° C., preferably from about 25° C. to about 50° C. This reaction can be carried out for a period of from about 1 hour to about 72 hours, preferably for about 24 hours.
The compound of formula II, wherein L 1 is a leaving group including halo (compound IIa) or sulfonate (compound IIb) can be prepared by reacting a compound of formula III, with an appropriate reagent, optionally in the presence of a solvent and a base. Suitable halo L 1 leaving groups include bromo or chloro. Suitable sulfonate L 1 leaving groups include (C 1 -C 6 )alkylsulfonate (such as methylsulfonate), trihalo(C 1 -C 6 )alkylsulfonate (such as trifluoromethylsulfonate), or (C 6 -C 10 )arylsulfonate (such as para-toluenesulfonate). When L 1 is halo, a suitable appropriate reagent is phosphoryloxychloride or phosphoryloxybromide. When L 1 is a sulfonate, a suitable appropriate reagent is triflic anhydride, mesyl chloride or tosyl chloride. Suitable solvents include methylene chloride, DMF or tetrahydrofuran (THF). Suitable bases include triethylamine, sodium hydride, potassiumcarbonate, or sodiumhydroxide. This reaction can be carried out at a temperature of from about 0° C. to about 100° C., preferably about 80° C. in the preparation of the compound of formula IIa; or about 25° C. in the preparation of the compound of formula IIb. This reaction can be carried out for a period of from about 1 hour to about 72 hours, preferably for about 24 hours.
The compound of formula III can be prepared by reacting a compound of formula IV with a compound of formula V:
or an acidic salt thereof, such as a hydrochloric salt thereof,
wherein the heterocyclic
as a general formula
wherein each of X, Y, or Z can be CR 7 or N and at least one of X, Y, or Z must be N as defined above. Specifically, the compounds of formula V (i.e., a compound of the formulae VA1-VA6, respectively):
can be reacted with a compound of formula IV under acidic, neutral or basic conditions, preferably in the presence of an acid or an acid salt of the compound of formula V in a solvent. Suitable acids include hydrochloric acid, acetic acid, trifluoroaceticacid, para-toluenesulfonic acid or sulfuric acid, preferably hydrochloric acid. Suitable acid salts include sodium acetate. Suitable bases include sodium hydroxide or potassium hydroxide. Suitable solvents include alcohol, such as ethanol, trifluoroethanol, methanol, propanol, isopropanol or butanol; dimethyl sulfoxide (DMSO), DMF, N,N-dimethylacetamide (DMA), N-methyl-2-pyrrolidinone (NMP), benzene, toluene, chloroform or mixtures thereof, preferably alcohol, most preferably ethanol or isopropanol. This reaction can be carried out at a temperature from about 0° C. to about 140° C., preferably at about 80° C. to about 100° C., or at reflux temperature of the solvent used. This reaction can be carried out for a period of from about 1 hour to about 72 hours, preferably for about 24 hours.
The compound of formula IV can be purchased or can be prepared according to methods described in the literature, e.g., Advanced Organic Chemistry, 4 th ed.,1992; J. Med. Chem. 1997, 40, 1347-1365; and references cited therein.
Scheme 2 illustrates alternative methods of synthesizing compounds of the formula IIb, as defined above. Referring to Scheme 2, a compound of the formula IIb can be prepared by reacting a compound of formula VI with an oxidizing agent in a solvent optionally in the presence of a base. Suitable oxidizing agents include meta-chloroperbenzoic acid, hydrogen peroxide, OXONE®, nitric acid or barium permangate. Suitable solvents include alcohol-water (such as methanol-water or ethanol-water), dioxane-water, tetrahydrofuran-water, methylene chloride, chloroform, di(C 1 -C 6 )alkylethers (such as diethylether), halogenated solvents (such as methylene chloride), or DMF, preferably methanol-water. Suitable bases include sodium hydroxide. This reaction can be carried out at a temperature of from about 0° C. to about 25° C., preferably from about 20° C. to about 25° C. This reaction can be carried out for a period of from about 0.5 hours to about 24 hours, preferably for about 3 hours.
The compound of formula VI can be prepared by reacting a compound of formula VII with a compound of formula V (i.e., a compound of the formulae VA1-VA6, respectively, as defined above), or an acidic salt thereof, such as a hydrochloric salt thereof, under acidic, neutral or basic conditions, preferably in the presence of an acid or an acid salt of the compound of the formula V in a solvent. Suitable acids include hydrochloric acid, acetic acid, trifluoroaceticacid, para-toluenesulfonic acid or sulfuric acid, preferably hydrochloric acid. Suitable acid salts include sodium acetate. Suitable bases include sodium hydroxide or potassium hydroxide. Suitable solvents include alcohol (such as ethanol, trifluoroethanol, methanol, propanol, isopropanol or butanol), alcohol-water, DMSO, DMF, DMA, NMP, benzene, toluene, chloroform or mixtures thereof, preferably alcohol, most preferably ethanol or isopropanol. This reaction can be carried out at a temperature from about 60° C. to about 100° C. This reaction can be carried out for a period of from about 1 hour to about 24 hours.
The compound of formula VII can be purchased or can be prepared according to methods described in the literature, e.g., Advanced Organic Chemistry, 4 th ed.,1992.
Scheme 3 refers to the preparation of compounds of the formula V (i.e., a compound of the formulae VA1-VA6, respectively, as defined above) in a multi-step process from a compound of formula X, wherein each of L 2 and L 3 , individually, are leaving groups. Referring to Scheme 3, a compound of the formula V can be prepared by reacting a compound of the formula VIII (i.e., a compound of the formulae VIIIA1-VIIIA6, respectively):
wherein L 3 is a leaving group, with hydrazine (preferably anhydrous hydrazine) in the presence of a solvent. Suitable L 3 leaving groups include halo, preferably chloro or bromo. Suitable solvents include alcohol (such as ethanol, methanol, propanol or butanol), DMSO, DMF, DMA, or NMP, preferably alcohol, most preferably ethanol. This reaction can be carried out at a temperature from about 0° C. to about 140° C., preferably from about 80° C. to about 100° C., or at about the reflux temperature of the solvent used in this reaction. This reaction can be carried out for a period of from about 1 hour to about 72 hours, preferably from about 1 hour to about 24 hours. Preferably the product is isolated as a salt, such as a hydrobromide or hydrochloride salt, preferably hydrochloride salt.
The compound of formula VIII (i.e., a compound of the formulae VIIIA1-VIIIA6, respectively, as defined above) can be prepared by reacting a compound of the formula IX (i.e., a compound of the formulae IXA1-IXA6, respectively):
wherein L 3 is a leaving group, with an oxidizing reagent in the presence of a solvent. Suitable leaving groups include halo, sulfonate, or sulfone, preferably halo such as chloro or bromo. Suitable oxidizing agents include meta-chloroperbenzoic acid, hydrogen peroxide, sodium perborate, or OXONE® Suitable solvents or solvent mixtures include methanol-water, dioxane-water, tetrahydrofuran-water, methylene chloride, or chloroform, preferably methanol-water. This reaction can be carried out at a temperature from about 0° C. to about 60° C., preferably the temperature may range from about 20° C. to about 25° C. (i.e. room temperature). This reaction can be carried out for a period of from about 0.5 hours to about 24 hours, preferably about 16 hours.
The compounds of the, formula IX (i.e., a compound of the formulae IXA1-IXA6, respectively, as defined above) can be prepared by reacting a compound of formula X (i.e., a compound of the formulae XA1-XA6, respectively):
wherein each of L 2 and L 3 independently is a leaving group, with a sulfur nucleophilic reagent optionally in the presence of a base in a solvent. Suitable leaving groups L 2 include halo (such as chloro or bromo), sulfonate, or sulfone, preferably chloro or bromo. Suitable leaving groups L 3 include halo (such as chloro or bromo), sulfonate, or sulfone, preferably chloro or bromo. Suitable sulfur nucleophilic reagents include alkylthiol, dialkyldisulfide, alkylsulfonate, sodium thioalkoxide or potassium thioalkoxide. Suitable bases include sodium hydroxide, triethylamine, alkyllithium (such as n-butyllithium, sec-butyllithium, or tert-butyllithium), or lithium diisopropylamide. Suitable solvents include di(C 1 -C 6 )alkylether (such as dimethylether), alcohol (such as methanol, ethanol or tert-butanol), THF, benzene, toluene, xylene, DMF, DMSO, dioxane, 1,2-dimethoxyethane, and a mixture of alcohol and water. This reaction can be carried out at a temperature from about −78° C. to about 200° C., preferably from about 0° C. to about 100° C. This reaction can be carried out for a period of from about 1 minute to 1 day, preferably about 30 minutes.
Scheme 4 refers to an alternative preparation of compounds of the formula V (i.e., a compound of the formulae VA1-VA6, respectively, as defined above) by multi step reactions, i.e., a nitrosation reaction followed by reduction. Referring to Scheme 4, a compound of the formula V can be prepared by reacting a compound of formula XI (i.e., a compound of the formulae XIA1-XIA6, respectively):
wherein P is —NH—NO or —N≡N + , with a reducing agent or a catalytic hydrogenating agent in an inert solvent. Suitable reducing agents include metal halides such as TiCl 3 , SnCl 2 , zinc powder-acetic acid, sodium-ethanol, sodium-aqueous ammonia, lithium aluminum hydride and the like. Suitable catalytic hydrogenating agents include hydrogen gas at a pressure from about 1 atmosphere to about 5 atmospheres and a temperature of from about 10° C. to about 60° C., in the presence of a catalyst such as palladium on carbon (Pd/C), palladium on barium sulfate (Pd/BaSO 4 ), platinum on carbon (Pt/C), or tris(triphenylphosphine) rhodium chloride (Wilkinson's catalyst). Preferably the catalytic hydrogenating agent is Pd/C at 25° C. and 50 psi of hydrogen gas pressure in methanol solvent. Suitable solvents include alcohol (such as methanol or ethanol), THF, dioxane, or ethyl acetate. This method also provides for introduction of hydrogen isotopes (i.e., deuterium or tritium) by replacing 1 H 2 with 2 H 2 or 3 H 2 in the above procedure.
A compound of the formula XI (i.e., a compound of the formulae XIA1-XIA6, respectively, as defined above) can be prepared by reaction of a compound of the formula XII (i.e., a compound of the formulae XIIA1-XIIA6, respectively):
with a suitable reagent. Suitable reagents include sodium nitrite in an aqueous medium (such as hydrochloric acid in water), nitrosyl chloride, nitrogen oxides and nitrile ethers. This reaction can be carried out at a temperature from about −78° C. to about 200° C., preferably from about −10° C. to about 0° C. This reaction can be carried out for a period of about 1 minute to about 10 hours.
Compounds of formula XII (i.e., a compound of the formulae XIIA1-XIIA6, respectively, as defined above) are commercially available or can be prepared by methods well known to those of ordinary skill in the art (see F. Walker et al., J. Chem. Soc. 1939, 1948).
Compounds of the formula V (i.e., a compound of the formulae VA1-VA6, respectively, as defined above) may be prepared by methods well known to those of ordinary skill in the art (see Collection Czechoslov. Chem. Commun . Vol. 37, p. 1721, 1972 by J. Vafrina et. al.; European Patent Publications EP 1104759 and EP 1104760).
Other methods of preparing the compounds of Formula I are well known to those skilled in the art such as those described in Heterocycles, 31,1041 (1990). The compounds of formula I can also be synthesized by using the method of Kharash, Negishi, Stille, or Suzuki et. al., which are well known in the art. In general, heteroaryl compounds are synthesized by a number of catalytic cross-coupling reactions from heteroaryl halides or triflates and heteroaryl metal reagents (such as Grignard reagent (the so-called Kharasch reaction), heteroaryl zinc reagent (the so-called Negishi reaction), heteroaryl tin reagent (the so-called Stille reaction), heteroaryl silyl reagent, etc. (see for example S. P. Stanforth, Tetrahedron, 1998, 54, 263-303)).
Unless indicated otherwise, the pressure of each of the above reactions is not critical. Generally, the reactions will be conducted at a pressure of about one to about three atmospheres, preferably at ambient pressure (about one atmosphere).
Those skilled in the art will appreciate that the above schemes describe general methods for preparing the compounds of the invention. Specific compounds of formula I may possess sensitive functional groups that require protecting groups when prepared with the intermediates described. Examples of suitable protecting groups may be found in T. W. Greene and P. Wuts, Protecting Groups in Organic Synthesis, John Wiley & Sons, 2nd Edition, New York, 1991.
The compounds of the formula I which are basic in nature are capable of forming a wide variety of different salts with various inorganic and organic acids. Although such salts must be pharmaceutically acceptable for administration to animals, it is often desirable in practice to initially isolate a compound of the formula I from the reaction mixture as a pharmaceutically unacceptable salt and then simply convert the latter back to the free base compound by treatment with an alkaline reagent, and subsequently convert the free base to a pharmaceutically acceptable acid addition salt. The acid addition salts of the base compounds of this invention are readily prepared by treating the base compound with a substantially equivalent amount of the chosen mineral or organic acid in an aqueous solvent medium or in a suitable organic solvent such as methanol or ethanol. Upon careful evaporation of the solvent, the desired solid salt is obtained.
The acids which are used to prepare the pharmaceutically acceptable acid addition salts of the base compounds of this invention are those which form non-toxic acid addition salts, i.e., salts containing pharmacologically acceptable anions, such as hydrochloride, hydrobromide, hydroiodide, nitrate, sulfate or bisulfate, phosphate or acid phosphate, acetate, lactate, citrate or acid citrate, tartrate or bitartrate, succinate, maleate, fumarate, gluconate, saccharate, benzoate, methanesulfonate and pamoate [i.e., 1,1′-methylene-bis-(2-hydroxy-3-naphthoate)] salts.
Those compounds of the formula I which are also acidic in nature, e.g., wherein A or any of R 1 , R 3 , R 4 , R 5 or R 6 include a hydroxycarbonyl, tetrazole, or other acidic moiety, are capable of forming base salts with various pharmacologically acceptable cations. Examples of such salts include the alkali metal or alkaline-earth metal salts and particularly, the sodium and potassium salts. These salts are all prepared by conventional techniques. The chemical bases which are used as reagents to prepare the pharmaceutically acceptable base salts of this invention are those which form non-toxic base salts with the herein described acidic compounds of formula I. These non-toxic base salts include those derived from such pharmacologically acceptable cations as sodium, potassium, calcium and magnesium, etc. These salts can easily be prepared by treating the corresponding acidic compounds with an aqueous solution containing the desired pharmacologically acceptable cations, and then evaporating the resulting solution to dryness, preferably under reduced pressure. Alternatively, they may also be prepared by mixing lower alkanolic solutions of the acidic compounds and the desired alkali metal alkoxide together, and then evaporating the resulting solution to dryness in the same manner as before. In either case, stoichiometric quantities of reagents are preferably employed in order to ensure completeness of reaction and maximum product yields.
Method for Assessing Biological Activities
The activity of the compounds of the formula I of the present invention was demonstrated by the following assays.
Human In Vitro Assays
Human Cell-Based COX-1 Assay
Human peripheral blood obtained from healthy volunteers was diluted to 1/10 volume with 3.8% sodium citrate solution. The platelet-rich plasma immediately obtained was washed with 0.14 M sodium chloride containing 12 mM Tris-HCl (pH 7.4) and 1.2 mM EDTA. Platelets were then washed with platelet buffer (Hanks buffer (Ca free) containing 0.2% BSA and 20 mM Hepes). Finally, the human washed platelets (HWP) were suspended in platelet buffer at the concentration of 2.85×10 8 cells/ml and stored at room temperature until use. The HWP suspension (70 μl aliquots, final 2.0×10 7 cells/ml) was placed in a 96-well U bottom plate and 10 μl aliquots of 12.6 mM calcium chloride added. Platelets were incubated with A23187 (final 10 μM, Sigma) with test compound (0.1-100 μM) dissolved in DMSO (final concentration; less than 0.01%) at 37° C. for 15 minutes. The reaction was stopped by addition of EDTA (final 7.7 mM) and TxB2 in the supernatant quantitated by using a radioimmunoassay kit (Amersham) according to the manufacturer's procedure.
Human Cell-Based COX-2 Assay
The human cell based COX-2 assay was carried out as previously described (Moore et al., Inflam. Res., 45, 54, 1996). Confluent human umbilical vein endothelial cells (HUVECs, Morinaga) in a 96-well flat bottom plate were washed with 80 ml of RPMI1640 containing 2% FBS and incubated with hIL-1β (final concentration 300 U/ml, R & D Systems) at 37° C. for 24 hours. After washing, the activated HUVECs were incubateed with test compound (final concentration; 0.1 nM-1 μM) dissolved in DMSO (final concentration; less than 0.01%) at 37° C. for 20 minutes and stimulated with A23187 (final concentration 30 mM) in Hanks buffer containing 0.2% BSA, 20 mM Hepes at 37° C. for 15 minutes. 6-Keto-PGF 1α , stable metabolite of PGI2, in the supernatant was quantitated by using a radioimmunoassay method (antibody; Preseptive Diagnostics, SPA; Amersham).
Canine In Vitro Assays
The following canine cell based COX 1 and COX-2 assays have been reported in Ricketts et al., Evaluation of Selective Inhibition of Canine Cyclooxyenase 1 and 2 by Carprofen and Other Nonsteroidal Anti - inflammatory Drugs , American Journal of Veterinary Research, 59 (11), 1441-1446.
Protocol for Evaluation of Canine COX-1 Activity
Test drug compounds were solubilized and diluted the day before the assay was to be conducted with 0.1 mL of DMSO/9.9 mL of Hank's balanced salts solution (HBSS), and stored overnight at 4° C. On the day that the assay was carried out, citrated blood was drawn from a donor dog, centrifuged at 190×g for 25 minutes at room temperature, and the resulting platelet-rich plasma was then transferred to a new tube for further procedures. The platelets were washed by centrifuging at 1500×g for 10 minutes at room temperature. The platelets were washed with platelet buffer comprising Hank's buffer (Ca free) with 0.2% bovine serum albumin (BSA) and 20 mM HEPES. The platelet samples were then adjusted to 1.5×10 7 /mL, after which 50 μl of calcium ionophore (A23187) together with a calcium chloride solution were added to 50 μl of test drug compound dilution in plates to produce final concentrations of 1.7 μM A23187 and 1.26 mM Ca. Then, 100 μl of canine washed platelets were added and the samples were incubated at 37° C. for 15 minutes, after which the reaction was stopped by adding 20 μl of 77 mM EDTA. The plates were then centrifuged at 2000×g for 10 minutes at 4° C., after which 50 μof supernatant was assayed for thromboxane B 2 (TXB 2 ) by enzyme-immunoassay (EIA). The pg/mL of TXB 2 was calculated from the standard line included on each plate, from which it was possible to calculate the percent inhibition of COX-1 and the IC 50 values for the test drug compounds.
Protocol for Evaluation of Canine COX-2 Activity
A canine histocytoma (macrophage-like) cell line from the American Type Culture Collection designated as DH82, was used in setting up the protocol for evaluating the COX-2 inhibition activity of various test drug compounds. There was added to flasks of these cells 10 μg/mL of LPS, after which the flask cultures were incubated overnight. The same test drug compound dilutions as described above for the COX-1 protocol were used for the COX-2 assay and were prepared the day before the assay was carried out. The cells were harvested from the culture flasks by scraping, and were then washed with minimal Eagle's media (MEM) combined with 1% fetal bovine serum, centrifuged at 1500 rpm for 2 minutes, and adjusted to a concentration of 3.2×10 5 cells/mL. To 50 μl of test drug dilution there was added 50 μl of arachidonic acid in MEM to give a 10 μM final concentration, and there was added as well 100 μl of cell suspension to give a final concentration of 1.6×10 5 cells/mL. The test sample suspensions were incubated for 1 hour and then centrifuged at 1000 rpm for 10 minutes at 4° C., after which 50 μl aliquots of each test drug sample were delivered to EIA plates. The EIA was performed for prostaglandin E 2 (PGE 2 ), and the pg/mL concentration of PGE 2 was calculated from the standard line included on each plate. From this data it was possible to calculate the percent inhibition of COX-2 and the IC 50 values for the test drug compounds. Repeated investigations of COX-1 and COX-2 inhibition were conducted over the course of several months. The results are averaged, and a single COX-1: COX-2 ratio is calculated.
Whole blood assays for COX-1 and COX-2 are known in the art such as the methods described in C. Brideau, et al., A Human Whole Blood Assay for Clinical Evaluation of Biochemical Efficacy of Cyclooxygenase Inhibitors, Inflammation Research , Vol. 45, pp. 68-74 (1996). These methods may be applied with feline, canine or human blood as needed.
In Vivo Assays
Carrageenan Induced Foot Edema in Rats
Male Sprague-Dawley rats (5 weeks old, Charles River Japan) were fasted overnight. A line was drawn using a marker above the ankle on the right hind paw and the paw volume (VO) was measured by water displacement using a plethysmometer (Muromachi). Animals were given orally either vehicle (0.1% methyl cellulose or 5% Tween 80) or a test compound (2.5 ml per 100 g body weight). One hour later, the animals were then injected intradermally with λ-carrageenan (0.1 ml of 1% w/v suspension in saline, Zushikagaku) into right hind paw (Winter et al., Proc. Soc. Exp. Biol. Med., 111, 544, 1962; Lombardino et al., Arzneim. Forsch., 25, 1629, 1975) and three hours later, the paw volume (V3) was measured and the increase in volume (V3-V0) calculated. Since maximum inhibition attainable with classical NSAIDs is 60-70%, ED 30 values were calculated.
Gastric Ulceration in Rats
The gastric ulcerogenicity of test compound was assessed by a modification of the conventional method (Ezer et al., J. Pharm. Pharmacol., 28, 655, 1976; Cashin et al., J. Pharm. Pharmacol., 29, 330-336, 1977). Male Sprague-Dawley rats (5 weeks old, Charles River Japan), fasted overnight, were given orally either vehicle (0.1% methyl cellulose or 5% Tween 80) or a test compound (1 ml per 100 g body weight). Six hours after, the animals were sacrificed by cervical dislocation. The stomachs were removed and inflated with 1% formalin solution (10 ml). Stomachs were opened by cutting along the greater curvature. From the number of rats that showed at least one gastric ulcer or haemorrhaging erosion (including ecchymosis), the incidence of ulceration was calculated. Animals did not have access to either food or water during the experiment.
Canine Whole Blood ex vivo Determinations of COX-1 and COX-2 Activity Inhibition
The in vivo inhibitory potency of a test compound against COX-1 and COX-2 activity may be evaluated using an ex vivo procedure on canine whole blood. Three dogs were dosed with 5 mg/kg of the test compound administered by oral gavage in 0.5% methylcellulose vehicle and three dogs were untreated. A zero-hour blood sample was collected from all dogs in the study prior to dosing, followed by 2- and 8-hour post-dose blood sample collections. Test tubes were prepared containing 2 μL of either (A) calcium ionophore A23187 giving a 50 μM final concentration, which stimulates the production of thromboxane B 2 (TXB 2 ) for COX-1 activity determination; or of (B) lipopolysaccharide (LPS) to give a 10 μ/mL final concentration, which stimulates the production of prostaglandin E 2 (PGE 2 ) for COX-2 activity determination. Test tubes with unstimulated vehicle were used as controls. A 500 μL sample of blood was added to each of the above-described test tubes, after which they were incubated at 37° C. for one hour in the case of the calcium ionophore-containing test tubes, and overnight in the case of the LPS-containing test tubes. After incubation, 10 μL of EDTA was added to give a final concentration of 0.3%, in order to prevent coagulation of the plasma which sometimes occurs after thawing frozen plasma samples. The incubated samples were centrifuged at 4° C. and the resulting plasma sample of ˜200 μL was collected and stored at −20° C. in polypropylene 96-well plates. In order to determine endpoints for this study, enzyme immunoassay (EIA) kits available from Cayman were used to measure production of TXB 2 and PGE 2 , utilizing the principle of competitive binding of tracer to antibody and endpoint determination by colorimetry. Plasma samples were diluted to approximate the range of standard amounts which would be supplied in a diagnostic or research tools kit, i.e., 1/500 for TXB 2 and 1/750 for PGE 2 .
The data set out in Table 1 below show how the percent inhibition of COX-1 and COX-2 activity is calculated based on their zero hour values. The data is expressed as treatment group averages in pg/ml of TXB 2 and PGE 2 produced per sample. Plasma dilution was not factored in said data values.
The data in Table 1 show that, in this illustration, at the 5 mg/kg dose there was significant COX-2 inhibition at both timepoints. The data in Table 1 also show that at the 5 mg/kg dose there was no significant inhibition of COX-1 activity at the timepoints involved. Accordingly, the data in Table 1 clearly demonstrates that at the 5 mg/kg dosage concentration this compound possesses good COX-2 selectivity.
TABLE 1
COX-1 ACTIVITY INHIBITION - Group Averages
TXB 2 Pg/mL/Well
Percent Inhibition
Hour
0-hour
2-hour
8-hour
2-hour
8-hour
Untreated
46
45
140
2%
0%
5 mg/kg
41
38
104
7%
0%
COX-2 ACTIVITY INHIBITION - Group Averages
PGE 2 Pg/mL/Well
Percent Inhibition
Hour
0-hour
2-hour
8-hour
2-hour
8-hour
Untreated
420
486
501
0%
0%
5 mg/kg
711
165
350
77%
51%
COX inhibition is observed when the measured percent inhibition is greater than that measured for untreated controls. The percent inhibition in the above table is calculated in a straightforward manner in accordance with the following equation:
% Inhibition ( 2 - hour ) = ( PGE 2 at t = 0 ) - ( PGE 2 at t = 2 ) ( PGE 2 at t = 0 )
Data Analysis
Statistical program packages, SYSTAT (SYSTAT, INC.) and StatView (Abacus Cencepts, Inc.) for Macintosh were used. Differences between test compound treated group and control group were tested for using ANOVA. The IC 50 (ED 30 ) values were calculated from the equation for the log-linear regression line of concentration (dose) versus percent inhibition.
Most compounds prepared in the Working Examples as described hereinafter were tested by at least one of the methods described above, and showed IC 50 values of 0.001 μM to 3 μM with respect to inhibition of COX-2 in either the canine or human assays.
COX-2 selectivity can be determined by ratio in terms of IC 50 value of COX-1 inhibition to COX-2 inhibition. In general, it can be said that a compound showing a COX-2/COX-1 inhibition ratio of more than 5 has good COX-2 selectivity.
The compounds of the formula I of this invention can be administered via oral, parenteral, anal, buccal or topical routes to mammals (including humans, dogs, cats, horses and livestock).
In general, these compounds are most desirably administered to humans in doses ranging from 0.01 mg to 100 mg per kg of body weight per day, although variations will necessarily occur depending upon the weight, sex and condition of the subject being treated, the disease state being treated and the particular route of administration chosen. However, a dosage level that is in the range of from 0.1 mg to 10 mg per kg of body weight per day, single or divided dosage is most desirably employed in humans for the treatment of abovementioned diseases.
These compounds are most desirably administered to said non-human mammals, e.g. dogs, cats, horses or livestock in an amount, expressed as mg per kg of body weight of said member per day, ranging from about 0.01 mg/kg to about 20.0 mg/kg/day, preferably from about 0.1 mg/kg to about 12.0 mg/kg/day, more preferably from about 0.5 mg/kg to about 10.0 mg/kg/day, and most preferably from about 0.5 mg/kg to about 8.0 mg/kg/day.
The compounds of the present invention may be administered alone or in combination with pharmaceutically acceptable carriers or diluents by either of the above routes previously indicated, and such administration can be carried out in single or multiple doses. More particularly, the novel therapeutic agents of the invention can be administered in a wide variety of different dosage forms, i.e., they may be combined with various pharmaceutically acceptable inert carriers in the form of tablets, capsules, lozenges, trochees, hard candies, powders, sprays, creams, salves, suppositories, jellies, gels, pastes, lotions, ointments, aqueous suspensions, injectable solutions, elixirs, syrups, and the like. Such carriers include solid diluents or fillers, sterile aqueous media and various nontoxic organic solvents, etc. Moreover, oral pharmaceutical compositions can be suitably sweetened and/or flavored. In general, the therapeutically-effective compounds of this invention are present in such dosage forms at concentration levels ranging from 5% to 70% by weight, preferably 10% to 50% by weight.
For oral administration, tablets containing various excipients such as microcrystalline cellulose, sodium citrate, calcium carbonate, dipotassium phosphate and glycine may be employed along with various disintegrants such as starch and preferably corn, potato or tapioca starch, alginic acid and certain complex silicates, together with granulation binders like polyvinylpyrrolidone, sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, sodium lauryl sulfate and talc are often very useful for tabletting purposes. Solid compositions of a similar type may also be employed as fillers in gelatine capsules; preferred materials in this connection also include lactose or milk sugar as well as high molecular weight polyethylene glycols. When aqueous suspensions and/or elixirs are desired for oral administration, the active ingredient may be combined with various sweetening or flavoring agents, coloring matter or dyes, and, if so desired, emulsifying and/or suspending agents as well, together with such diluents as water, ethanol, propylene glycol, glycerin and various combinations thereof.
A preferred composition for dogs comprises an ingestible liquid peroral dosage form selected from the group consisting of a solution, suspension, emulsion, inverse emulsion, elixir, extract, tincture, and concentrate, optionally to be added to the drinking water of the dog being treated. Any of these liquid dosage forms, when formulated in accordance with methods well known in the art, can either be administered directly to the dog being treated, or may be added to the drinking water of the dog being treated. The concentrate liquid form, on the other hand, is formulated to be added first to a given amount of water, from which an aliquot amount may be withdrawn for administration directly to the dog or addition to the drinking water of the dog.
A preferred composition provides delayed-, sustained-, and/or controlled-release of said anti-inflammatory selective COX-2 inhibitor. Such preferred compositions include all such dosage forms which produce ≧80% inhibition of COX-2 isozyme activity and result in a plasma concentration of said inhibitor of at least 3 fold the COX-2 IC 50 for at least 4 hours; preferably for at least 8 hours; more preferably for at least 12 hours; more preferably still for at least 16 hours; even more preferably still for at least 20 hours; and most preferably for at least 24 hours. Preferably, there is included within the above-described dosage forms those which produce ≧80% inhibition of COX-2 isozyme activity and result in a plasma concentration of said inhibitor of at least 5 fold the COX-2 IC 50 for at least 4 hours, preferably for at least 8 hours, more preferably for at least 12 hours, still more preferably for at least 20 hours, and most preferably for at least 24 hours. More preferably, there is included the above-described dosage forms which produce ≧90% inhibition of COX-2 isozyme activity and result in a plasma concentration of said inhibitor of at least 5 fold the COX-2 IC 50 for at least 4 hours, preferably for at least 8 hours, more preferably for at least 12 hours, still more preferably for at least 20 hours, and most preferably for at least 24 hours.
For parenteral administration, solutions of a compound of the present invention in either sesame or peanut oil or in aqueous propylene glycol may be employed. The aqueous solutions should be suitably buffered (preferably pH>8) if necessary and the liquid diluent first rendered isotonic. These aqueous solutions are suitable for intravenous injection purposes. The oily solutions are suitable for intra-articular, intramuscular and subcutaneous injection purposes. The preparation of all these solutions under sterile conditions is readily accomplished by standard pharmaceutical techniques well-known to those skilled in the art. Additionally, it is also possible to administer the compounds of the present invention topically when treating inflammatory conditions of the skin and this may preferably be done by way of creams, jellies, gels, pastes, ointments and the like, in accordance with standard pharmaceutical practice.
The compounds of formula I may also be administered in the form of suppositories for rectal or vaginal administration of the active ingredient. These compositions can be prepared by mixing the active ingredient with a suitable non-irritating excipient which is solid at room temperature (for example, 10° C. to 32° C.) but liquid at the rectal temperature and will melt in the rectum or vagina to release the active ingredient. Such materials are polyethylene glycols, cocoa butter, suppository and wax.
For buccal administration, the composition may take the form of tablets or lozenges formulated in conventional manner.
For transdermal administration, transdermal patches prepared in accordance with well known drug delivery technology may be prepared and applied to the skin of a mammal, preferably a human or a dog, to be treated, whereafter the active agent by reason of its formulated solubility characteristics migrates across the epidermis and into the dermal layers of the skin where it is taken up as part of the general circulation, ultimately providing systemic distribution of the active ingredient over a desired, extended period of time. Also included are implants which are placed beneath the epidermal layer of the skin, i.e. between the epidermis and the dermis of the skin of the patient being treated. Such an implant will be formulated in accordance with well known principles and materials commonly used in this delivery technology, and may be prepared in such a way as to provide controlled-, sustained-, and/or delayed-release of the active ingredient into the systemic circulation of the patient. Such subepidermal (subcuticular) implants provide the same facility of installation and delivery efficiency as transdermal patches, but without the limitation of being subject to degradation, damage or accidental removal as a consequence of being exposed on the top layer of the patient's skin.
EXAMPLES
The following examples contain detailed descriptions of the methods of the preparation of compounds of formula I. These detailed descriptions fall within the scope of the invention and serve to exemplify the above described general synthetic procedures which form part of the invention. These detailed descriptions are presented for illustrative purposes only and are not intended to restrict the scope of the present invention.
The invention is illustrated in the following non-limiting examples in which, unless stated otherwise: all operations were carried out at room or ambient temperature, that is, in the range of 18-25° C.; evaporation of solvent was carried out using a rotary evaporator under reduced pressure with a bath of up to 60° C.; reactions were monitored by thin layer chromatography (TLC) and analytical column liquid chromatography, and reaction times are given for illustration only; melting points (m.p.) given are uncorrected (polymorphism may result in different melting points); structure and purity of all isolated compounds were assured by at least one of the following techniques: TLC (Merck silica gel 60 F-254 precoated plates), high performance liquid chromatograpy (HPLC), or mass spectrometry. Flash column chromatography was carried out using Merck silica gel 60 (230-400 mesh ASTM). Preparative HPLC was carried out using Hewlett Packard 1100 Liquid Chromatography/Mass Selective Detector (LC/MSD). Separation was done on a Monochrom 5μ CN column PN 0509-250*212 from MetaChem Technologies. The flow rate was 20 ml/min running a gradient of 0 to 90% of isopropanol in n-hexane. Low-resolution mass spectral data (EI) were obtained on an Automass 120 (JEOL) mass spectrometer. Liquid Chromatography data was collected on a Hewlett Packard 1100 Liquid Chromatography/Mass Selective Detector (LC/MSD). Analysis was performed on a Luna C-18 column with dimensions of 3.0×150 mm. The flow rate was 0.425 ml/minute running a gradient of 50% 0.1% aqueous formic acid and 50% acetonitrile to 100% acetonitrile in 15 minutes. The ionization type for the mass detector of the Mass Spectrophotometer was atmospheric pressure electrospray in the positive ion mode with a fragmentor voltage of 50 volts.
Procedure:
Example 1
1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-phenyl-1H-pyrazole-4-carbonitrile
A mixture of the 2-hydrazino-5-methylsulfonyl pyridine (180 mg, 0.81 mmol) and 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene (201 mg, 0.81 mmol) in anhydrous ethanol was refluxed overnight. The resulting solution was cooled to room temperature, diluted with water (25 ml) and extracted with ethyl acetate (2×25 ml). The ethyl acetate layer was dried with sodium sulfate and concentrated to give crude product. Chromatography of the mixture led to the isolation of the desired product (26 mg, 9%) in the form of a white solid.
The following examples were prepared by a procedure analogous to that of Example 1, except where indicated. LC refers to liquid chromatography elution time (minutes) and MS refers to mass spectral peaks (AMU). The particular apparatus and data acquisition parameters are as defined above.
Example 2
5-(4-Chloro-phenyl)-1-(5-methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-1H-pyrazole-4-carbonitrile
The title compound was prepared as in Example 1 wherein 1-(4-chloro benzoyl)-2,2-bis(methylthio)-1-cyano ethene was used in place of wherein 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene. Chromatography of the mixture led to the isolation of the desired product (45 mg, 24%) in the form of a white solid.
Example 3
1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-p-tolyl-1H-pyrazole-4-carbonitrile
The title compound was prepared as in Example 1 wherein 1-4-methyl benzoyl)-2,2-bis(methylthio)-1-cyano ethene was used in place of 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene. Chromatography of the mixture led to the isolation of the desired product (24 mg, 14%) in the form of a pale white solid.
Example 4
1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-thiophen-2-yl-1H-pyrazole-4-carbonitrile
The title compound was prepared as in Example 1 wherein 1-(thiophene-2-carbonyl)-2,2-bis(methylthio)-1-cyano ethene was used in place of 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene. Chromatography of the mixture led to the isolation of the desired product (53 mg, 30%) in the form of a white solid.
Example 5
1-(5-Methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-5-m-tolyl-1H-pyrazole-4-carbonitrile
The title compound was prepared as in Example 1 wherein 1-(3-methylbenzoyl)-2,2-bis(methylthio)-1-cyano ethene was used in place of 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene. Chromatography of the mixture led to the isolation of the desired product (8 mg, 4.4%) in the form of a pale white solid.
Example 6
5-(3-Chloro-phenyl)-1-(5-methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-1H-pyrazole-4-carbonitrile
The title compound was prepared as in Example 1 wherein 1-(3-chlorobenzoyl)-2,2-bis(methylthio)-1-cyano ethene was used in place of 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene. Chromatography of the mixture led to the isolation of the desired product (8 mg, 4.3%) in the form of a white solid.
Example 7
1-(5-methanesulfonyl-pyridin-2-yl)-3-methylsulfonyl-5-phenyl-1H-pyrazole-4-carbonitrile
The title compound was prepared by reacting the compound of Example 1 with meta-chloroperbenzoic acid.
Example 8
5-furan-2-yl-1-(5-methanesulfonyl-pyridin-2-yl)-3-methylsulfanyl-1H-pyrazole-4-carbonitrile
The title compound was prepared as in Example 1 wherein 1-(furan-2-oyl)-2,2-bis(methylthio)-1-cyano ethene was used in place of 1-benzoyl-2,2-bis(methylthio)-1-cyano ethene. Chromatography of the mixture led to the isolation of the desired product in the form of a white solid.
The chemical structures and molecular weights of the above Examples 1-8 are tabulated below in Table 2.
TABLE 2
Example
Structure
MW
LC
MS
1
370
10.882
371
2
405
13.34
405 (M+) 406 (M + H)
3
384
12.532
385
4
376
10.71
377
5
384
12.51
385
6
405
N/A
406
7
402
N/A
403
8
360
N/A
361
While the invention has been described and illustrated with reference to certain particular embodiments thereof, those skilled in the art will appreciate that various adaptations, changes, modifications, substitutions, deletions, or additions of procedures and protocols may be made without departing from the spirit and scope of the invention. It is intended, therefore, that the invention be defined by the scope of the claims that follow and that such claims be interpreted as broadly as is reasonable. | The present invention relates to compounds of the formula
wherein R 1 , R 3 , R 5 , R 6 , and A are defined as in the specification, to pharmaceutical compositions containing them and to their medicinal use. The compounds of the invention are useful in the treatment of inflammation and other inflammation associated disorders, such as osteoarthritis, rheumatoid arthritis, colon cancer and Alzheimer's disease, in mammals (preferably humans, dogs, cats and livestock). | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for locating a cutting bit on a rotary drum used to cut earth, rock, pavement and the like and, in particular, to an improved cutting lacing method and cutter bit assembly.
2. Background
This invention is directed to locating a plurality of offset points with reference to a peripheral surface or portions of a peripheral surface. Although the invention is to such locating it is believed easier to understand with reference to cutter bits for rotating drums of a coal mining machine for which the invention was initially developed. The methods and apparatus apply to positioning cutter bits on chains for trenchers as well. Inasmuch as the principles of this invention in locating bit points (i.e., the points of the bits) applied to rotary cutting drums, the prior methods and apparatus for locating cutter bits on a rotary drum are discussed for the sake of simplicity in understanding the invention. Diameters and lengths of a cutter drum section vary so that, while the procedures discussed are the same, the tools and aids utilized will vary to compensate for the variations in drum diameter. It is also to be noted that a drum section carries various bit blocks at various locations which receive the bits, and pedestals upon which the bit blocks are mounted. The geometry of the bit blocks and bits is known and, for a specific combination, fixed. Accordingly, such bits and drums are described herein as the presently preferred embodiment of the invention.
In materials mining and in other fields in which a large volume of hard materials must be cut, it is typical to employ an apparatus which includes a vertically moveable horizontal axis cutting drum having cutting bits attached thereto. By virtue of the engagement of the cutting bits which are mounted on the rotating cutting drum with the surface to be cut, material is removed from such surface for further processing.
Due to the substantial forces generated during the cutting operations, the cutting bits must be securely mounted on the cutting drums, but must also be readily removable for replacement. In one prior art form of cutting bit holding apparatus, a cutting bit having an elongated cylindrical shank and a hard cutting tip at one end is retained in a cutter bit holder block which is usually welded directly to the cutting drum or a drum pedestal. A shank receiving bore in the bit holder block is adapted for receiving the shank of the cutting bit therethrough.
Cutter drums vary in design for various mining machines including drums manufactured by a specific manufacturer. As is known, a cutting drum may consist of elongated drum sections, end sections and ring sections between the drum and end sections. The drum, end, and ring segments form a cutter head with various cutter head designs being utilized. Regardless of the design of a cutter head or cutting chain, it is necessary that the cutter head or chain cut its own clearance. That is, the bits on the cutter head cut and break the coal, rock or earth such that the cutter head can be moved forward into a coal seam. In this regard, it is to be noted that coal is a fragile material and that the path of movement of a cutter bit through a coal seam to cause coal breakage is an important aspect of proper lacing of the cutting bits on a drum or cutter chain. Also, each section of a cutter head must carry cutter bits to cut its own clearance. A cutter head which cannot cut clearance for itself is not an acceptable mining machine.
In the mining of coal, it is accepted practice to arrange cutter bits on a traveling or rotating member, such as a cutter chain or a rotating drum, such that the cutting edges or tips of the cutter bits travel through separate paths in the coal seam to be mined. There are various factors regarding the cutting of coal seams which are evaluated by various manufacturers of mining machinery in locating cutter bits on a rotating member including, but not limited to, the hardness and abrasiveness of the material being excavated. The locating of the cutter edges or cutting tip points of a cutter bit is referred to as the “lacing” of a cutter chain or drum and varies among various machinery manufacturers; however, all machinery manufacturers want as accurate locating of the cutter edge or tip point as is possible under the various manufacturing processes.
In the mining and construction industry, the accuracy in connecting a bit holder block to a drum is critical in achieving the designed lacing for the drum. The contact of the conical tip of a cutter bit and the earth strata enhances the rotation of the cutting tool during the road planing operation. The conical tip that actually impinges and rubs against the surface of the earth strata together with the angle of attack enhances or reduces the rotation of the cutting tool. For instance, an increase in the distance that the contact is away from the central longitudinal axis of the hard insert results in an increase in the extent to which such contact encourages rotation of the cutting tool. The angle of attack for cutter bits is designed to optimize rotation of the cutter bit, hence any variation from the designed angle of attack results in a change in the designed rotation characteristics of the cutter bits. Reduced rotation of the cutting tool causes the cutting tool bit to become unevenly worn on one side, for instance, and the cutting bit quickly becomes damaged and inoperative. Such bit holder blocks on rotary drums must be removed and attached back onto the drum. It is well-known in the industry that the accurate lacing of the cutter bits onto a drum is important to the performance of the mining/construction drum. Therefore, the cutter tips must be accurately welded onto the cutting drum or chain. As will be appreciated, such failures of cutter bits are quite costly because the cutting apparatus must be removed from service in order that the remaining portion of the cutter bit can be removed away from the cutting drum and a replacement cutter bit attached.
The typical road milling drum of the past comprises a generally cylindrical drum with a plurality of road milling bit-block assemblies attached to a pedestal or directly to the surface of the drum. More specifically, the holder block, which rotatably holds the bit, is welded to the pedestal or surface of the drum.
In the construction industry for road milling it is essential that that each bit impinges on the road substrate at an exclusive discrete point so that the points of impact span the length of the drum. Typical impact point spacing for road milling has been about 0.625 inches.
In the prior art, methods of locating cutter bit blocks to mining and construction drums have included automated systems that use programmed machines for positioning and welding the blocks in their proper position. U.S. Pat. Nos. 4,897,904 and 4,947,535 disclose automated equipment that places and fixes the tip point with respect to a rotatable drum. The tip point is held in its programmed position at a preselected position by an automated arm having a gripper for grasping the cutter bit holder block. The holder block is welded onto the preselected position. Such automated lacing equipment is expensive and requires skilled technicians to ensure proper programming for the lacing and maintenance of the manufacturing equipment.
When bit holder block location pins were forged perpendicular to the forge parting lines, they were consistent and located the blocks very accurately. For instance, Kennametal' C10AMC block in the Kennametal Road Planing catalogue, catalogue number BO 1-1 (12)D1, illustrates a block with perpendicular cylindrical pins which effectively positioned a block on the drum. Also see the prior art perpendicular locating pins in U.S. Pat. No. 5,842,747.
A different method to manufacture (forge) bit holder blocks has been developed recently. This new method of forging produces blocks having the block shape shown in FIG. 1 at 10 and marketed in Kennametal' 2001 “Road Planing Soil Stabilization and Reclamation Tools” catalogue, Kennametal Inc., Latrobe Pa., the C10LG block (SAP #: 1012345). The C10LG block is formed by forging the block from steel blanks and stamping out the block shape with reciprocating upper and lower rams. A parting line 23 is formed where the upper and lower rams come together during stamping. The steel is compressed along a reciprocating axis perpendicular to the parting line by the rams. As is well known in the industry, during one-dimensional pressing and stamping processes, it is not possible to form/manufacture a surface oriented at an angle greater than ninety degrees (see dash line perpendicular to parting line 23 ) with respect to the parting line. Cylindrical pin locator protrusions, therefore, can only be formed projecting from block surfaces perpendicular to the axis of reciprocation of the rams. The cylindrical sidewall of the pins are oriented parallel to the axis of reciprocation of the stamping rams. For instance the cylindrical locator pins on the C10AMC block (SAP 1012285) in the “Road Planing Soil Stabilization and Reclamation Tools” catalogue, Kennametal Inc., Latrobe Pa., show a horizontal parting line and cylindrical locator pins oriented perpendicular to the horizontal parting line. As seen in FIG. 1, the block cannot be formed with locator protrusions 20 in the shape of cylindrical pins. The bottom surface of the block is not perpendicular to the axis of reciprocation of the rams. As can be seen in FIG. 1, the locator protrusions 20 are not cylindrical. The cylindrical locator protrusion must be truncated along surface 21 because a cylindrical surface cannot be formed perpendicular to the bottom surface of the block. Surface 21 as seen in FIG. 1, at best can only be oriented parallel to the axis of reciprocation of the rams.
The locating protrusion in FIG. 1 changed from a cylindrical shape, as on the C10AMC block, to an irregular shape. The irregular shape still locates the C10LG block, but no longer as accurately as the perpendicular cylindrical shape did. The blocks with the irregular shaped locating protrusion would be susceptible to shift up to {fraction (1/16)}″ (inch) or more while welding the base of the block to the drum. The {fraction (1/16)}″ (inch) shift at the base of the block, it should be recognized, results in an exaggerated shift at the tip point of the cutter bit. Additionally, this inaccuracy and fit play caused by the irregular shape of the locator protrusion results in some blocks being skewed. A slight misalignment at the base of a cutter bit result in a significant shift in the position of the cutter tip point at its very end. A corresponding cutter tip point misalignment of about as much as ⅛″ or more occurs at the cutter tip point of some block systems whenever the base is mislocated just {fraction (1/16)}″. In addition, the block can be skewed about 4 degrees in either direction out of alignment from its designed position. The skew in the orientation of the block can cause premature wear.
Such inaccuracies in positioning the new forge method blocks on drums causes the cutter tip point to miss the discrete point it was designed to cut by ⅛″ inch. Thus, for instance, in the drum lacing example given above of a uniform 0.625 inch spacing, the cutter bit might cut ½ inches away from the adjacent previous tip cut and next succeeding tip will accordingly cut ¾ inches from that cut. The tip that is continually undercutting its fair portion ½ inch as the drum operates often does not make sufficient contact with enough substrate to properly rotate, and the cutter tip that is continually cutting a larger share ¾inch of substrate becomes worn quickest and is more prone to failure than the other tips due to increased fatigue. If two such adjacent blocks are misaligned toward each other, the spacing might be ⅜″ (0.625−⅛″−⅛″), or if two adjacent blocks are aligned apart from each other, the spacing therebetween would be ⅞″ (0.625+⅛+⅛″), perpetuating such problems discussed immediately above to a greater degree. It is preferred in the industry that each tip along the length of the drum is evenly spaced so that all the tips wear and fail at a uniform rate.
Such 0.625 inch spacing is satisfactory for removing road surfaces in some instances. It is, however, on occasion necessary to design a road milling machine that provides for 0.200 inch spacing to make the texture of the road surface less coarse. Such a smooth texture may be required when resurfacing is not being performed, but the road is being milled to smooth out traffic ruts. A coarse textured surface can be irritating to the driver as a vehicle travels over a coarse cut because of the vibrations and high noise level. For such close spacing used to achieve a smooth textured roadway, it is even more critical to have a method for affixing the cutter bit assemblies to the drum/chain accurately without the need for fixturing.
The subject invention is directed toward an improved bit holder block locating design and method and which overcomes, among others, the above-described problems with prior art bit holder blocks and provides a bit holder block which is much less prone to such failures and the concomitant apparatus downtimes, while being capable of being manufactured at similar costs thereto.
SUMMARY OF THE INVENTION
The subject invention overcomes the problems in the prior art in a cutting tool assembly having a holder block mounting scheme which effectively and accurately positions the cutting tip point at its designed angle of attack.
In accordance with the present invention, there is provided a bit holder block assembly for attachment of a cutting bit to a cutting drum. The cutter bit block assembly includes a separate mounting plate that is positioned between the bit holder block and drum/pedestal for accurately aligning the bit holder block to the drum/pedestal. Once the bit holder block is aligned into position by the plate as designed, the bit holder block is welded to the drum/pedestal.
In one embodiment, an adaptable plate is designed with circular openings at one end and an elongated oval opening at the other end so that locating protrusions with different relative spacing therebetween may be used with the plate. The mounting plate with its oval opening can accommodate block designs with locating protrusions having different spacing.
In another embodiment, the alignment members are hexagonal and cooperate with hexagonal holes on the base/pedestal for fixing the holding block in position.
Accordingly, the present invention provides solutions to the aforementioned problems present with prior art cutting bit holders. These and other details, objects and advantages of the invention will become apparent as the following description of the present preferred embodiment thereof proceeds.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, there has been shown a present preferred embodiment of the invention wherein:
FIG. 1 is a side view of the cutter bit assembly of the present invention;
FIG. 2 is an exploded view of the connection assembly of including the bit holder block, mounting plate and a pedestal;
FIGS. 3A and 3B, respectively, are a side view of the mounting plate and a perspective view of the mounting plate shown in FIG. 2 of the instant invention;
FIGS. 4A and 4B are a top view and perspective side view of a second embodiment of the mounting plate; and
FIGS. 5A, 5 B and 5 C illustrate a third embodiment of a mounting plate with a top view, perspective top view and perspective bottom view, respectively.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The cutting bits which may be employed with the subject invention comprise an elongated shank having a hard cutting tip at one end thereof. As is also known cutter bits have various forms of cutting edges with the conical bit being the preferred form of bit. It is to be realized that the principles of this invention are equally applicable to a linear edged cutting bit since the center of the linear length is equivalent to the tip point of a conical bit. Accordingly, further description of this invention is with reference to a conical bit having a tip point.
Referring now to the drawings wherein the showings are for purposes of illustrating the present preferred embodiments of the invention only and not for purposes of limiting same, FIG. 1 shows a cutting bit holder block 10 for supporting a cutting bit 12 on a rotatable cutting drum or other driven element. The cutting bit 12 includes an elongated shank which defines an axis A—A, having at one end a conical tip 18 forming a tip point 19 at its forward end.
More particularly and with reference to FIG. 2, an exploded view of the connection assembly is shown including a cutting bit holder block 10 , a mounting plate 26 , and a pedestal 14 that has a bottom 16 for being integrally fixed to a rotary mining/construction drum. Specifically, bit holder block 10 is mounted by welding or a similar attaching means to a pedestal 14 which is integrally fixed to the rotary drum (not shown) typically by welding. In the invention, a mounting plate 26 is positioned between the pedestal 14 and block 10 . The mounting plate 26 is assembled to the block first as shown in FIG. 1 and then positioned into alignment with the fixture holes 22 in the pedestal. The block, plate and pedestal are then welded together. Weld material is applied around the bottom circumference of the block. The bottom of the block is typically chamfered 15 for receiving weld material. The plate 26 is made of a low temperature steel so that during the process of welding the bottom periphery of the block to the pedestal, the tabs 30 are melted off and a weld is formed along the entire circumference of the bottom of the block. The attachment of the holder block 10 to a pedestal is for purposes of illustrating the invention and is not to limit the scope of the invention. The holder block 10 could be directly attached to a drum (no pedestal) having fixture holes 22 machined directly into the circumferential surface of the drum.
The mounting plate alignment members 28 are designed to snugly fit into the alignment holes 22 so that no loose play exists between the plate and pedestal. The tight no tolerance fit ensures that the mounting plate 26 is affixed to the drum/pedestal in its designed exact location. The mounting plate is made of non-heat treated steel which can be precisely stamped out in accordance with its blueprint design within very small tolerances. The mounting plate can be made from an SAE 1010, 1018 or A36 grade steel. It will be appreciated that, for this embodiment and each of the embodiments disclosed herein, the bit holder block 10 may be mounted directly on the rotary cutting drum rather than onto a pedestal.
The mounting plate has a bottom 38 contoured to the bottom of the block base forging and a plurality of bent tabs 30 that are tightly contoured to the base of the block. Similar to the alignment members 28 the tabs can be stamped out and shaped with high accuracy within very precise tolerance limits. As seen in FIG. 1, the tabs smoothly cooperate with the bottom of the holder block. The cooperation of the tabs with the bottom contour of the block provides for a very exact connection of the block to the mounting plate 26 upon welding. Openings 32 in the mounting plate alignment members, in conjunction with the locating protrusions 20 , help secure the plate as well, but are not necessary. It should be noted that since the bent tabs help secure the plate to the block during welding, the design of a plate can be altered to fit a number of block styles, which blocks may or may not have locator protrusions 20 . Typically, the bottom surface of a block is generally flat except for the locator protrusions. For instance, a mounting plate can be designed to accommodate a bit holder block with locator protrusions or without protrusions. Along these lines it should be apparent that the geometric shape of the locator protrusions is not significant or critical to the function or scope of the invention. Additionally, the shape of the alignment members 28 are sized and shaped to provide a snug fit into locating holes on drums/pedestals and the tabs in cooperation with the contour of the holder block base achieve precise positioning of the cuter tip points. This is the same general method of locating tip points on the new forged irregular shaped locating protrusions in the prior art as discussed above accept for the improvement in accuracy.
FIGS. 4A and 4B illustrate a second alternative mounting plate embodiment to FIGS. 3A and 3B, which have hexagonal alignment members that are designed to cooperate in conjunction with alignment holes on the pedestal (or drum itself) that are hexagonal. Like the embodiment in FIGS. 1-3 and described above the hexagonal shaped alignment members can be stamped out with great accuracy so that the cutter tip block assembly is precisely positioned on a rotary drum. The geometries of the cooperating alignment members and base apertures is not to be limited to circular or hexagonal shapes but it is contemplated that many different shapes and sizes could also be employed. In general the alignment member must have vertical sidewalls that snugly fit against vertical sidewalls of the fixture holes 22 . The cooperating vertical walls of the alignment member and fixture hole form cooperating contact between the alignment member and fixture hole for the majority of the inner circumference of the fixture hole so as to prevent undesirable shifting.
A third embodiment is shown in FIGS. 5A-5C, and as best seen in FIG. 5A has a plate formed with a circular aperture 36 and elongated oval aperture 34 . The oval aperture allows for variations in the relative distance between the locating protrusions 20 on blocks. With the third embodiment illustrated in FIGS. 5A-5C, holder blocks with varying distances between the locating protrusions can be employed with this mounting plate. The forward locating protrusion nearest the cutting bit is inserted into aperture 36 , first and the second protrusion is then positioned in the oval aperture. The width of the oval opening is manufactured to snugly guide onto the locating protrusion, and the elongated length for the oval aperture permits for accommodating locating protrusions of different size in length and/or spacing therebetween. In FIG. 5A, the minimum allowable spacing between the locating protrusions on the block 10 is shown as distance “C”and the maximum distance between the two protrusions is represented by “B.” FIG. 5C best illustrates the alignment members. As seen in FIG. 5C, the alignment member 28 that corresponds to the aperture 36 is a complete ring; however, the alignment member 28 that extends from the oval aperture is in the shape of two symmetric crescents. The two arcuate crescents are received in one cylindrical hole on a drum/pedestal and the complete ring alignment member is received in a second cylindrical hole similar to the embodiment shown in FIGS. 1-3.
The plate has a bottom surface 38 that is attached to the circumferential surface of the rolling drum. The surface may be either flat, as shown in FIG. 4, or have a radius of curvature that corresponds to the radius of curvature of the rolling drum.
It is contemplated that instead of the tabs shown in each of the mounting plate embodiments, side rails (walls) could be employed to accurately position the bottom of a block onto the mounting plate. Such side rails along the base of an assembled product are well-known in the industry and used in the manufacturing of a large variety of products.
There are additional benefits and advantages in using a mounting plate assembly to accurately align a bit holder block. Block, pedestal and drums typically are made from harder steels due to the harsh, violent environment these elements are placed into. For instance, blocks are typically made form SAE 4140 steel. One disadvantage of these hard metal steels is that they do not lend themselves to being materials that form strong weld joints. The mounting plate, in addition to assisting in more accurately positioning a block on a rotary drum, it is believed also provides for a stronger weld joint by relieving some of the weld stress, which can build during cooling and contraction of the joint. It is believed that, since the mounting plate is made from a more ductile material than the block or pedestal, it is more flexible and enhances the flexibility of the joint so that the joint may better contract and compress during cooling of the weld.
It will be understood that various changes in the details, materials and arrangements of parts which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. It is intended that equivalents, adaptations and modifications reasonably inferable from the invention described herein be included within the scope of the invention as disclosed. | A cutting tool assembly having a holder block mounting scheme which effectively and accurately positions the cutting tip point at its designed angle of attack. The connection assembly limits undesirable shifting during attachment of the holder block to a cutting drum. The holder block connection assembly of the present invention includes a separate mounting plate that is positioned between the bit holder block and drum/pedestal for accurately aligning the bit holder block onto to the drum/pedestal. Once the bit holder block is aligned into position by the plate as designed the bit holder block is welded to the drum/pedestal. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to both method and apparatus for removing nail coatings and particularly fingernail polish from the nails of a user.
2. Description of the Prior Art
The most common nail coating takes the form of a variety of fingernail polishes which include a solvent such as acetone, the polish hardening on evaporation of the solvent after application to the nails. Such coatings are usually removed in order to apply new coating or to simply remove the coating for convenience. Removal of nail coatings such as fingernail polish has traditionally been accomplished by application of a nail polish remover which includes acetone or the like to a cotton ball and by then rubbing the acetone-bearing cotton ball against the polished nail. This time-consuming and messy process has conventionally been employed both by the professional manicurist and by the "home" user. In recent years, the home user has had available to her "dip" nail polish removal devices which include a nail polish removal solvent saturated in a foam body whereby the user dips each nail sequentially into a slit formed in the foam body so that polish is readily removed from each nail. The professional manicurist cannot use the dip nail polish removal devices of the prior art unless one of such devices is provided for each client. Health regulations do not allow use of such devices by more than one client due to sanitation reasons. Since the residue of nail polish from a previous user of such devices remains in the devices, the fingers of a subsequent user can become discolored from the residue remaining in the device. Still further, the polish residue in such devices accumulates and causes the solvent within the devices to weaken and thus require a longer period of time for removal of polish. Motorized nail polish removal devices also exist as exemplified by Boyd in U.S. Pat. No. 4,255,826 which discloses a cup containing a mohair brush or the like wherein the cup is rotatable in one direction only and receives each finger sequentially for removal of polish from each nail. In order for the Boyd device to be used by professional manicurists, it would be necessary for the manicurist to remove contaminated polish remover from the Boyd device after use by each client and to clean the mohair brush, a process which would require at least partial disassembly of the device to remove the brush and contaminated polish remover. Use of a brush in a motorized device for polish removal also tends to cause wear on the finger of a user and further does not remove polish quickly from a nail and especially from difficult areas such as the cuticle.
Again referring to the environment of the beauty salon, the professional manicurist is further disadvantaged by prior methodology for nail polish removal since the manicurist has not been able to wear nail polish due to the fact that the manual process of removing the client's polish with a saturated cotton tissue would at least partially remove or disfigure any polish or coating on the manicurist's own nails. The manicurist is further disadvantaged by the continual contact of acetone and other polish removal solvents with the fingers and hands, these solvents defating the hands and fingers quickly and thus causing the hands to dry out. The manual method of removing nail polish is also time consuming and requires that the manicurist be personally involved with the client during the nail polish removal work phase. The professional manicurist would definitely welcome a less labor-intensive method for removal of nail polish and especially would welcome the ability to be removed from the location of the polish removal in order to be accomplishing other tasks and also to be subjected less to fumes of the polish removal solvent, the inhalation of which may be injurious to health.
A long-felt need thus exists, especially by the professional manicurist, for methodology and apparatus which provide more rapid and safer removal of nail coatings such as nail polish and which decreases the involvement of the manicurist with a client during a relatively perfunctory work phase such as the removal of nail polish while increasing the ability of the manicurist to create greater dollar volume when freed of a task requiring little skill. The methodology and apparatus of the present invention not only provides these advantages to the professional manicurist but further enables the manicurist to substantially avoid contact with solvents which dry the hands and fingers and also to reduce inhalation of solvent fumes associated with removal of nail coatings and especially fingernail polish from the nails of clients. Practice of the invention by the professional manicurist also allows the manicurist to wear nail polish or to use other nail coatings without damage thereto, this ability causing the manicurist to personally display glamorous nail coatings, polish patterns, etc. which can constitute an immediate advertisement of the valuable services of the manicurist.
SUMMARY OF THE INVENTION
The invention provides method and apparatus for removing coatings such as fingernail polish from the fingernails, the invention being particularly useful to a professional manicurist who must operate under certain legal and ethical constraints relating to sanitation and who is particularly impacted disadvantageously by prior methodology for removal of nail coatings from the nails of clients. The invention can also be utilized by the "home" user since a substantial number of advantages accrue to the home user and to any user, these advantages relating to ease of use, effectiveness in removing nail coatings both rapidly and efficiently in difficult portions of the nail such as the cuticle area, reduced exposure to solvents both to the hands and fingers by the liquid phase of the solvents and exposure to solvent fumes. The apparatus of the invention includes a motor-driven container open at the top end of the container for receipt of a single-use cartridge filled with a flexible foam body saturated with a solvent capable of removing a nail coating such as fingernail polish. The foam body contained within the cartridge is provided with a finger-receiving slit, slot, aperture or series of slits, such that each finger can be inserted into the solvent-saturated foam body and the container, and thus the cartridge and foam body, rotated to rapidly remove the nail coating from the nails of a user. The abrasion provided by surfaces of the foam body which contact the nail coating coupled with the solvent being contacted with the nail coating through saturation by the solvent of the foam body quickly causes removal of the nail coating from the fingernail. Rotation of the container can be intermittently changed from clockwise to counter-clockwise rotation in order to facilitate removal of the nail coating especially from the cuticle areas and the like. The direction of rotation can be changed within a single revolution or can be changed after a desired number of revolutions.
The present apparatus is sufficiently simple and easy to that the professional manicurist can allow a client to utilize the apparatus while the manicurist is involved with tasks requiring greater skill than that of simply removing nail coatings such as fingernail polish from the nails of the client. The invention thus saves substantial professional time and further reduces exposure of the manicurist to solvents. The apparatus further reduces exposure to solvent fumes on the part of both the professional manicurist and the client (as well as any user) due to the fact that the solvent-containing cartridge is sealed prior to use and is only opened through the sealing structure by means of an aperture which is essentially only large enough for insertion of the finger therethrough. Accordingly, the solvent and fumes of the solvent are less able to either contact more anterior portions of the fingers and hands or be inhaled or contact the eyes and other sensitive portions of the body. Ambient exposure of individuals in a beauty salon to solvent fumes is therefore reduced substantially through use of the present invention.
The foam material comprising the flexible foam body contained within the single-use cartridge of the invention can be made such that the foam or portions of the foam can be substantially abrasive. While the foam itself can be abrasive, abrasive grid or similar materials can be laminated to at least portions of the foam body which contact the nail areas of a user, this abrasive capability being best utilized for removal of nail coatings such as acrylic artificial nails or artificial nails formed of other materials such as can be softened and/or dissolved by means of solvents such as acetone and the like. Prior methodology for removing such artificial nails involves the prolonged soaking of the fingers including the nail areas in a solvent such as acetone, the fingers thus being exposed to prolonged contact with the liquid solvent. Further, solvent vapors issuing from such a soaking bath are unavoidably inhaled by a user and further by individuals in proximity to the user. This time-consuming and labor-intensive task, whether accomplished by a professional manicurist or by an individual caring for her own nails, is markedly expedited through use of the present invention. The methodology of the invention is of particular significance in this situation since a continual and repeated reversing of the cartridge-bearing container facilitates removal of artificial nails and similar coatings. When a portion of a foam body is formed to be aggressively abrasive such as for removal of acrylic artificial nails and the like, then the motor driving the container can be reversed repeatedly within the same revolution such that the abrasive portion of the foam body contacts only the nail surfaces and does not contact the surfaces of the finger opposite the nails, thereby producing less wear on the skin of the fingers.
The single-use cartridge of the invention can be filled with materials in addition to the coating-removing solvent, materials such as cuticle conditioner, nail conditioner, nail buffer, etc. being packaged within these cartridges to provide treatment of the nails and even of the skin of the fingers while nail coatings are being removed according to a practice of the invention. The methodology and apparatus of the invention are especially useful to the professional manicurist but are also of benefit to any user. The professional manicurist saves valuable professional time and reduces exposure to solvents through use of the invention thereby increasing income through the ability to devote more time to those tasks requiring skill. The professional manicurist and those working in the environment of a beauty salon also enjoy reduced exposure to solvent fumes when the manicurist utilizes the methodology and apparatus of the invention.
It is therefore an object of the present invention to provide method and apparatus for removing coatings from the fingernails whereby a single-use cartridge containing a flexible foam body saturated with a coating-removing solvent is rotated in contact with a fingernail to remove a coating on said nail.
It is another object of the invention to provide method and apparatus for removal of nail coatings from the fingernails whereby a solvent-saturated foam body is rotated in both clockwise and counter-clockwise rotation while in contact with a coated fingernail, the change of rotation being either within a single revolution or after a number of revolutions in each direction to facilitate removal of a coating from the nail.
A further object of the invention is to provide method and apparatus useful particularly by a professional manicurist which facilitates removal of nail coatings from the nails of a client while providing a more healthful environment for the manicurist, client and other individuals in proximity thereto.
Further objects and advantages of the invention will become more readily apparent in light of the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus suitable for table-top use, the structure seen in the drawing housing the nail coating removal structure of the invention and further housing manicuring articles ancillary to use of the invention;
FIG. 2 is an elevational view in partial section of the apparatus of FIG. 1 and including a simplified circuit diagram;
FIG. 3 is a perspective of a reduced portion of the apparatus of FIG. 1 and which is partially cut away to illustrate particular portions of the apparatus, the figure also comprising an assembly view illustrating use of the apparatus;
FIG. 4 is a perspective view in section of a single-use cartridge usable with the apparatus of FIGS. 1 through 3; and,
FIG. 5 is a perspective view of an alternative embodiment of a sealing foil used to cover the structure of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIG. 1, an apparatus configured according to the present invention is shown generally at 10 to include a housing 12 which is particularly suited for use in the environment of a beauty salon. The housing 12 comprises an upper base 14 and a lower base 16 (best seen in FIG. 2), the lower base having pad mounts 18 preferably formed of rubber or other elastomeric material so that vibration is reduced on operation of the apparatus 10. The upper base 14 is seen to include a drawer 20 which is capable of holding articles useful in the manicuring process. A switch 22 is disposed on a forward face of the upper base 14 and includes an offsetting as well as "forward" and "reverse" settings such that rotation of structure yet to be described can be manually changed from clockwise to counter-clockwise rotation and back as desired and as will be discussed in greater detail hereinafter. The settings for the switch 22 can also be configured to include an off setting as well as a setting for automatic reversals of rotation after a partial revolution. The housing 12 can further be provided with formed depressions such as the tray 24 and cylindrical apertures 26 which are suited to receive articles useful in the manicuring process.
A support housing 28 rises from surface of the upper base 14 and is preferably formed integrally with the upper base 14. The support housing 28 includes a slanted support surface 30 and an arcuate rear housing portion 32, the rear housing portion 32 having an upper horizontal surface 34 formed with an opening 36 which is best seen in FIG. 3. A hinged cover plate 38 is mounted to close the opening 36, the plate 38 having an aperture 40 disposed centrally therein which allows a user of the apparatus 10 to extend at least the distal end of a finger into said aperture 40 for treatment by structure yet to be described.
As can be appreciated from the illustration of FIG. 1 as well as FIGS. 2 and 3, upper portions of the housing 12 can be formed substantially as a single molded unit with lower portions of the housing 12, such as the lower base 16, being removably attached to the upper base 14, for example, by means of screws (not shown) or other fasteners in order that structure yet to be described can be mounted within the interior of the housing 12 and serviced as desired. As will be appreciated by those of skill of the art, structural features such as the drawer 20, tray 24, etc. need not be provided but are useful within the environment of use of the apparatus 10.
Referring now not only to FIG. 1 but also to FIGS. 2 and 3, an inner housing cup 42 is shown to be formed about the opening 36 in the rear housing portion 32, the housing cup 42 having an aperture 44 formed in the bottom thereof which receives a pedestal plate 46 for rotation within said aperture 44. The pedestal plate 46 mounts either removably or integrally a container 48 which is open at its uppermost end. The container 48 can be rotated in either direction depending on rotation of the pedestal plate 46 as will be described hereinafter. The container 48 can take the shape of a cylinder or other geometrical figure. However, it is preferred to form the container 48 as a hollow rectangular solid. For the sake of appearance, and for ease of using thermally formed plastic cartridges as will be described hereinafter, the container 48 is provided with rounded corners which provide a softer appearance. The container 48 is centered on the pedestal plate 46 such that the aperture 40 in the cover plate 38 is centered above the open end of the container 48 when the cover plate is closed over the opening 36.
The pedestal plate 46 can be provided with upper and lower base elements 50 and 52, the diameter of the upper base element 50 being reduced relative to the diameter of the lower base element 52 such that a track is provided to allow receipt of a flange 54 which defines the aperture 44 formed in the housing cup 42. The pedestal plate 46 thereby rotates with the upper base element 50 being received within the aperture 44 so that said plate 46 is maintained in a desired location.
The pedestal plate 46 is attached to a drive shaft 56 driven through a control unit 58 which is in turn driven through shaft 60 by motor 62, the motor 62 being electrically driven. It should be noted that the drive shaft 56 could be otherwise driven, such as by gear arrangements, belting, etc. However, it is preferred to drive the shaft 56 through a control unit such as the unit 58 which can contain gear reduction devices, rotational control apparatus, eccentric drive mechanisms, etc. such as are conventional art and which are not illustrate for the sake of convenience. The switch 22 acts through switch control element 64 to both provide power to the motor 62 and to allow control of the control unit 58 such that the rotational sense of the container 48 can be controlled as desired and as will be discussed in more detail hereinafter.
The motor 62 is mounted within housing 66 which extends from inner surfaces of the lower base 16, the motor 62 being mounted such as by conventional fasteners 68 to maintain the motor 62 in a desired position. The motor can take the form of an automatically reversible unit such as is manufactured by Hurst Manufacturing Company, a division of Emerson Electric Company, Princeton, Indiana. This motor automatically reverses when stopped either after a partial revolution or one or more full revolutions. Similarly useful motors are available in the art and need not be described in detail herein. The motor 62 drives the shaft 60 which transmits rotation through the control unit 58 to the drive shaft 56. As will be appreciated from a review of FIG. 2, the shafts 56 and 60 are not aligned so that eccentric mechanisms (not shown) located within the control unit 58 can cause rotation of the container 48 only during a portion of each revolution of said shafts 56 and 60. However, the control unit 58 can be configured such that an essentially direct drive, or a reduced gearing drive, can rotate the container 48 through the drive shaft 56 through full revolutions. Further, the control unit 58 is configured to be controlled by the switch control 64 to change the angular sense of the drive shaft 56 and thus the container 48 as is desired in practicing the methodology of the invention. The control unit 58 which acts in concert with the motor 62 functions when the control switch 22 is appropriately set to cause the motor 62 to reverse rotational sense after a partial revolution as aforesaid. The motor 62 and the control unit 58 are conventional apparatus as aforesaid.
The control unit 58 can be seen particularly in FIG. 2 to be supported in spaced relation to the motor 62 by means of support posts 70. Leveling posts 72 are also seen in FIGS. 2 and 3 to be provided below the pedestal plate 46 to prevent undesired canting of the pedestal plate 46.
Referring now to FIGS. 2, 3 and 4, a single-use cartridge 74 as seen to be insertable into the container 48 for rotation with said container 48 when the apparatus 10 is in use. The cartridge 74 essentially comprises a thermally formed plastic material or material otherwise produced and includes a cup portion 76 open at one end and surmounted at the open end by means of a flange 78. The cup portion 76 of the cartridge 74 receives a foam body 80 which is saturated with a solvent for a nail coating, the solvent typically being acetone or certain acetate compounds. The foam body 80 fits snuggly within the cup portion 76 such that said foam body 80 positively moves with the cartridge 74 and does not slip within cartridge 74. While the foam body 80 and the cup portion 76 can be formed in a substantially cylindrical manner, the potential exists with cylindrical shapes for "free wheeling" such that the foam body 80 does not positively move with the cartridge 74. Similarly, the cartridge 74 with its essentially square cross section fits closely within the interior of the container 48 such that slippage between said container 48 and said cartridge 74 does not occur.
The foam body 80 can be provided with a central bore 82 having slits 84 formed regularly thereabout, the bores 82 receiving the distal end of a finger, and particularly the nail portion of the finger, therewithin such that a nail coating contacts walls of the bore 82 substantially over all surfaces of the nail such that the nail coating is brought into intimate contact not only with the relatively abrasive foam walls of the bore 82 but also with the solvent saturating the foam body 80. The slits 84 allow a more regular expansion of the bore 82 on insertion of a relatively larger finger, the slits 84 allowing the bore 82 to more easily conform to various finger dimensions. It should be appreciated here that the foam body 80 can be simply formed with slits such as the slits 84 located centrally therein without the need for a formed bore. The use of a single slit or a single slot as well as intersecting slits or slots will allow a finger to be received into the foam body 80 in a suitable manner.
As best seen in FIG. 4, a given surface portion of the bore 82 such as is represented by that portion 86 between the illustrated portions of the slits 84 can be provided with a more aggressively abrasive material such as grit bonded to the portion 86 of the foam body 80. Through controlled rotation of the container 48 and thus of the cartridge 74, the more abrasive surface portion 86 can be rotated only in contact with a nail coating on the finger of a user, such coating comprising an artificial fingernail or the like, in order to more efficiently remove the artificial fingernail without substantial contact between the skin on the distal end of the finger and the more abrasive surface portion 86. Alternatively, the foam body 80 itself can be formed of various foam materials of varying relative abrasiveness depending upon the nature of the nail coating which is to be removed.
As is best seen in FIG. 4, a foil sheet 88 is formed over the open end of the cartridge 74 and is sealed in place through contact with upper surfaces of the flange 78. In use, the entire foil sheet 88 can be removed from the cartridge 74 either prior to or after insertion of the cartridge 74 into the container 48. In this manner, the solvent contained within the cartridge 74 and saturating the foam body 80 is not permitted to evaporate. The structure of FIG. 5 can be utilized to minimize evaporation of a solvent saturating the foam body 80 even during use of the apparatus 10. In particular, foil sheet 90 is seen to be provided with a weakened portion 92 which can conveniently be shaped as a circle and which can have two or more weakened diameters 94. Through use of the foil sheet 90, the cartridge can be inserted into the container 48 and not "opened" until a user is ready to insert a finger through the weakened portion 92 of the foil sheet 90. The weakened diameters 94 can have weakened portions 96 extending beyond the weakened circle such that fingers of varying size can cause a substantially controlled tearing along the diameters 94 to accommodate various finger dimensions. Use of the foil sheet 90 results in only a portion of the solvent saturated foam body 80 being open to the atmosphere, thereby reducing the quantity of solvent which evaporates into the atmosphere.
Referring again to FIG. 3, it is seen that the hinged cover plate 38 can be opened to facilitate insertion or removal of one of the cartridges 74 into the container 48. The cover plate 38 is then closed, the aperture 40 allowing access by the finger of a user into the interior of the foam body 80. The bore 82 of the foam body 80 is located within said foam body 80 such that it is substantially aligned with the center of the aperture 40. The hand of a user is conveniently rested on the slanted support surface 30 such that each finger can be separately and sequentially inserted through the aperture 40 in the plate 38 and into the bore 82 of the foam body 80. Solvent and surface portions of the bore 82 intimately contact a nail coating substantially over the full surface thereof when the distal end of a finger is inserted thereinto. Operation of the switch 22 then causes a desired rotation of the container 48 and thus rotation of the foam body 80, a nail coating thus being very rapidly removed from the nail of the inserted finger. Rotation of the container 48 can be controlled manually through the switch 22 or controlled automatically according to- a "program" of rotation devised for particular settings of the switch 22. The direction of rotation of the container 48 can be initially either clockwise or counter-clockwise and can proceed through one or more full revolutions in any given directional sense or through only a partial revolution as is desired for a particular coating removal situation. Reversal of the original angular direction can then proceed for one or more full revolutions or even a partial revolution only before again reversing direction. Change of angular direction can occur with any desired rapidity, the change of direction acting to more completely remove coatings from the fingernail especially in traditionally difficult areas such as the nail cuticle. The functions thus described are carried out through use of the control unit 58 and the motor 62 which are conventional in terms of structure per se and are available as conventional apparatus as is referred to hereinabove.
Use of the apparatus 10 by a professional manicurist is particularly advantageous since the cartridge 74 can be changed after use of the apparatus 10 by successive clients. In essence, each client would use one of the cartridges 74 with that cartridge then being discarded after use. The client is thus assured sanitary conditions and the manicurist readily complies with health restrictions which do not allow use of a dip polish remover by more than one individual within the environment of a beauty salon. In addition, different cartridges 74 can include different materials intended for different applications. One of the cartridges 74 can be provided with emollient compositions either with or without nail coating removal solvents such that the nails and skin of the fingers can be conditioned either separately or simultaneously with removal of nail coatings. Further, certain of the cartridges 74 can be provided with more abrasive materials utilized as one of the foam bodies 80 or with foam materials having abrasive surfaces to facilitate removal of more difficulty removed nail coatings.
Accordingly the present methods and apparatus of the invention provide substantial advantage over the methodology and apparatus of the prior art and especially within the use environment of a professional manicurist. While the invention has been described in light of particular embodiments thereof, it is to be appreciated that the invention can be practiced other than as explicitly shown and described herein, the scope of the invention being defined by the appended claims. | A motorized device for removing nail coatings such as fingernail polish or the like and usable by either a professional manicurist or by an individual caring for her own nails, the invention includes a container controllably rotatable in both clockwise and counter-clockwise directions, the container receiving a single-use cartridge filled with a flexible foam body saturated with a solvent capable of removing the coating. In the environment of a beauty salon, a client inserts each nail sequentially into a finger-receiving slit in the foam body of the cartridge and the cartridge-bearing container is rotated after each insertion to remove the coating, the cartridge then being discarded so that only one client uses a given cartridge. Sequential reversing of the cartridge-bearing container according to the invention speeds removal of the nail coating especially in cuticle areas from which nail coatings are difficult to remove according to prior methodology. The methods and apparatus of the invention provide for more rapid and safer removal of nail coatings such as nail poish when compared to prior methodology and polish removal apparatus. | 0 |
This is a division of application Ser. No. 100,331, filed Dec. 5, 1979, now U.S. Pat. No. 4,268,676.
BACKGROUND
The present invention relates generally to antibiotic mitosane compounds and to their use in the treatment of neoplastic disease states in animals.
Pertinent to the background of the invention are those antibiotics which are isolated from the fermented broth of Streptomyces verticillatus and named Mitomycin A, B, and C. The structures of these three compounds are well known in the art [being eludicated, for example, in a publication of J. S. Webb, et al., in J.A.C.S., 84, 3185(1962)] and are set out below. ##STR5##
Mitomycin A, B, and C are acknowledged as excellent antibiotics but are relatively highly toxic to humans. This has prompted the prior art synthesis of numerous mitomycin derivatives and analogs in an attempt to secure compounds having equal or enhanced antibiotic activity but lesser toxicity than the naturally-occuring mitomycins. Among the mitomycin derivatives having structures and activities of interest to the present invention are those described in U.S. Pat. Nos. 3,332,944 (Colusich, et al.); 3,450,705 (Matsui, et al.); and 3,514,452 (Matsui, et al.), as well as in Kinoshita, et al., J.Med.Chem., 14, No. 2, 103-112 (1971) and French Pat. No. 1,449,947.
Also of interest to the present invention are reports of workers in the art that certain mitomycins and mitomycin derivatives possess a degree of in vivo antitumor activity. See, e.g., Oboshi, et al., GANN, 58, 315-321 (1967); Usubuchi, et al., GANN, 58 307-313 (1967); Matsui, et al., J. Antibiotics, XXI, No. 3, 189-198 (1968); Japanese Pat. No. 68 06,627 to Matsui, et al. [as reported in Chem. Abstracts, Vol. 69, 86986K (1968)] and Cheng, et al., J.Med.Chem., 20, No. 6, 767-770 (1977). The last-mentioned publication by the inventor and one of his co-workers discloses activity against P388 leukemia in mice for mitomycin A, mitomycin C and N-methylmitomycin A.
Mitomycin C is assertedly active against a relatively broad spectrum of experimental tumors including both hematological and solid types. In clinical practice, however, its use is limited to certain carcinomas owing to its toxicity and particularly its myelosuppressive effects. See, e.g., "Mitomycin C: Current Status and Development", Carter, et al. Eds., Academic Press, New York (1977). Numerous analogs of mitomycin C have been prepared in the hope of obtaining compounds with improved therapeutic properties, especially antitumor properties. The semi-synthetic analogs of the above-noted patents and publications have involved substituents on the aziridine ring, carbamoyl or acyl groups on the hydroxymethyl side chain, and replacement of the 7-substituent in the quinone ring with other functional groups, especially, substituted amines. None of these analogs has emerged as a clinical agent, although a 7-hydroxy analog of mitomycin C has received intensive study recently in Japan. This analog is asserted to be less leukopenic than mitomycin C, although it is also much less potent. Totally synthetic mitomycin analogs of the mitosene [Mott, et al., J.Med.Chem., 21, 493 (1978)] and indoloquinone [Weiss, et al., J.Med.Chem., 11, 742 (1968)] types have been prepared, but mainly for their antibacterial activity. The most active antitumor agent of the mitosene type is considerably less active than mitomycin C.
The art, therefore, persists in its search for new and useful compounds which are structurally related to the mitomycins, which possess antibiotic activity, have low toxicity and display a substantial degree of antitumor activity in animals.
SUMMARY
According to the present invention, there are provided novel compounds of the formula, I, ##STR6## wherein: Y is hydrogen or lower alkyl; and X is a thiazolamino radical, a furfurylamino radical or a radical of the formula, ##STR7## in which R, R 1 , and R 2 are the same or different and selected from the group consisting of hydrogen and lower alkyl, and R 3 is selected from the group consisting of lower alkenyl, halo-lower alkenyl, lower alkynyl, lower akloxycarbonyl, thienyl, formamyl, tetrahydrofuryl and benzene sulfonamide.
Also provided according to the invention are novel methods for treatment of neoplastic disease states in animals, which methods comprise administering a therapeutically effective amount of a compound of the formula, Ia, ##STR8## wherein: Y is hydrogen or lower alkyl; and Z is a thiazolamino radical, a furfurylamino radical, a cyclopropylamino radical, a pyridylamino radical, or a radical of the formula, ##STR9## in which R 4 , R 5 , and R 6 are the same or different and selected from the group consisting of hydrogen and lower alkyl, and R 7 is selected from the group consisting of lower alkenyl, halo-lower alkenyl, lower alkynyl, lower alkoxycarbonyl, halo-lower alkyl, hydroxy-lower alkyl, pyridyl, thienyl, formamyl, tetrahydrofuryl, benzyl, and benzene sulfonamide.
The term "lower," as applied to "alkyl" radicals shall designate such straight or branched chain radicals as include from one to six carbon atoms. By way of illustration, "lower alkyl" shall mean and include methyl, ethyl, propyl, butyl, pentyl and hexyl radicals as well as ispropyl radicals, t-butyl radicals and the like. Similarly, "lower" as applied to "alkenyl" or "alkynyl" shall designate a radical having two to six carbon atoms.
It will be apparent that the compounds of formula I are all comprehended by the specifications of formula Ia. Put another way, all the novel antibiotic mitomycin derivatives of formula I are useful in practice of the novel antineoplastic therapeutic methods which involve administration of compounds of formula Ia.
Mitomycin derivatives of the invention are prepared by the reaction of mitomycin A with appropriately selected amine compounds. The N-alkylmitomycin (e.g., N-methylmitomycin) derivatives are similarly prepared by the reaction of a selected amine with N-alkylmitomycin A prepared from mitomycin C, e.g., according to the methods generally disclosed in Cheng, et al., J.Med.Chem., 20, No. 6, 767-770 (1977). The preparative reactions generally yield the desired product as a crystalline solid which is readily soluble in alcohol.
Therapeutic methods of the invention comprehend the administration of effective amounts of one or more of the compounds of formula Ia, as an active ingredient, together with desired pharmaceutically acceptable diluents, adjuvants and carriers, to an animal suffering from a neoplastic disease state. Unit dosage forms of compounds administered according to the methods of the invention may range from about 0.001 to about 5.0 mg and preferably from about 0.004 to about 1.0 mg, of the compounds. Such unit dosage quantities may be given to provide a daily dosage of from about 0.1 to about 100 mg per kg, and preferably from about 0.2 to about 51.2 mg per kg, of body weight of the animal treated. Parental administration, and especially intraperitoneal administration, is the preferred route for practice of the inventive methods.
Other aspects and advantages of the present invention will become apparent upon consideration of the following description.
DESCRIPTION OF THE INVENTION
The following examples 1 through 25, describing preparation of certain presently preferred compounds according to the invention, are for illustrative purposes only and are not to be construed as limiting the invention. Unless otherwise indicated, all reactions were carried out at room temperature (20° C.), without added heat. Unless otherwise indicated, all thin layer chromatographic (TLC) procedures employed to check the progress of reactions involved the use of a pre-coated silica-gel plate and a mixture of acetone and benzene (4:1 by volume) as a developing solvent.
EXAMPLE 1
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(2-thiazolamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A mixture of potassium carbonate (80 mg) and 2-aminothiazole (18 mg) in 4 ml of anhydrous methanol was stirred under nitrogen atmosphere. To this mixture mitomycin A (30 mg or 0.085 mmol) was added with stirring. The progress of the reaction was checked periodically by TLC and the reaction appeared to be complete in 40 hours. The insoluble potassium carbonate was filtered and the filtrate was evaporated under reduced pressure. The residue obtained was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of benzene and acetone (6:4 by volume) was evaporated. Recrystallization from a mixture of chloroform and acetone gave 16 mg (45% yield) of the desired product having a melting point of 85°-87° C. and providing the following analysis:
NMR (CDCl 3 , TS): `δ` values in ppm. The disappearance of a singlet at 4.02 (due to the 6-methoxy group in the starting materials) and the appearance of new signals at 6.46 (s,1), 7.36 (d,1) and 7.80 (d,1) were indicated.
EXAMPLE 2
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-furfurylamino-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 60 mg (0.17 mmol) of mitomycin A in 8 ml of anhydrous methanol, 0.5 ml of furfurylamine was added with stirring. The progress of the reaction was periodically checked by TLC and the reaction appeared to be complete in 3 hours. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated. Recrystallization from a mixture of chloroform and here gave 30 mg (42.7% yield) of the desired product as colored crystals having a melting point of 62°-63° (decomposing) and providing the following analysis:
NMR (CDCl 3 , TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02, and the appearance of new peaks at 4.67(split s,2), 6.33-6.53(m,2) 6.57(t,1) and 7.33(split s,1) were indicated.
EXAMPLE 3
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-furfurylamino-azirino[2',3':3,4]pyrrolo-[1,2a]indole-4,7-dione carbamate
To a solution of 50 mg (0.13 mmol) of N-methylmitomycin A in 6 ml of anhydrous methanol, 0.5 ml of furfurylamine was added with stirring. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of chloroform and ethyl acetate (1:1 by volume) was evaporated under reduced pressure. Recrystallization from a mixture of chloroform and hexane gave 31 mg (55.7% yield) of the desired product as purple colored crystals having a melting point of 140°-141° (decomposing) and providing the following analyses:
NMR (CDCl 3 , TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 ppm and the appearance of new peaks at 4.67(split s,2), 6.33-6.53(m,2), 6.57(t,1) and 7.33 (split s,1) were indicated.
EXAMPLE 4
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-cyclopropylamino-azirino[2',3':3,4]pyrrolo-[1,2a]indole-4,7-dione carbamate
To a solution of 75 mg (0.2 mmol) of N-methylmitomycin A in 10 ml of anhydrous methanol, 2 ml of cyclopropylamine was added with stirring. The reaction mixture was stirred overnight, whereupon TLC indicated no remaining starting material. The solvent was then evaporated under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of methylene chloride and hexane gave 47.8 mg (59.7% yield) of the desired product as purple-colored crystals having a melting point of 166°-167° (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 0.70-0.90(broad s,5) and at 6.30-6.43(broad s,1) was indicated.
EXAMPLE 5
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(3-pyridylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 60 mg mitomycin A (0.17 mmol) in 5 ml of anhydrous methanol was added 61 mg of 3-aminopyridine (1.2 mmol) with stirring. The progress of the reaction was checked periodically by TLC and the reaction appeared to be complete after 44 hours. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of ethyl acetate and acetone (10:1 by volume) was evaporated to dryness. Recrystallization from chloroform gave 38 mg (56% yield) of green solid having a melting point of 78°-80° C. and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 7.27 (s.2), 7.67(s,1) and 8.35 (s,2) were indicated.
EXAMPLE 6
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-allylamino-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 100 mg (0.28 mmol) of mitomycin A in 8 ml of anhydrous methanol, 150 mg (2.6 mmol) of allylamine was added with constant stirring. The reaction mixture was stirred overnight whereupon TLC indicated the absence of starting material. The solvent was then evaporated under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column from ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of methylene chloride and hexane gave 29 mg (27.0% yield) of the desired product as purple-colored crystals having a melting point of 81°-82° (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of peaks 3.30-3.43(m,2), 5.10(d,2), 5.50-6.10(m,1), 6.50(t,1) were indicated.
EXAMPLE 7
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-allylamino-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 100 mg (0.275 mmol) of N-methylmitomycin A in 15 ml of anhydrous methanol, 58 mg (1 mmol) of allylamine was added with stirring. The reaction mixture was stirred overnight, whereupon TLC indicated the absence of starting material. The solvent was then evaporated under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the colum with ethyl acetate was evaporated to dryness. Recrystallization from a mixture of ethyl acetate and hexane gave 38.5 mg (38% yield) of the desired product as purple-colored crystals having a melting point of 70°-71° C. (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of peaks at 3.30-3.43(m,2), 5.10(d,2), 5.50-6.20(m,1), 6.50(t,1) were indicated.
EXAMPLE 8
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(2-methylallylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A solution of 50 mg mitomycin A (0.138 mmol) in 8 ml. of anhydrous methanol was stirred with 29 mg of 2-methylallylamine. The progress of the reaction was periodically checked by TLC and, after 2 hours, the solvent was removed by evaporation under reduced pressure and the residue was purified by column chromatography using silica-gel as adsorbent and ethyl acetate as the eluant. Recrystallization from a mixture of chloroform and hexane gave 30 mg (55% yield) of the desired product as purple crystals having a melting point of >250° C. (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS) `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 1.97 (s,3), 4.00(d,2), 4.85 (d,2) and 6.53 (t,1) were indicated.
EXAMPLE 9
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-(2-chloroallylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a] indole-4,7-dione carbamate
A solution of 50 mg (0.138 mmol) of N-methylmitomycin A in 6 ml of anhydrous methanol was stirred with 0.2 ml of 2-chloroallylamine. The progress of the reaction was checked periodically by TLC and appeared to be complete in 3 hours. The solvent was then evaporated under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of chloroform and ethyl acetate (1:1 by volume) was evaporated under reduced pressure. Recrystallization from a mixture of chloroform and hexane gave 20 mg (34% yield) of the desired product as purple-colored crystals having a melting point of 71°-72° C. (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 4.03-4.55 (split s,2), 5.30-5.4 (broad s,2) and 6.53 (t,1).
EXAMPLE 10
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(N-methylpropargylamino)-azirino[2',3':3,4]pyrrolo[1,2-a]indole-4,7-dione carbamate
To a solution of 50 mg (0.14 mmol) of mitomycin A in 10 ml of anhydrous methanol was stirred with 150 mg (2 mmol) of N-methylpropargylamine at room temperature. The reaction appeared to be completed in 3 hours, as revealed by TLC. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of methylene chloride and hexane gave 20 mg (37% yield) of the desired product as purple-colored crystals having a melting point of 86°-87° C. (decomposing) and providing the following analysis:
NMR (CDl 3 , TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 2.00(s,1), 3.20 (s,3), 4.20(s,2) and 6.20-6.40(broad s,1) were indicated.
EXAMPLE 11
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethy)-8a-methoxy-5-methyl-6-(1,1-dimethylpropargylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 50 mg (0.14 mmol) of mitomycin A in 6 ml of anhydrous methanol, 1 ml. of 1,1-dimethylpropargylamine was added with stirring. The progress of the reaction was checked by TLC and appeared to be complete after 72 hours. The solvent was then evaporated under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of chloroform and hexane gave 11.6 mg (21% yield) of the desired product as purple-colored crystals having a melting point of 99°-100° C. (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 1.68(s,6), 2.47(s,1) and 6.23-6.60(broad s,1) were indicated.
EXAMPLE 12
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-propargylamino-azirino[2',3',:3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A solution of 100 mg (0.28 mmol) of mitomycin A in 10 ml of anhydrous methanol was stirred with 84 mg (1.5 mmol) of propargylamine for 4 hrs. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed by using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of ethyl acetate and acetone (8:2 by volume) was evaporated under reduced pressure. Recrystallization from a mixture of chloroform and hexane gave 36.5 mg (35% yield) of the desired product as purple-colored crystals having a melting point of 95°-96° (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of peaks at 2.40(s,1), 4.33(s,2) and 6.37(t,1) were indicated.
EXAMPLE 13
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-propargylamino-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A solution of 107 mg (0.27 mmol) of N-methylmitomycin A in 10 ml of anhydrous methanol was stirred with 85 mg (1.5 mmol) of propargylamine for 3 hours, whereupon TLC indicated no remaining starting material. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of methylene chloride and hexane gave 52.2 mg (50% yield) of the desired product as purple-colored crystals having a melting point of 86°-87° (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 2.40(s,1), 4.33(s,2), and 6.38(t,1) were indicated.
EXAMPLE 14
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(methoxycarbonyl-methylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A solution of 40 mg of the methyl ester of glycine hydrochloride (0.42 mmol) in anhydrous methanol was cooled in ice-bath. To this cold solution a methanolic solution of 23 mg sodium methoxide (0.42 mmol) was added with stirring. A solution 76 mg of mitomycin A (0.21 mmol) in 45 ml of anhydrous methanol was added to this mixture with stirring under a nitrogen atmosphere. The resultant mixture was stirred at room temperature and the progress of the reaction was checked by TLC. The reaction appeared to be complete in 3.5 hours. Solvent was removed by evaporation under reduced pressure and the residue was purified by preparative thin-layer chromatograph to give 6 mg (13% yield) of the desired product having a melting point of 95°-97° and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 3.50 (s,2), 3.73 (s,3) and 5.33-5.66 (broad s,1) were indicated.
EXAMPLE 15
1,1a,2,8,8a,8b-Hexahydro-8(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-(2-chloroethylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 33 mg (0.09 mmol) of N-methylmitomycin A in 5 ml of anhydrous methanol, a solution of 56 mg of 2-chloroethylamine hydrochloride (0.5 mmol) in 2.5 ml of methanol and a solution of 41 mg sodium acetate (0.5 mmol) in 2.5 ml of methanol were added alternatively with constant stirring over a period of 10 minutes. The stirred reaction mixture was checked frequently by TLC and the reaction appeared to be complete in 24 hours. The solvent was evaporated and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of chloroform and hexane gave 16 mg (38% yield) of the desired product as purple-colored crystals having a melting point of 73°-74° C. (decomposing) and providing the following analysis: NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 3.30-4.00(2t,4), 6.57(t,1) were indicated.
EXAMPLE 16
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(2-chloroethylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate.
To a solution of 100 mg mitomycin A (0.286 mmol) in 10 ml. of anhydrous methanol, a solution of 82 mg sodium acetate (1 mmol) in 2.5 ml. of methanol and a solution of 116 mg 2-chloroethylamine hydrochloride (1 mmol) in 2.5 ml. of methanol were added alternatively with constant stirring, over a period of ten minutes. The stirred reaction mixture was periodically checked by TLC and the reaction appeared to be complete in 24 hours. The insoluble sodium chloride was removed by filtration and the solvent was removed by evaporation under reduced pressure. The residue was purified by column chromatography using ethyl acetate and acetone (4:1 by volume) as the eluant. Recrystallization from a mixture of chloroform and hexane gave 34 mg. (30% yield) of the desired product as purple-colored crystals having a melting point of 59° C. (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 3.30-4.00 (m,4) and 6.40(t,1) were indicated.
EXAMPLE 17
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(3-chloropropylamino)-azirino[2',3':3:4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 100 mg mitomycin A (0.286 mmol) in 10 ml of anhydrous methanol, a solution of 82 mg sodium acetate (1 mmol) in 2.5 ml. of methanol and a solution of 130 mg 3-chloropropylamine hydrochloride (1 mmol) in 2.5 ml. of methanol were added alternatively with constant stirring over a period of ten minutes. The stirred reaction mixture was periodically checked by TLC and the reaction appeared to be complete in 24 hours. The insoluble sodium chloride precipitate was removed by filtration and the solvent was removed by evaporation under reduced pressure. The residue was purified by column chromatography using silica-gel as adsorbent and a mixture of ethyl acetate and acetone (4:1 by volume) as the eluant. Recrystallization from a mixture of chloroform and hexane gave 35 mg. (30% yield) of the desired product as colored crystals having a melting point of 64° C.(decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS), `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 1.87-2.30 (m,2) 3.55-3.95 (m,4), and 6.28 (t,1) were indicated.
EXAMPLE 18
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-1,5-dimethyl-6-(3-hydroxypropylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate (7)
To a solution of 50 mg(0.13 mmol) of N-methylmitomycin A in 10 ml of anhydrus methanol, a solution of 82 mg (1 mmol) sodium acetate in 2.5 ml of methanol and a solution of 130 mg (1 mmol) of 3-hydroxypropylamine hydrochloride in 2.5 ml of methanol were added alternatively with vigorous stirring, over a period of 10 minutes. The progress of the stirred reaction was checked frequently by TLC and appeared to be complete in 24 hours. The solvent was evaporated under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated. Recrystallization from a mixture of methylene chloride and hexane gave 31 mg. (61% yield) of the desired product as purple-colored crystals having a melting point of 139°-140° (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy pead at 4.02 and the appearance of new peaks at 1.80-2.13(m,2), 3,43-4.00(m,4), and 6.34(t,1) were indicated.
EXAMPLE 19
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(3-hydroxypropylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 60 mg mitomycin A (0.17 mmol) in 5 ml of anhydrous methanol was added with stirring 0.5 ml of 3-hydroxypropylamine. The progress of the reaction was checked by TLC and the reaction appeared to be complete in two hours. The solvent was removed by evaporation under reduced pressure. The residue was dissolved in 100 ml of ethyl acetate and the organic layer was washed with water, dried over anhydrous sodium sulfate, and the solvent was removed by evaporating under reduced pressure. The residue was then chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of ethyl acetate and acetone (9:1 by volume) was evaporated to dryness under reduced pressure. Recrystallization from acetone gave 60.7 mg (91% yield) of the desired product as purple crystals having a melting point of >250° (decomposing and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 1.52-1.92 (m,2), 3.43-4.00 (m,4), and 6.73(t,1) were indicated.
EXAMPLE 20
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(3-pyridylmethylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 115 mg mitomycin A (0.33 mmol) in 5 ml of anhydrous methanol, 71 mg 3-aminomethylpyridine (0.66 mmol) was added and the mixture was stirred. The progress of the reaction was checked by TLC and appeared to be complete in 16 hours. The solvent was removed by evaporation under reduced pressure. The residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with a mixture of chloroform and ethyl acetate (1:1 by volume) was evaporated to give 107 mg (76% yield) of the desired product as purple-colored crystals having a melting point of 116°-118° after recrystallization from chloroform-hexane and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of a 6-methoxy peak at 4.02 and the appearance of new peaks at 3.88 (s,2), 6.58 (t,1), 7.00-7.40 (d,1), 7.43-7.90 (d,1) and 8.53(s,2) were indicated.
EXAMPLE 21
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(2-thienylmethylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 25 mg mitomycin A (0.071mmol) in 2 ml. of anyhdrous methanol, 16.2 mg 2-aminomethylthiophene (0.143 mmol) was added with stirring. The progress of the reaction was checked periodically by TLC and the reaction appeared to be complete in 24 hours. Removal of the solvent by evaporation under reduced pressure gave a dark-blue residue. The residue was purified by preparative thin-layer chromatography using a pre-coated silica-gel plate (2 mm thickness) and acetone as developing solvent. The product was further purified by recrystallizing from a mixture of chloroform and hexane to give 20 mg (65% yield) of the desired product having a melting point of 92°-94° C. and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 3.72 (s,2), 6.47 (t,1) and 6.77-7.33 (m,3) were indicated.
EXAMPLE 22
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(aminocarbonylmethylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A mixture of mitomycin A (40 mg, 0.11 mmol) and glycinamide (42 mg) in 3.5 ml of absolute ethanol was stirred at room temperature for 4 hours. The solvent was evaporated under reduced pressure and the residue was purified by preparative thin-layer chromatography using a pre-coated silica-gel plate (2 mm thickness) and a mixture of ethanol and ethyl acetate (1:3 by volume) as developing solvent. The blue zone was eluted with ethanol and evaporated under reduced pressure to give 12.8 mg (29.7% yield) of the desired product having a melting point of 124°-126° C. and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 3.95 (s,2), 5.36 (broad, 2) and 6.35 (m,1) were indicated.
EXAMPLE 23
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-(2-tetrahydrofurfurylamino)-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 100 mg mitomycin A (0.3 mmol) in 8 ml of anhydrous methanol, 0.2 ml of tetrahydrofurfurylamine was added with stirring. The progress of the reaction was checked by TLC using a pre-coated silica-gel plate and acetone as developing solvent. The reaction appeared to be complete in 3 hours. The solvent was removed by evaporation under reduced pressure and the residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure. Recrystallization from a mixture of chloroform and pentane gave 52 mg (43.5% yield) of the desired product as a dark-blue solid having a melting point of 236°-237° C. (decomposing) and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new signals at 1.26 (s,2), 1.66-2.37 (m,4), 3.50-4.10 (m,3) and 6.55 (t,1) were indicated.
EXAMPLE 24
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-phenylethylamino-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
To a solution of 115 mg of mitomycin A (0.33 mmol) in 4 ml of anydrous methanol was added with stirring 80 mg of phenylethylamine (0.66 mmol) in 2 ml of anhydrous methanol. After 18 hours, the solvent was removed by evaporation under reduced pressure. The residue was dissolved in 15 ml of ethyl acetate, and then washed with five 15 ml portions of pH 4 buffer solution. The solvent was removed under reduced pressure and the residue was chromatographed using silica gel as adsorbent and ethyl acetate as solvent. Recrystallization of the product from ethyl acetate-ether gave 85 mg (58.7% yield) of purple solid having a melting point of 94°-96° C. and providing the following analysis:
NMR (CDCl 3 ,TMS): `δ` values in ppm. Absence of the 6-methoxy peak at 4.02 and the appearance of new peaks at 3.40-3.90 (m,4), 6.33(t,1) and 7.27 (s,5) were indicated.
EXAMPLE 25
1,1a,2,8,8a,8b-Hexahydro-8-(hydroxymethyl)-8a-methoxy-5-methyl-6-[(4-sulphonamidophenyl)methylamino]-azirino[2',3':3,4]pyrrolo-[1,2-a]indole-4,7-dione carbamate
A solution of mitomycin A (76.6 mg. 0.22 mmol) in 3 ml of anydrous methanol was stirred at room temperature with p-aminomethylbenzenesulfonamide (80 mg). The mixture was kept at room temperature for 4 hours and at 0° C. for 12 hours. Solvent was removed by evaporation under reduced pressure. The dark residue was chromatographed using silica-gel as adsorbent. The fraction obtained by eluting the column with ethyl acetate was evaporated under reduced pressure to give 104 mg of the crude product. The crude product was dissolved in a minimum volume of methanol and anhydrous ether was added to this solution. The dark-blue precipitate was filtered and dried to give 52 mg (47% yield) of the desired product having a melting point of 93°-96° C. after crystallization from benzene and providing the following analysis:
NMR (DMSO-d 6 ,TMS): `δ` in ppm. Absence of the 6-methoxy peak at 4.02 ppm and the appearance of new signals at 3.66-4.00 (broad s,2), 6.47(s,1) and 7.27-8.00(2d,6) were indicated.
With specific reference to the compounds comprehended by formula Ia, the above examples illustrate the following structural variations:
1. In the compounds of Examples 3, 4, 7, 13, 15 and 18, Y is lower alkyl and, more specifically, methyl. In all other examples, Y is hydrogen. The identity of Y is independent of the identity of Z (compare e.g., Examples 2 and 3 wherein Y is hydrogen and lower alkyl respectively, although Z has the same identity).
2. In Example 1, Z is thiazolamino; in Examples 2 and 3, Z is furfurylamino; in Example 4, Z is cyclopropylamino; and, in Example 5, Z is pyridylamino.
3. In Examples 6 through 25, Z is a radical of the formula ##STR10## wherein R 4 , R 5 , R 6 and R 7 are set out above.
4. R 4 , R 5 and R 6 may be the same or different and selected from among hydrogen and lower alkyl and may be selected independently of R 7 . In some exemplary compounds (e.g., those of Examples 2 and 6), R 4 , R 5 and R 6 are the same and are hydrogen, while in others (e.g., Example 10) R 4 is lower alkyl, and preferably methyl, while R 5 and R 6 are hydrogen. In still others (e.g., Example 11) R 5 and R 6 are the same and lower alkyl while R 4 is hydrogen.
The identity of the R 7 substituent is subject to wide variation, i.e., R 7 may be lower alkenyl (Examples 6, 7 and 8); halo-lower alkenyl (Example 9); lower alkynyl (Examples 10, 11, 12 and 13); lower alkoxycarbonyl (Example 14); halo-lower alkyl (Examples 15, 16 and 17); hydroxy-lower alkyl (Examples 18 and 19); pyridyl (Example 20); thienyl (Example 21); formamyl (Example 22); tetrahydrofuryl (Example 23); benzyl (Example 24); and benzene sulfonamide (Example 25).
6. Where R 7 is halo-lower alkyl or hydroxy lower alkyl, it is preferred that the halo or hydroxy group be attached to the terminal carbon atom of the alkyl group (i.e., the carbon atom distal to the atom attached to the ring). When R 7 is halo-lower alkenyl, it is preferred that the halo group be attached to a carbon atom other than the terminal carbon atom of the alkenyl radical. Finally, when R 7 is either alkenyl or alkynyl, it is preferred that the site of unsaturation in the carbon chain be at the terminal two carbon atoms of the radical.
Compounds according to the invention display antibacterial activity against gram-positive or gram-negative microorganisms in a manner similar to that observed for the naturally occurring mitomycins and are thus potentially useful as therapeutic agents in treating bacterial infections in humans and animals. Table I below provides data illustrative of such activity in the form of results of an antibacterial screening procedure involving mitomycin C and the compounds prepared according to Examples 4, 6, 12, 13 and 15. In the screening procedure, Bacillus subtilis was grown in a standard growth culture (pH6) and the test compound was placed on a 10 mm disk in the center of the culture plate. The measure of antibiotic activity was observation of the diameter of the zone surrounding the disk in which specified concentrations of test compound inhibited bacterial growth.
TABLE I______________________________________Zone of Inhibition (mm)vs. B Subtilis Concentration (mg/ml)Compound 12.5 3.1 0.8 0.2 0.005______________________________________Mitomycin C --(a) -- 28 20 11Example 4 -- 23 -- -- --Example 6 14.3 10.2 0(b) 0 0Example 12 -- 38 32 25 17Example 13 38 32 26 20 13Example 15 42 -- -- 33 25______________________________________ (a)indicates not tested. (b)indicates no inhibitory activity observed.
Usefulness of compounds of formula Ia in the antineoplastic therapeutic methods of the invention is demonstrated by the results of in vivo screening procedures wherein the compounds are administered in varying dosage amounts to mice in which a P338 leukemic condition is induced. The procedures were carried out according to "Lymphocytic Leukemia P338--Protocol 1.200", published in Cancer Chemotherapy Reports, Part 3, Vol. 3, No. 2, page 9 (September, 1972). Briefly put, the screening procedures involved administration of the test compound to CDF 1 female mice previously infected with 10 6 ascites cells implanted intraperitoneally. Test compounds were administered on the first day of testing only, and the animals were monitored for vitality, inter alia, over a 35 day period.
Results of screening of compounds of Examples 1 through 25 are set forth in Table II below. Data given includes optimal dose ("O.D."), i.e., that dosage in mg/kg of body weight of the animal at which the maximum therapeutic effects are consistently observed. Also included is the median survival time ("MST") expressed as the MST of the test animals compared to the MST of controls×100 ("% T/C"). Within the context of the in vivo P388 procedure noted above, a % T/C value of 125 or greater indicates significant antineoplastic therapeutic activity. The lowest dose in mg/kg of body weight at which the 125% T/C value is obtained is known as the minimum effective dose ("MED"). These doses also are listed in Table II. It is worthy of note that the exceptionally high MST values obtained in the P388 screenings reported in Table II are also indicative of the absence of substantial toxicity of the compounds at the dosages indicated.
TABLE II______________________________________EXAMPLE # O.D. MST as % T/C MED______________________________________1 1.6 167 0.22 12.8 276 0.43 12.8 256 1.64 12.8 167 6.45 3.2 211 0.26 6.4 150 3.27 6.4 189 3.28 25.6 245 1.69 25.6 178 3.210 6.4 210 0.811 25.6 178 1.612 12.8 358 0.213 25.6 300 1.614 12.8 300 0.415 51.2 205 6.416 12.8 190 1.617 12.8 140 12.818 12.8 272 1.619 25.6 244 3.220 12.8 167 3.221 12.8 167 3.222 3.2 217 0.423 12.8 289 0.424 25.6 194 1.625 25.6 150 6.4______________________________________
Clearly among the most preferred compounds employed as antineoplastic agents according to the invention are those exhibiting more than twice the relative life-extending capacity generally characterized as evidencing significant therapeutic potential, i.e., those having an MST % T/C value greater than 2×125. The class of such compounds is seen to include the compounds of Examples 2, 3, 12, 13, 14, 18 and 23.
As may be noted from Table II, initial single dosages of as little as 0.2 mg/kg showed substantial long term antineoplastic activity. Accordingly, the methods of the invention may involve therapeutic administration of unit dosages of as little as 0.001 mg or as much as 5 mg, preferably from 0.004 mg to 1.0 mg, of the compounds as the active ingredient in a suitable pharmaceutical preparation. Such preparations may be administered in a daily regimen calling for from 0.1 mg to 100 mg per kg, preferably from about 0.2 to about 51.2 mg per kg, of the body weight of the animal suffering from neoplastic disease. It is preferred that the compounds be administered parenterally. Pharmaceutical compositions suitable for use in practice of methods of the invention may comprise simple water solutions of one or more of the compounds of formula Ia, but may also include well known pharmaceutically acceptable diluents adjuvants and/or carriers such as saline suitable for medicinal use.
Further aspects and advantages of the present invention are expected to occur to those skilled in the art upon consideration of the foregoing description and consequently only such limitations as appear in the appended claims should be placed thereon. | Compounds of the formula, I, ##STR1## wherein: Y is hydrogen or lower alkyl; and X is a thiazolamino radical, a furfurylamino radical or a radical of the formula, ##STR2## in which R, R 1 , and R 2 are the same or different and selected from the group consisting of hydrogen and lower alkyl, and R 3 is selected from the group consisting of lower alkenyl, halo-lower alkenyl, lower alkynyl, lower akloxycarbonyl, thienyl, formamyl, tetrahydrofuryl and benzene sulfonamide.
Also disclosed are novel methods for treatment of neoplastic disease states in animals, which methods comprise administering a therapeutically effective amount of a compound of the formula, Ia, ##STR3## wherein: Y is hydrogen or lower alkyl; and Z is a thiazolamino radical, a furfurylamino radical, a cyclopropylamino radical, a pyridylamino radical, or a radical of the formula, ##STR4## in which R 4 , R 5 , and R 6 are the same or different and selected from the group consisting of hydrogen and lower alkyl, and R 7 is selected from the group consisting of lower alkenyl, halo-lower alkenyl, lower alkynyl, lower alkoxycarbonyl, halo-lower alkyl, hydroxy-lower alkyl, pyridyl, thienyl, formamyl, tetrahydrofuryl, benzyl, and benzene sulfonamide. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to an automatic releasing hinge that enables a pintle hub disengaging automatically from a connecting section when being turned outside the normal range to avoid damages.
[0003] 2. Description of the Prior Art
[0004] Hinges are commonly used apparatus for turning. For instance, personal digital assistance (PDAs), notebook computers, handsets, and face panels of many devices have hinges to perform turning, supporting and anchoring functions. However, conventional hinges are easily damaged when being forced to turn beyond their normal utilization ranges. The invention aims at providing an improved hinge that is capable of releasing automatically at the connecting section when the turning angle exceeds a selected value resulting from inadvertent operations so that the device where the hinge is installed may be prevented from damaging.
SUMMARY OF THE INVENTION
[0005] The primary object of the invention is to provide an automatic releasing hinge to resolve the disadvantages set forth above. The hinge according to the invention automatically disengages and releases at the connecting section when being turned beyond the normal range, thus the object being mounted may be prevented from damaging and the appearance may be maintained intact.
[0006] Another object of the invention is to provide an automatic releasing hinge that is simply structured with a smaller number of elements and easy to assemble so that users may assemble and repair by themselves.
[0007] The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is an exploded view of an embodiment of the invention.
[0009] [0009]FIG. 2A is a prospective view of an embodiment of a pintle hub of the invention.
[0010] [0010]FIG. 2B is a side view of the pintle hub of the invention.
[0011] [0011]FIG. 3A is a sectional view of an embodiment of a barrel of the invention.
[0012] [0012]FIG. 3B is a sectional view of an embodiment of a bushing of the invention.
[0013] [0013]FIG. 3C is a schematic view of the pintle hub in a turning condition.
[0014] [0014]FIG. 3D is a side view of the pintle hub in a turning condition.
[0015] [0015]FIG. 4 is a schematic view of the pintle hub in an anchor condition.
[0016] [0016]FIG. 5A is a schematic view of the pintle hub in a released condition.
[0017] [0017]FIG. 5B is a schematic side view of the pintle hub in a released condition.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Refer to FIG. 1 for an embodiment of the invention. The hinge of the invention includes an upper lid 10 and a lower lid 12 . The upper lid 10 has a first bushing 10 a and a second bushing 10 b . The lower lid 12 has a barrel 120 which may be coupled with the first bushing 10 a and the second bushing 10 b to enable the upper lid 10 and the lower lid 12 to form a turning relationship. The barrel 120 further houses an elastic element 14 and a pintle hub 16 therein to perform automatic releasing function. The picture shown in FIG. 1 is only an embodiment for reference. Other shapes and forms may be adopted and function equally well.
[0019] Referring to FIG. 2A, the pintle hub 16 includes a center spindle 205 , a first anchor ridge 201 and a second anchor ridge 203 . The center spindle 205 is hollow for coupling with an axle 35 of the bushing shown in FIG. 3B for turning purpose (which will be described later). The first anchor ridge 201 and the second anchor ridge 203 are jutting outside the periphery of the cylindrical pintle hub 16 to perform turning, latching and releasing functions. Referring to FIG. 2B, the first anchor ridge 201 has a corresponding first anchor side 201 a while the second anchor ridge 203 has a corresponding anchor side 203 a , and the center spindle 205 has a spindle side 205 a.
[0020] Refer to FIG. 3A for the barrel of the invention. The hub trough 38 is a latch trough firmly engaged with the pintle hub 16 to enable the lower lid 12 be driven and turned by the pintle hub 16 .
[0021] Referr to FIG. 3B for the bushing of the invention. The first bushing 10 a and the second bushing 10 b of the upper lid 10 connect to the lower lid 12 through the pintle hub 16 coupled in the barrel 120 , and is turnable relative to the barrel 120 . The first bushing 10 a connects to the upper lid 10 through a connecting section 30 , and the pintle hub 16 is coupled in the first bushing 10 a . The turning ridge 37 presses the first anchor ridge 201 and the second anchor ridge 203 of the pintle hub 16 to prevent it from releasing. When the pintle hub 16 is turned to the release trough 39 as shown in FIG. 3B, it is at a released position. Details will be discussed later by referring to FIGS. 3C and 3D.
[0022] Refer to FIG. 3C for the pintle hub at the turning position. It is a schematic view done by overlapping FIG. 3A and FIG. 3B. When the device is turned in the clockwise direction from the initial position, the first anchor ridge 201 and the second anchor ridge 203 of the pintle hub 16 are turned respectively in a first turning trough a and a second turning trough a′. In other words, the first turning trough a and the second turning trough a′ form a free turning space. The device has a connecting section 30 located on the lower lid 12 shown in FIG. 1. Thus the lower lid and the connecting section 30 can move the barrel 120 to turn freely in the free turning space.
[0023] Refer to FIG. 3D for the pintle hub at the turning position. When the pintle hub 16 is turned freely in the free turning space (as shown in FIG. 3A), the elastic element 14 located in the barrel 120 has one end forming a first position P 31 while the pintle hub 16 has one end located in the first bushing 10 a to become a first pintle hub position P 33 . The first anchor side 201 a and the second anchor side 203 a are wedged in a first bushing space 35 a and a second bushing space 35 b formed on the periphery of the axle 35 without escaping.
[0024] Referring to FIG. 4, when the device is turned with the connecting section 30 , the first anchor ridge 201 of the pintle hub 16 passes over a first hump e and is stopped by a third hump f and is wedged in a first anchor trough b, while the second anchor ridge 203 passes over a second hump e′ and is stopped by a fourth hump f′ and is wedged in a second anchor trough b′. As two ends of the pintle hub 16 are wedged in the anchor troughs, the device is at an anchor position.
[0025] Referring to FIG. 5A, when the device is turned continuously with the connecting section 30 , the first anchor ridge 201 of the pintle hub 16 passes over the hump f and is stopped by a fifth hump g and is wedged in a first release trough c, while the second anchor ridge 203 passes over the fourth hump f′ and is stopped by a sixth hump g′ and is wedged in a second release trough c′. The two ends of the pintle hub 16 are wedged in the release troughs, the device is at a release position (also referring to FIG. 5B).
[0026] Referring to FIGS. 5A and 5B, at the release position, the first anchor ridge 201 of the pintle hub is wedged in the first release trough c, and the second anchor ridge 203 is wedged in the second release trough c′. As the pintle hub 16 is wedged in the release troughs, one end of the elastic element 14 is located at a second position P 51 while the pintle hub 16 is located at a second pintle hub location P 53 in the first bushing 10 a . Meanwhile the third bushing space 35 c and the fourth bushing space 35 d at two ends of the axle 35 do not have gap with the first anchor side 201 a and the second anchor side 203 b of the pintle hub 16 , thus the pintle hub 16 can run through the space without being stopped, and may be released by means of the elastic element 14 . And the first bushing 10 a may be separated from the barrel 120 . As a result, the invention can achieve automatic release function without compromising the exterior design of the device.
[0027] While the preferred embodiment of the invention has been set forth for the purpose of disclosure, modifications of the disclosed embodiment of the invention as well as other embodiment thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention. | An automatic releasing hinge enables a device to be turned under an external force, and to be automatically released when the turning angle exceeding a selected limit so that the device may be prevented from damaging when being turned by force beyond the normal range. | 4 |
This application is a divisional application of U.S. application Ser. No. 10/203,323, filed Oct. 28, 2002, now U.S. Pat. No. 6,787,607 which is a national application based on International application number PCT/US01/04924, filed Feb. 15, 2001, which is based on a provisional U.S. application Ser. No. 60/182,852, filed Feb. 16, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to thermoplastic elastomer (TPE) materials. Thermoplastic elastomers are broadly defined as rubber-like materials that, unlike conventional vulcanized rubbers, can be processed and recycled like thermoplastic materials, yet have properties and performance similar to that of vulcanized rubber at service temperatures. The invention more specifically relates to thermoplastic vulcanizates (TPV), which are thermoplastic elastomers with a cross-linked rubbery phase produced by the process of dynamic vulcanization. The thermoplastic vulcanizates of the invention are foamed materials produced by physical or chemical blowing agents, wherein processing characteristics and foam properties are improved by the inclusion of a modifier derived from polytetrafluoroethylene. The invention also relates to foamed articles obtainable by the process of the invention.
2. Description of the Prior Art
There has been considerable activity on the development of thermoplastic vulcanizate compositions, especially those based on polyolefin thermoplastic resins, which have good foaming properties, and on processes for producing foams having improved properties. U.S. Pat. No. 5,070,111, incorporated herein by reference, discloses a process of foaming thermoplastic elastomer compositions using water as the sole foaming agent. U.S. Pat. Nos. 5,607,629 and 5,788,889, both incorporated herein by reference, describe methods for the production of foamed thermoplastic elastomer profiles by extrusion with a water blowing agent. U.S. Pat. No. 5,824,400 discloses foamed thermoplastic elastomer compositions which incorporate styrenic elastomers. Published European Patent Application No. 0 860 465 teaches a method of foaming thermoplastic elastomers using a water containing chemical compound which releases water at temperatures above the melting point of the thermoplastic elastomer. Published European Patent Application 0 872 516 discloses the use of polypropylene resins having specific rheological properties to enhance the foaming performance of olefinic thermoplastic elastomers.
However, the problems of providing thermoplastic elastomer foams which are soft, with good surface smoothness, low water absorption, improved compression set and compression load deflection, and having fine and uniform cell structure have not been overcome by prior art.
SUMMARY OF THE INVENTION
The present invention is based on the discovery that superior thermoplastic elastomer foams can be produced by incorporating into the thermoplastic elastomer, prior to foaming, an acrylic-modified polytetrafluoroethylene. Incorporation of this additive provides a very soft foam product having a number of desirable attributes, including improved processability, high melt strength, high cell density and uniformity, smooth surface, low water absorption, with improved compression set and compression load deflection.
In detail the present invention relates to a process for foaming a thermoplastic elastomer using a physical or chemical blowing agent, wherein an acrylic-modified polytetrafluoroethylene is incorporated into the thermoplastic elastomer composition prior to foaming. Sufficient acrylic-modified polytetrafluoroethylene is incorporated to be effective in achieving the desired attributes. The invention also encompasses thermoplastic elastomer compositions containing the acrylic-modified polytetrafluoroethylene, and foamed articles prepared therefrom.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Thermoplastic Elastomer
Thermoplastic Resin Component
Thermoplastic resins suitable for use in the compositions of the invention include thermoplastic, crystalline polyolefin homopolymers and copolymers. They are desirably prepared from monoolefin monomers having 2 to 7 carbon atoms, such as ethylene, propylene, 1-butene, isobutylene, 1-pentene, 1-hexene, 1-octene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, mixtures thereof and copolymers thereof with (meth)acrylates and/or vinyl acetates. Preferred, however, are monomers having 3 to 6 carbon atoms, with propylene being most preferred. As used in the specification and claims the term polypropylene includes homopolymers of propylene as well as reactor and/or random copolymers of propylene which can contain about 1 to about 30 weight percent of ethylene and/or an alpha-olefin comonomer of 4 to 16 carbon atoms, and mixtures thereof. The polypropylene can have different types of molecular structure such as isotactic or syndiotactic, and different degrees of crystallinity including materials with a high percentage of amorphous structure such as the “elastic” polypropylenes. Further polyolefins which can be used in the invention are high, low, linear-low and very low density polyethylenes, and copolymers of ethylene with (meth)acrylates and/or vinyl acetates.
The polyolefins mentioned above can be made using conventional Ziegler/Natta catalyst systems or by single site catalyst systems. Commercially available polyolefins may be used in the practice of the invention.
The amount of thermoplastic polyolefin resin found to provide useful thermoplastic elastomer compositions is generally from about 8 to about 90 weight percent. Preferably, the thermoplastic polyolefin content will range from about 9 to about 60 percent by weight.
Elastomer Component
Suitable rubbers include non-polar, rubbery copolymers of two or more alpha-monoolefins, preferably copolymerized with at least one polyene, usually a diene. Saturated monoolefin copolymer rubber, for example ethylene-propylene copolymer rubber (EPM) can be used. However, unsaturated monoolefin rubber such as EPDM rubber is more suitable. EPDM is a terpolymer of ethylene, propylene and a non-conjugated diene. Satisfactory non-conjugated dienes include 5-ethylidene-2-norbornene (ENB); 1,4-hexadiene; 5-methylene-2-norbornene (MNB); 1,6-octadiene; 5-methyl-1,4-hexadiene; 3,7-dimethyl-1,6-octadiene; 1,3-cyclopentadiene; 1,4-cyclohexadiene; dicyclopentadiene (DCPD); and vinyl norbornene (VNB).
Butyl rubbers are also useful in the thermoplastic elastomer compositions. As used in the specification and claims, the term butyl rubber includes copolymers of an isoolefin and a conjugated monoolefin, terpolymers of an isoolefin with or without a conjugated monoolefin, divinyl aromatic monomers and the halogenated derivatives of such copolymers and terpolymers. Another suitable copolymer within the scope of the olefin rubber of the present invention is a copolymer of a C 4-7 isomonoolefin and a para-alkylstyrene, and preferably a halogenated derivative thereof. The amount of halogen in the copolymer, predominantly in the para-alkylstyrene, is from about 0.1 to about 10 weight percent. A preferred example is the brominated copolymer of isobutylene and para-methylstyrene. Natural rubbers are also olefin rubbers suitable for use in the thermoplastic elastomer composition.
The amount of rubber in the thermoplastic elastomer generally ranges from about 92 to about 10 weight percent. Preferably the olefin rubber content will be in the range of from about 40 to about 91 weight percent.
Additives
The thermoplastic elastomer may optionally contain reinforcing and non-reinforcing fillers, plasticizers, antioxidants, stabilizers, rubber processing oils, extender oils, lubricants, antiblocking agents, antistatic agents, waxes, foaming agents, pigments, flame retardants and other processing aids known in the rubber compounding art. Such additives may comprise up to about 70 weight percent, more preferably up to about 65 weight percent, of the total composition. Fillers and extenders which can be utilized include conventional inorganics such as calcium carbonate, clays, silica, talc, titanium dioxide, carbon black and the like. The rubber processing oils generally are paraffinic, napthenic or aromatic oils derived from petroleum fractions. The oils are selected from those ordinarily used in conjunction with the specific rubber or rubber component present in the composition.
In one particularly preferred embodiment of the invention, the inclusion of an adsorptive inorganic additive has been found to improve the odor properties of the foamed products. The addition of an additive such as magnesium oxide in the range of about 0.1 to about 3 weight percent, preferably about 0.5 to about 2 weight percent, based on the total composition, is effective in eliminating odors.
Processing
The rubber component of the thermoplastic elastomer is generally present as small, i.e. micro size, particles within a continuous thermoplastic resin matrix, although a co-continuous morphology or a phase inversion is also possible depending upon the amount of rubber relative to thermoplastic resin and the degree of vulcanization, if any, of the rubber. Preferably, the rubber is at least partially vulcanized, and most preferably it is fully vulcanized (crosslinked).
The partial or full crosslinking can be achieved by adding an appropriate rubber curative to the blend of thermoplastic olefin polymer and olefin rubber, and vulcanizing the rubber to the desired degree under vulcanizing conditions. It is preferred that the rubber be crosslinked by the process of dynamic vulcanization. As used in the specification and claims, the term dynamic vulcanization means a vulcanization or crosslinking (curing) process wherein the rubber is vulcanized under conditions of shear at a temperature above the melting point of the polyolefin component.
Those of ordinary skill in the art will appreciate the appropriate quantities and types of vulcanizing agents, and the conditions required to achieve the desired vulcanization. Any known crosslinking system can be used, so long as it is suitable under the vulcanization conditions for the elastomer component and it is compatible with the thermoplastic olefin polymer component of the composition. Crosslinking (curing) agents include sulfur, sulfur donors, metal oxides, phenolic resin systems, maleimides, peroxide based systems, hydrosilylation systems, high energy radiation and the like, both with and without accelerators and co-agents.
The terms fully vulcanized or completely vulcanized as used herein mean that the olefin rubber component of the composition has been crosslinked to a state in which the elastomeric properties of the crosslinked rubber are similar to those of the rubber in its conventional vulcanized state, apart from the thermoplastic elastomer composition. The degree of crosslinking (or cure) of the rubber can also be expressed in terms of gel content, crosslink density or amount of uncrosslinked rubber which is extractable by a rubber solvent. All of these descriptions are well known in the art. A typical partially crosslinked composition will have less than about 50 to less than about 15 weight percent of the elastomer extractable by a rubber solvent, while a fully crosslinked composition will have less than about 5 weight percent, and preferably less than about 3 weight percent, of the elastomer extractable by a rubber solvent.
Usually about 5 to about 20 parts by weight of the crosslinking agent or system are used per 100 parts by weight of the rubber component to be vulcanized.
As used herein, the terms thermoplastic elastomer and thermoplastic vulcanizate refer to blends of polyolefinic thermoplastic resin and vulcanized [cured; cross-linked] rubber [elastomer]. Such materials have the characteristic of elasticity, i.e. they are capable of recovering from large deformations quickly and forcibly. One measure of this rubbery behavior is that the material will retract to less than 1.5 times its original length within one minute, after being stretched at room temperature to twice its original length and held for one minute before release (ASTM D1566). Another measure is found in ASTM D412, for the determination of tensile set. The materials are also characterized by high elastic recovery, which refers to the proportion of recovery after deformation and may be quantified as percent recovery after compression. A perfectly elastic material has a recovery of 100% while a perfectly plastic material has no elastic recovery. Yet another measure is found in ASTM D395, for the determination of compression set.
Modified Polytetrafluoroethylene
The composition of the invention includes an acrylic-modified polytetrafluoroethylene (PTFE) component. This component is generally described as a mixture of a polytetrafluoroethylene and alkyl (meth)acrylate having from 5 to 30 carbon atoms. One such blend which is particularly suited for use in the process of the invention is available as Metablen™ A-3000, available from Mitsubishi Rayon Co., Ltd.
The amount of the modified polytetrafluoroethylene component in the composition of the invention generally ranges from about 0.1 to about 4 weight percent, based on the total weight of the composition including the thermoplastic resin component, the rubber component, additives and the modified polytetrafluoroethylene component. The preferred amount of modified polytetrafluoroethylene ranges from about 0.5 to about 2 weight percent, with about 1 to about 2 weight percent being most preferred. Alternatively, the amount of acrylic-modified polytetrafluoroethylene can be expressed in terms of the total weight of thermoplastic resin and modified polytetrafluoroethylene. The preferred amount of modified polytetrafluoroethylene, expressed in this manner, ranges from about 8 to about 30 weight percent with a range of about 15 to about 30 weight percent being most preferred.
In the preparation of thermoplastic elastomers of the invention, the acrylic-modified polytetrafluoroethylene was generally incorporated directly into the thermoplastic elastomer during production of the thermoplastic elastomer so that it was an integral part of the composition. Alternatively, the acrylic-modified polytetrafluoroethylene can be mechanically blended with a preformed thermoplastic elastomer composition, or it can be introduced into the foaming process simultaneously with the thermoplastic elastomer.
EXAMPLES
The combined thermoplastic elastomer and acrylic-modified polytetrafluoroethylene was fed into an extruder or other mixing device capable of maintaining melt temperatures in the range of about 165° C. to about 220° C. If the blowing agent was a solid material, it was also blended with the thermoplastic elastomer prior to introduction into the mixing device. When the blowing agent was a gas or liquid, it was injected into the mixing device through an appropriate inlet. The blowing agent was thus thoroughly dispersed in the molten thermoplastic elastomer, and the mixture was maintained at a pressure sufficient to prevent premature foaming. The mixture was passed through a die or other appropriate outlet, where foaming occurred. The foamed product was cooled in air or in a water mist.
In the following examples thermoplastic elastomers were prepared from blends of polypropylene thermoplastic resin and EPDM rubber, with common additives and processing aids. Acrylic-modified polytetrafluoroethylene was incorporated into the blends and the rubber component was cross-linked by dynamic vulcanization using a phenolic resin cure system. For the fabrication of foamed articles by an extrusion process, the thermoplastic elastomer was introduced into a single screw extruder and thoroughly melted. The blowing agent, water in the examples set forth in Table 1, was then injected under pressure into the molten thermoplastic elastomer at rates of 1.1 to 1.4 weight percent. The melt was mixed and conveyed, under pressure, to the extruder exit and through a shaping die. The hot and fragile foam was transferred to a conveyor belt where it was cooled by air and water mist. The foamed article may then be cut or shaped for specific applications. Foamed profiles can be either extruded alone as described or coextruded with a dense carrier.
The following measurement methods were used in evaluating the examples of the invention:
Tensile strength at break; tensile set; tensile modulus; elongation at break—ASTM D412 (ISO 37, type 2)
Shore hardness—ASTM D2240
Specific gravity—ASTM D792
Surface (Ra)—Surface finish was evaluated as the arithmetic average of roughness irregularities measured from a mean line with the sampling length, using a Surface Analyzer System from Federal Products Corporation, Providence, R.I.
Compression set—The sample was compressed inside spaced sample holders to 40% of its initial height, and held at 100° C. for 22 hours. The sample was removed and allowed to recover for 30 minutes at room temperature. Compression set was then determined as: CS(%)=(H initial −H final )/(H initial −H 0 )×100, where H 0 is the gap of the sample holder (60% of H initial ).
Compression load deflection—The force necessary to compress a 100 mm sample to 40% of its original height, at room temperature.
Water absorption—Two test methods were used to measure water absorption. In the first method (A) a weighed foam profile 50 mm long was submerged in water at room temperature two inches below the surface of the water. The specimen was allowed to remain submerged for either 24 hours at atmospheric pressure, or for three minutes at 23 inches Hg vacuum (above the surface of the water). After the appropriate time, the specimen was removed, blotted dry, weighed and the percent change in mass was calculated. In the second method (B) a weighed foam profile 254 mm long was submerged in water at room temperature eight inches below the surface of the water, with a one inch section of the specimen located above the water at each end. The specimen was allowed to remain thus submerged for either 24 hours at atmospheric pressure, or for five minutes at 26 inches Hg vacuum (above the surface of the water). After the appropriate time, the specimen was removed, dried, weighed and the percent change in mass was calculated.
TABLE 1
Con.
Con.
Example
A
B
1
2
3
4
Components (parts by
weight)
Polypropylene
42
32
32
32
28
32
EPDM rubber
100
100
100
100
100
100
Process oil
150
150
150
150
150
150
Additives/Curative
63
63
63
63
63
63
Metablen ™ A3000
0
0
3
7
7
7
TPE Properties
Hardness (Shore A)
66
62
61
61
54
57
Ultimate tensile strength
6.9
5.3
5.2
4.7
4.2
4.4
(MPa)
Modulus - 100 (MPa)
2.71
1.94
2
1.7
1.5
1.63
Ultimate elongation (%)
520
368
330
317
389
382
Tensile set (%)
8
9
10
8.5
9
Viscosity (poise)
353
544
603
672
707
729
Foam Properties
Specific gravity (1.1 wt %
0.47
0.45
0.47
0.51
0.55
water)
Specific gravity (1.4 wt %
0.45
0.4
0.4
0.42
0.45
0.49
water)
Surface (microns)
9.1
8.1
7.8
6.3
8
7.4
H 2 O absorption (test A) -
38
6.1
2.4
4.8
4.8
2.8
Atmosphere (%)
H 2 O absorption (test A) -
50
16.4
14.4
2.8
4.5
3.4
Vacuum (%)
Compression set (%)
52
30
33
31
44
44
Compression load
0.77
0.6
0.51
0.56
0.31
0.5
deflection (kg)
As can be seen from the examples, the foamed thermoplastic elastomer of the invention provides a smooth surface, low water absorption, good compression set and improved compression load deflection. Visual inspection shows that foam cell density is high and the cells are uniform in structure with cell size distribution in a narrow range. Microscopy indicates that about 60% of the cells have a diameter of less than 100 microns.
Additional examples were prepared using different thermoplastic elastomer formulations, and foams were generated using various levels of water as the blowing agent. The foam properties were evaluated, and the results are set forth in Tables 2 and 3.
TABLE 2
Example
5
6
7
Components (weight %)
EPDM rubber
49.7
49.3
49
Polypropylene
9.1
9
9
Process oil
21.3
21.1
21
Clay
11.9
11.8
11.8
ZnO
0.6
0.6
0.6
SnCl 2
0.4
0.3
0.3
Curative
1.1
1.1
1.1
Carbon black
4
3.9
3.9
Modified PTFE
2
2
2
MgO
0
0.8
1.4
TPE Properties
Hardness (Shore A)
60
60
60
Ultimate tensile strength (MPa)
6.3
5.1
3.9
Modulus - 100 (MPa)
2
1.8
1.7
Ultimate elongation (%)
390
470
510
Viscosity (poise)
375
685
485
TABLE 3
Example
5
6
7
Blowing agent (wt %)
0.9
1.3
1.8
0.9
1.3
1.8
0.9
1.3
1.8
Density
0.59
0.47
0.42
0.55
0.43
0.34
0.6
0.46
0.37
Surface (microns)
6.6
8.1
11.6
5.7
5.2
5.6
5.1
5.4
6.5
H 2 O absorption (test
0.8
1.7
1.8
0.5
0.7
0.5
0.3
0.5
0.8
B) - Atmosphere (%)
H 2 O absorption (test
0.15
0.16
0.18
0.5
0.1
0.1
1
1.5
2.7
B) - Vacuum (%)
Compression set (%)
31
27
27
41
42
40
47
55
63
Compression load
2.1
1.9
1.8
1
0.8
0.6
1
0.6
0.6
deflection (%)
The materials used in the thermoplastic elastomers of Table 2 were EPDM rubber—Vistalon™ 3666 (ExxonMobil Chemical Co.); polypropylene—D008M™ (Aristech Chemical Corp.); process oil—Sunpar™ 150M; clay—Icecap K™ (Burgess); curative—SP-1045™ (Schenectady International); carbon black—Ampacet 49974 (Ampacet Corp.); modified PTFE—Metablen™ A3000 (Mitsubishi Rayon Co., Ltd.).
The foamed thermoplastic elastomer composition and the molded and shaped articles made therefrom are useful in a variety of applications such as handles and grips for tools or utensils, as well as weather strip for automotive and construction uses. | An olefinic thermoplastic elastomer composition which includes an acrylic-modified polytetrafluoroethylene. When foamed, such compositions produce a very soft foam with improved processing properties and physical characteristics. A process of foaming and foamed articles are also disclosed. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to data processing, and more specifically, the invention relates to a process and methodology to maintain consistency across disparate interfaced systems. Even more specifically, the preferred embodiment of the invention relates to a process for interfacing of a customer order to manufacturing and shipment systems as well as a shipping and packing information repository.
[0003] 2. Background Art
[0004] Customers who order items that are manufactured for the customers often deal with several different groups of people at the manufacturer, and each of these groups may have their own computer system or systems. For example, a particular customer who wants an item manufactured may deal with manufacturing and shipment systems of the manufacturer as well as a shipping and packing information repository of the manufacturer. A particular customer order may be sent to both of these systems, and both systems may use and process data items in the order.
[0005] The architecture of the landscape dictates the need for interfacing of a customer order to these two series of systems: the manufacturing and shipment system as well as the shipping and packing information repository. Currently, there are no known methods to support this environment in handling the consistency between disparate interfaces.
[0006] The downstream Manufacturing & Shipment systems are asynchronously interfaced to through an intermediary system using the standard SAP IDoc processing function and an existing legacy function. Following are the drawbacks to this function: the legacy application is not able to support a change to a new synchronous interfacing functionality; this legacy function is unavailable for change due to it's current use in other applications; the SAP IDoc function does not support synchronous communication; and the status of the order as well as any failures in the processing of the communication in the downstream system are not recognized in the sending application. This leads to the following situations: (1) Disparate information in the systems within the architecture which is unrecoverable; 2) Inefficient communication; (3) Customer dissatisfaction; and (4) Additional rework cost and effort to support reconciliation of the systems.
[0007] The procedure to determine the status of the order in the Manufacturing & Shipment systems is manual. This procedure requires contacting the Manufacturing & Shipment system relevant for a given material, which is subject to the availability of the Manufacturing & Shipment system personnel.
[0008] The downstream Shipping & Packing Information Repository system will be synchronously interfaced to through a middleware exchanging data in a more flexible format. The synchronous interfacing is through an intermediary system, which reformats the information in a structure that is legible to the Repository.
[0009] While this is the preferred method, there are drawbacks when used as a component in a distributed architecture of disparate interface functionality if processes are not implemented that support the distinctions of each environment. These drawbacks include: the inability to take advantage of the value add of the synchronous interchange; and the timely representation of current order information not effecting the outcome of the exchange with the asynchronous environment the same disparate information existing in the systems within the architecture. This leads to the same issues encountered with an asynchronous exchange. Specifically: (1) Disparate information in the systems within the architecture which is unrecoverable; (2) Inefficient communication; (3) Customer dissatisfaction; and (4) Additional rework cost and effort to support reconciliation of the systems.
SUMMARY OF THE INVENTION
[0010] An object of this invention is to provide an effective means of handling the communication in a distributed environment in which disparate interfacing functionality is utilized.
[0011] Another object of the invention is to support useful and timely information exchange, maintenance of data and order consistency, and controlled interaction between disparate systems to minimize system-processing overhead.
[0012] These and other objectives are attained with a process and methodology to maintain consistency across disparate interfaced systems. The preferred embodiment of the invention comprises: (i) a single parameter setting to enable the inclusion of the synchronously interfaced system into the environment; (ii) implementation of remote function call functionality to the synchronous system during critical points of the order create and change function to establish the status of the system availability and the status of the order at the exact time of the activity; (iii) posting of the information regarding the order status as both a displayed on-line message to the user as well as in distinct status fields for future review; (iv) provide the user the flexibility to continue or discontinue processing based on the status of the order; and (v) table driven function to drive the times at which exchange with the systems is required. The exchange would only be engaged based on changes affecting data elements relevant to that system.
[0013] The invention also preferably comprises: (vi) implementation of function to support limitation of changes allowed for an order that is considered unavailable for change based on status in the shipment process; (vii) implementation of function to support the suppression of output to all systems in the distributed environment when the system status indicates lack of availability; (viii) implementation of function to support the suppression of output to all systems in the distributed environment when the order status indicates the need to suspend output based on the condition of the order or the position of the order in the shipment processing function; and (ix) dynamic reaction to failed communication through the resetting of an order to the previous state to ensure data integrity across the landscape.
[0014] The preferred embodiment of the invention, described below in detail, provides a number of important advantages. For instance, this embodiment provides the ability to take advantage of the benefits of the use of synchronous system in a distributed environment without disrupting the asynchronous legacy function or causing legacy rework; and the ability to seamlessly insert additional business into the interface to the Shipping & Packing Information Repository. The invention also provides the required timely reflection of order status, as well as data consistency within the components of the distributed environment; and elimination of the manual procedure required to determine the current order status in the Manufacturing & Shipment systems. The preferred embodiment further provides management of consistent data between the components of the distributed environment; and minimal interchange between the systems with communication engaged only based on specific order updates; i.e., reduction in network traffic and system overhead.
[0015] Further benefits and advantages of this invention will become apparent from a consideration of the following detailed description, given with reference to the accompanying drawings, which specify and show preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates a process flow embodying the present invention.
[0017] FIG. 2 shows a distributed computing environment with which the present invention may be used.
[0018] FIG. 3 is a block diagram illustrating a data processing system that may be implemented as a client in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The preferred embodiment of the invention comprises: (i) a single parameter setting to enable the inclusion of the synchronously interfaced system into the environment; (ii) implementation of remote function call functionality to the synchronous system during critical points of the order create and change function to establish the status of the system availability and the status of the order at the exact time of the activity; (iii) posting of the information regarding the order status as both a displayed on-line message to the user as well as in distinct status fields for future review; (iv) provide the user the flexibility to continue or discontinue processing based on the status of the order; and (v) table driven function to drive the times at which exchange with the systems is required. The exchange would only be engaged based on changes affecting data elements relevant to that system.
[0020] Preferably, the invention further comprises (vi) implementation of function to support limitation of changes allowed for an order that is considered unavailable for change based on status in the shipment process; (vii) implementation of function to support the suppression of output to all systems in the distributed environment when the system status indicates lack of availability; (viii) implementation of function to support the suppression of output to all systems in the distributed environment when the order status indicates the need to suspend output based on the condition of the order or the position of the order in the shipment processing function; and (ix) implementation of function to support a dynamic reaction to failed communication through the resetting of an order to the previous state to ensure data integrity across the landscape.
[0021] FIG. 1 illustrates a process flow embodying the present invention. This Interface is comprised of a Fulfillment client 10 (SAP CBS—Cross Brand Solutions) in which orders are placed, a middleware 12 (WBI—Websphere Business Integrator) through which data is passed, and the Shipping & Packing Information Repository system 14 (DDAD—Direct Delivery Address Database) in which the data necessary to pack and ship product is housed. The Shipping & Packing Information Repository also houses the shipment processing status of the customer order and passes that data back to the Fulfillment client through the middleware.
[0022] The interfacing of data to the Shipping & Packing Information Repository 14 is contingent on the availability of the middleware and the Shipping & Packing Repository System as well as the ability to update the legacy Manufacturing Systems.
[0023] In accordance with the preferred embodiment of the invention, an agreed to number of data elements in the customer's order which are relevant for packing and shipment processing are passed from the Fulfillment client 10 (SAP CBS) to the middleware 12 (WBI). The middleware formats the data into a format that is legible to the Shipping & Packing Information Repository system. The data is passed to the Shipping & Packing Information Repository system for storage and extraction by the downstream manufacturing systems. If the middleware or Shipping & Packing Information Repository system is not available, and/or the legacy Scheduling & Manufacturing Interface System will be unable to be updated due to failures in the order processing, the customer's order is saved however, it is blocked from being routed to both the Shipping & Packing Repository and the Scheduling & Manufacturing system. A delivery block is placed at the header of the order, a workflow is initiated to alert the user, and a status field is updated to indicate the current status of the order.
[0024] Future updates to the order are passed to the Shipping & Packing Information Repository system 14 . Before attempting to update the Shipping & Packing Information Repository system, an RFC is made to establish the availability of the middleware and Shipping & Packing Repository system as well as the status of the customer order. If the middleware and/or the Shipping & Packing Repository are not available, the user attempting the change in the Fulfillment system is alerted via and on-line message. The fields that are relevant for storage in the Shipping & Packing Repository are made unavailable for editing, and the order is not passed to the Scheduling & Manufacturing system. If there is continued order processing issues that would prevent the order from routing to the Scheduling & Manufacturing system, the order is prevented from routing to the Shipping & Packing Repository system. If the customer's order is in the process of being shipping, the user on the Fulfillment client is notified via a message indicating the locked status of the order. The fields that are relevant for storage in the Shipping & Packing Repository are made unavailable for editing. The fields that are relevant to the Scheduling & Manufacturing System are also made unavailable for editing. If the middleware and Shipping & Packing Repository are available, the customer's order has not started the shipment process, and the order processing issues have been resolved, the order is made available for updating. If during the order update activity, the customer's order begins the process of shipment, the user is notified via an express document. The changes made to the order are not saved, and the order does not route to the Shipping & Packing Repository or to the Scheduling & Manufacturing system.
[0025] To support the processing, the following are required.
Fields and Tables
[0026] There are fields on the Fulfillment Order (Header and Line Item) that are updated based on the response to the call to the Shipping & Packing Repository. These fields include a Status Code field, a Result Code field, and a Result Code Message class.
[0027] The Status Code field indicates the relevancy of an SAP Order/order item and its status in the Shipping & Packing Repository. The possible values are NA, NU, U and L. NA indicates that the order/order item is not applicable to routing to the Shipping & Packing Repository, and NU indicates that the order/order item is applicable to routing to the Shipping & Packing Repository but not updated in that system. U indicates that the order/order item is applicable to and updated in the Shipping & Packing Repository, and L indicates that the order/order item is applicable to Shipping & Packing Repository but currently reflected as impending shipment.
[0028] The L is applied based on a response from Shipping & Packing Repository indicating that the order item is LOCKED. However, the L is also applied within the Fulfillment client when a delivery is created against the line item and the line item did not already reflect an L status. This is to ensure consistency in the information reflected at the line item level. The STATUS CODE field is editable ONLY WHEN THE STATUS is L. The value can only be changed to an E to indicate the unlock process (an exception process) has been engaged. However, once a delivery has been created against an order line item, the STATUS CODE field cannot be changed, even when the L is present. For SEO BUNDLES, which can contain multiple items relevant for the Shipping & Packing Repository, when one of those items is LOCKED, the entire SEO BUNDLE is locked. The change in the STATUS CODE field from L to E must be made to all items relevant to the Shipping & Packing Repository.
[0029] The RESULT CODE is issued from Shipping & Packing Repository for indicating the results of the RFC made to the system. The result codes indicate whether there are connectivity issues, database issues, or file feed format issues. The codes also indicate whether the order/order item is unavailable for change based on impending shipment.
[0030] The RESULT CODE Message class houses all the result codes and their description.
[0031] There are tables in the Fulfillment system used to regulate the Interface function. These Tables include a ZWVDDAD Table and a ZWV_DDADRFC Table. The ZWVDDAD Table is the Interface Table. This table is used both by code as well for informational purposes to indicate items NOT RELEVANT for the Shipping & Packing Repository, the fields which are considered triggers for an RFC to the Shipping & Packing Repository, and the fields relevant for locking (i.e., being made unavailable for editing) when the Order/Order item is impending shipment. The ZWV_DDADRFC table is used to house any rules for specialized extraction.
Interface Processing.
[0032] Interface Processing uses Function code, which is the code used internally in the processing to indicate to the middleware and the Shipping & Packing Repository the order activity. The function codes used support standard functions and specialized functions. The extraction is handled so as to minimize the amount of data flowing between the systems. Only those elements relevant for the Shipping & Packing Repository that are changed are passed. They are highlighted to the middlesware as changed via a field indicating updated. If there are data elements that are both Header and Line Item, the Header data only is passed if the information is the same at both the Header and Line Item level.
[0033] The extraction is handled to ensure the ‘logical groups’ of data elements are passed when an element within the group is changed. An example is the Ship-to Address information. The ‘logical group’ includes several lines used for the Company Name, the Street Address, the City/State/Province/Country/Zip Code/Postal Code. If any of these elements are changed, the whole group is passed.
Order Create and Order Change.
[0034] During the order create process, there is only one call made to the Shipping & Packing Repository. The call is made at Order Save. If the response from the Shipping & Packing Repository is the update was successful, the Status Code field will be updated with a U, and the Result Code field will be blank or updated with a 00. If the response from the Shipping & Packing Repository is the update was not successful, the Status Code field will be updated with an NU, the Result Code field will be updated with the result code value as passed back from the Shipping & Packing Repository, and—if no other delivery block exists—a Header Delivery Block will be applied to the order. The user status will remain in PEND. The order will not be routed to the Shipping & Packing Repository or to the Scheduling & Manufacturing system. Application of a Header Delivery Block will result in a WORKFLOW indicating that the order has not been sent to the Shipping & Packing Repository (as well as not sent to the Scheduling & Manufacturing system).
[0035] During the order change process, there are two calls made to the Shipping & Packing Repository. A call is made as the user enters the order, and another is made at Order Save. The first call made to the Shipping & Packing Repository can be a PING to ascertain availability of the middleware and the Shipping & Packing Repository, or a QUERY to determine the status of the Order Items in the Shipping & Packing Repository.
[0036] A PING is used when the order/order items did not update the Shipping & Packing Repository in the previous order create/change. A ping is used only when the previous order activity resulted in or retained a Status Code of NU (not updated in the Shipping & Packing Repository). If the ping is successful, no information will be displayed upon entering the order and the user is free to make adjustments as needed. If the ping is not successful, a message will be displayed regarding the lack of success and the user will be given the opportunity to decide whether to continue or not. When the initial call is a Ping, opting to continue will allow the user to make adjustments to all fields.
[0037] A QUERY is used when the order/order items updated the Shipping & Packing Repository in the previous order create/change. A Query is used when the previous order activity resulted in a Status Code of U (updated in the Shipping & Packing Repository). If the query is successful, no information will be displayed upon entering the order and the user is free to make adjustments as needed. If the query is not successful, a message will be displayed regarding the lack of success and the user will be given the opportunity to decide whether or not to continue. When the initial call is a Query, and the query response indicates lack of success, fields relevant for the Shipping & Packing Repository and fields relevant for the Scheduling & Manufacturing system will be rendered either not editable or changes made to the fields will not be posted. The affected fields are reflected in the table ZWVDDAD.
[0038] The second call to the Shipping & Packing Repository is at Order Save. If the response from the Shipping & Packing Repository is successful update, the Status Code field will be updated with (or retain) a U, and the Result Code field will be blank or updated with a 00. If the response from the Shipping & Packing Repository is the update was not successful, the Status Code field will either retain an NU or a U (depending on the status prior to the call), the Result Code field will be updated with the result code reflecting the problem. A list of result codes and their descriptions are housed in an independent message class. If the status is an NU, a Header Delivery Block will be applied to the order, if no other delivery block exists. The user status will remain in PEND. The order/order item will NOT be routed to the Shipping & Packing Repository or to the Scheduling & Manufacturing system. The STATUS CODE and RESULT CODE fields are able to be viewed on the order.
Specialized Processing
[0039] If the call made to the Shipping & Packing Repository indicates the order/order items are impending shipment, the Status Code field is updated to an L. If the response from the Shipping & Packing Repository is the items are impending shipment, agreement must be received from the manufacturing system(s) responsible for shipping the order/order items to allow for updated processing of the order. These systems also update the Shipping & Packing Repository with the shipment status of the order. The manufacturing system also can remove the order from an impending shipment status.
[0040] Once the order/order items is removed from an impending shipment status in the Shipping & Packing Repository, the Status Code on the order can be changed to an E, and order updates may be made. If the manufacturing system did not remove the order from an impending shipment status, the second call to the Shipping & Packing Repository will again return the impending shipment status. The Status Code will be adjusted to L (locked), and the changes made to the order will not be accepted. The order/order items will not route to the Shipping & Packing Repository or to the Scheduling & Manufacturing System.
[0041] The “Line Item Split” function is also supported within the Shipping & Packing Repository interface. The Line Item Split function provides the ability to separate specific order line items within an order. The function provides for the ability to retain the same basic order line item information across the newly separated line(s), but allow for changes to specific information in accordance with customer needs. During the Line Item Split process, there are two calls made to the Shipping & Packing Repository. A call is made as the user enters the function, and another is made Save. The first call may be either a Query or a Ping.
[0042] A QUERY is used when the order/order items updated the Shipping & Packing Repository in the previous order create/change. A Query is used when the previous order activity resulted in a Status Code of L (locked) or U (updated in the Shipping & Packing Repository). The results of the query will be automatically used to adjust the processing screen to allow for update of only those items, which are not impending shipment in the Shipping & Packing Repository system. The results of the query will automatically update the Line Item split processing screen to allow
[0043] A PING is used when the order/order items did not update the Shipping & Packing Repository in the previous order create/change. A ping is used only when the previous order activity resulted in or retained a Status Code of NU (not updated in the Shipping & Packing Repository). If the ping is successful, no information will be displayed upon entering the order and the user is free to make adjustments as needed. If the ping is not successful, a message will be displayed regarding the lack of success. A message will be displayed informing the user that an attempt to Line Item Split should be made later when the middleware and/or the Shipping & Packing Repository are available.
[0044] The preferred embodiment of the invention provides a number of important advantages. For example, this embodiment provides the ability to take advantage of the benefits of the use of a synchronous system in a distributed environment without disrupting the asynchronous legacy function or causing legacy rework; and the ability to seamlessly insert additional business into the interface to the Shipping & Packing Information Repository. The invention also provides the required timely reflection of order status, as well as data consistency within the components of the distributed environment; and elimination of the manual procedure required to determine the current order status in the Manufacturing & Shipment systems. The preferred embodiment further provides management of consistent data between the components of the distributed environment; and minimal interchange between the systems with communication engaged only based on specific order updates; i.e., reduction in network traffic and system overhead.
[0045] FIGS. 2 and 3 are exemplary diagrams of data processing environments in which embodiments of the invention may be implemented. It should be appreciated that FIGS. 2 and 3 are only exemplary and are not intended to assert or imply any limitation with regard to the environments in which embodiments may be implemented. Many modifications to the depicted environments may be made without departing from the spirit and scope of the present invention.
[0046] FIG. 2 depicts a pictorial representation of a network of data processing systems in which illustrative embodiments may be implemented. Network data processing system 100 is a network of computers in which embodiments may be implemented. Network data processing system 100 includes network 102 , which is the medium used to provide communications links between various devices and computers connected together within network data processing system 100 . Network 102 may include connections, such as wire, wireless communication links, or fiber optic cables.
[0047] In the depicted example, server 104 connects to network 102 along with storage unit 106 . In addition, clients 108 , 110 , and 112 connect to network 102 . These clients 108 , 110 , and 112 may be, for example, personal computers or network computers. In the depicted example, server 104 provides data, such as boot files, operating system images, and applications to clients 108 , 110 , and 112 . Clients 108 , 110 , and 112 are clients to server 104 in this example. Network data processing system 100 may include additional servers, clients, and other devices not shown.
[0048] In the depicted example, network data processing system 100 is the Internet with network 102 representing a worldwide collection of networks and gateways that use the Transmission Control Protocol/Internet Protocol (TCP/IP) suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers, comprised of thousands of commercial, governmental, educational and other computer systems that route data and messages. Of course, network data processing system 100 also may be implemented as a number of different types of networks, such as for example, an intranet, a local area network (LAN), or a wide area network (WAN). FIG. 2 is intended as an example, and not as an architectural limitation for different embodiments.
[0049] With reference now to FIG. 3 , a block diagram illustrates a data processing system that may be implemented as a client, such as client 108 in FIG. 2 , in accordance with the present invention. Data processing system 300 is an example of a client computer. Data processing system 300 employs a peripheral component interconnect (PCI) local bus architecture. Although the depicted example employs a PCI bus, other bus architectures, such as Micro Channel and ISA, may be used. Processor 302 and main memory 304 are connected to PCI local bus 306 through PCI bridge 308 . PCI bridge 308 also may include an integrated memory controller and cache memory for processor 302 . Additional connections to PCI local bus 306 may be made through direct component interconnection or through add-in boards.
[0050] In the depicted example, local area network (LAN) adapter 310 , SCSI host bus adapter 312 , and expansion bus interface 314 are connected to PCI local bus 306 by direct component connection. In contrast, audio adapter 316 , graphics adapter 318 , and audio/video adapter 319 are connected to PCI local bus 306 by add-in boards inserted into expansion slots. Expansion bus interface 314 provides a connection for a keyboard and mouse adapter 320 , modem 322 , and additional memory 324 . SCSI host bus adapter 312 provides a connection for hard disk drive 326 , tape drive 328 , and CD-ROM drive 330 . Typical PCI local bus implementations will support three or four PCI expansion slots or add-in connectors.
[0051] An operating system runs on processor 302 and is used to coordinate and provide control of various components within data processing system 300 in FIG. 3 . The operating system may be a commercially available operating system such as OS/2, which is available from International Business Machines Corporation. “OS/2” is a trademark of International Business Machines Corporation. An object oriented programming system such as Java may run in conjunction with the operating system and provides calls to the operating system from Java programs or applications executing on data processing system 300 . “Java” is a trademark of Sun Microsystems, Inc. Instructions for the operating system, the object-oriented operating system, and applications or programs are located on storage devices, such as hard disk drive 326 , and may be loaded into main memory 304 for execution by processor 302 .
[0052] Those of ordinary skill in the art will appreciate that the hardware in FIG. 3 may vary depending on the implementation. Other internal hardware or peripheral devices, such as flash ROM (or equivalent nonvolatile memory) or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIG. 3 . Also, the processes of the present invention may be applied to a multiprocessor data processing system.
[0053] For example, data processing system 300 , if optionally configured as a network computer, may not include SCSI host bus adapter 312 , hard disk drive 326 , tape drive 328 , and CD-ROM 330 , as noted by dotted line 332 in FIG. 3 , denoting optional inclusion. In that case, the computer, to be properly called a client computer, must include some type of network communication interface, such as LAN adapter 310 , modem 322 , or the like. As another example, data processing system 300 may be a stand-alone system configured to be bootable without relying on some type of network communication interface, whether or not data processing system 300 comprises some type of network communication interface. As a further example, data processing system 300 may be a Personal Digital Assistant (PDA) device, which is configured with ROM and/or flash ROM in order to provide non-volatile memory for storing operating system files and/or user-generated data.
[0054] The depicted example in FIG. 3 and above-described examples are not meant to imply architectural limitations.
[0055] The hardware in FIGS. 2 and 3 may vary depending on the implementation. Other internal hardware or peripheral devices, such as flash memory, equivalent non-volatile memory, or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIGS. 2 and 3 . Also, the processes of the illustrative embodiments may be applied to a multiprocessor data processing system.
[0056] In some illustrative examples, data processing system 300 may be a personal digital assistant (PDA), which is generally configured with flash memory to provide non-volatile memory for storing operating system files and/or user-generated data. A bus system may be comprised of one or more buses, such as a system bus, an I/O bus and a PCI bus. The bus system may be implemented using any type of communications fabric or architecture that provides for a transfer of data between different components or devices attached to the fabric or architecture. A communications unit may include one or more devices used to transmit and receive data, such as a modem or a network adapter.
[0057] The illustrative embodiments provide for a computer-implemented method, data processing system, and computer usable program code for providing a services model based provisioning in a multi-tenant environment. The computer-implemented methods of the illustrative embodiments may be performed in a data processing system, such as data processing system 100 shown in FIG. 2 or data processing system 300 shown in FIG. 3 .
[0058] As will be readily apparent to those skilled in the art, the present invention can be realized in hardware, software, or a combination of hardware and software. Any kind of computer/server system(s)—or other apparatus adapted for carrying out the methods described herein—is suited. A typical combination of hardware and software could be a general-purpose computer system with a computer program that, when loaded and executed, carries out the respective methods described herein. Alternatively, a specific use computer, containing specialized hardware for carrying out one or more of the functional tasks of the invention, could be utilized.
[0059] The present invention, or aspects of the invention, can also be embodied in a computer program product, which comprises all the respective features enabling the implementation of the methods described herein, and which—when loaded in a computer system—is able to carry out these methods. Computer program, software program, program, or software, in the present context mean any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following: (a) conversion to another language, code or notation; and/or (b) reproduction in a different material form.
[0060] While it is apparent that the invention herein disclosed is well calculated to fulfill the objects stated above, it will be appreciated that numerous modifications and embodiments may be devised by those skilled in the art, and it is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention. | A process and methodology are disclosed to maintain consistency across disparate systems. An interface is provided comprised of a fulfillment client in which to place orders, a middleware to pass data, manufacturing and shipment systems to process orders, and a shipping and packing information repository system to house data. The methodology implements, inter alia, remote function calls to the asynchronously/synchronously interfaced systems during defined points of order processing to establish the status of the systems availability and the status of the order at the exact time of a predetermined activity. Also, information regarding the order status is posted as both a displayed on-line message to a user and in distinct status fields for future review. Furthermore, this method dynamically reacts to failed communication through the resetting of orders to a previous state to ensure data integrity across the distributed computing environment. | 6 |
REFERENCE TO RELATED APPLICATION
This Application is a con of Ser. No. 09/274,755 filed Mar. 23, 1999 now U.S. Pat. No. 6,137,657 issued Oct. 24, 2000 which claim United States Provisional Application Ser. No. 60/079,300, filed Mar. 25, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to disk drive suspensions, and more particularly to improvements in limiter-featured disk drive suspensions comprising a load beam and attached thereto a flexure comprising a flexure frame and a flexure tongue adapted to carry a slider for increased load-unload efficiency. The invention provides an improved form of limiter structure to that blocks undue movement of the flexure tongue relative to the flexure frame by engaging the tongue free end with the frame in response to an undue excursion of the tongue. The tongue free end-flexure frame contact is localized to a single locus on the tongue free end. This locus is centrally located to avoid possible tipping of the tongue that can occur when outboard limiter structures at the edges of the tongue free end are employed owing to a possible difference in time of engagement. Non-simultaneous engaging contact of the limiters can tip the slider by first raising only one side of the tongue. This does not occur in this invention, since the limiter engagement locus is centrally located and unitary and thus incapable of not being uniform in time of engagement.
2. Related Art
Limiter structures are broadly known. They are generally designed to either prevent excessive excursions during shock events such as the jarring or dropping of the computer, or to prevent damage to the suspension during loading and unloading cycles. These two situations have different requirements. In load-unload, the slider is lifted from the disk against the forces holding it in position including spring loading by the suspension and the vacuum developed between the slider and the rotating disk. Load-unload cycles in present computers occur frequently, particularly in laptop computers, in an effort to conserve power and thus prolong battery life.
It has been suggested to limit flexure tongue travel with slot and tab arrangements with the tab interfitting the slot, the tab extending typically from the load beam and the slot in the tongue, or vice-versa, with fold-over tabs extending from the load beam and embracing the flexure so as to limit the flexure tongue travel, and with expandable ribbons linking the tongue free end with the opposing frame, or attached to the load beam, but these expedients are more complex to satisfactorily manufacture and may be too costly.
SUMMARY OF THE INVENTION
The repeating load-unload cycles of lifting and replacing the slider at the disk should not be a source of potential failure of the drive. Nonetheless, inadequate design in the lifter may cause failures. In U.S. Pat. No. 5,771,136, for example, a lifter is disclosed that has left and right sides intended to engage the flexure tongue at both its left and right edges with the opposing frame surfaces. Apparently intended primarily for shock situations, the disclosed lifter in an unloading situation must necessarily engage both left and right tongue edges simultaneously or risk tipping the tongue and thus the slider. Given the close proximity of the slider to the disk, tipping from non-simultaneous, and thus uneven engagement, is to be avoided. Manufacturing tolerances are unlikely to be capable of being held so tight, and manufacturing operations unlikely of being kept so free of mishandling that even a perfect design for simultaneous engagement is not proof against mishaps.
The present invention provides a single contact lifter that is incapable of separated-in-time contact by different parts of the lifter structure, that is thus highly suited to load-unload cycling, and which, in reducing failures, is more efficient as a lifter.
The invention, in particular, provides a disk drive suspension assembly of a flexure and a flexure support, the flexure having a tongue adapted to carry in gimbaling relation a slider in operating proximity to a disk, the flexure support and the flexure tongue defining cooperating structures inboard of the tongue edges, and preferably located within the middle third of the tongue free end width, which limit motion of the tongue relative to the disk to a predetermined range.
In preferred embodiments the cooperating structures comprise a relatively movable structure, such as a hook carried by the tongue and a relatively fixed structure such as the flexure frame surrounding the tongue. The specific form of the cooperating structures is not narrowly critical provided the motion of the tongue free end is restricted past a predetermined point and by a single structure of a single or double or divided wall located centrally of the flexure tongue free end.
More particularly, the invention provides a load-unload efficient disk drive suspension comprising a load beam having a base portion, a spring portion and a rigid portion, and a flexure secured to the load beam rigid portion, the flexure comprising a frame and a generally planar tongue cantilevered from the frame to have a free end spaced from the frame, a limiter structure limiting the relative movement of the flexure tongue and the flexure frame to a predetermined range, the limiter structure comprising a centrally located portion of the tongue free end bent to extend out of the plane of the tongue and shaped to extend beyond the tongue free end to intersect with the flexure frame to limit tongue movement relative to the frame to within the predetermined range.
In this and like embodiments, typically, the flexure tongue free end has an outermost tip, the tip being locally deflected to a plane generally normal to the tongue plane, the tongue free end centrally located portion lies within the central one-third of the lateral width of the tongue free end, or is centered on the tongue free end longitudinal axis of revolution.
In a further embodiment, typically, there is provided a load-unload efficient disk drive suspension comprising a load beam having a base portion, a spring portion and a rigid portion, and a flexure secured to the load beam rigid portion, the flexure comprising a frame and a generally planar tongue cantilevered from the frame to have a free end spaced from the frame, the flexure frame comprising first and second transverse portions and left and right side longitudinally disposed outriggers connected together to define a surrounded opening, the tongue extending into the surrounded opening in cantilevered relation, a limiter structure limiting the relative movement of the flexure tongue and the flexure frame to a predetermined range, the limiter structure comprising a centrally located portion of the tongue free end shaped to extend beyond the tongue free end to intersect with the flexure frame to limit tongue movement relative to the frame to within the predetermined range.
In a further embodiment the invention provides a load-unload efficient disk drive suspension comprising a load beam and a flexure having a tongue with a free end forming a limiter structure, including defining a cut along a transverse line inward of the tongue free end from a first edge of the tongue free end partway across the free end to the centrally located portion of the free end to free a flap of material from the tongue free end and leave an uncut remainder to the second edge of the tongue free end, defining the flap to have a head including the tongue free end first edge and a neck of reduced extent relative to the head such that the flap is hook-shaped and its head portion extends beyond the tongue free end remainder, and bending the flap into a substantially normal orientation relative to the tongue free end to have the head overlie the flexure frame transverse portion opposite the tongue free end in spaced relation corresponding to the predetermined range.
In this and like embodiments, typically, the first and second edges of the tongue free end are spaced laterally of the tongue free end central portion and free of limiter structure, the tongue free end centrally located portion lies within the central one-third of the width of the tongue free end, and the centrally located portion is centered on the tongue free end longitudinal axis of revolution.
In its method aspects, the invention includes the method of forming a limiter structure on a load-unload efficient disk drive suspension comprising a load beam and a flexure, the flexure comprising a frame and a tongue cantilevered from the frame and having a free end, the method including defining a cut along a transverse line inward of the tongue free end from a first edge of the tongue free end partway across the free end to the centrally located portion of the free end to free a flap of material from the tongue free end and leave an uncut remainder to the second edge of the tongue free end, the flap having a head including the tongue free end first edge and a neck of reduced extent relative to the head such that the flap is hook-shaped and its head portion extends beyond the tongue free end uncut remainder, and bending the flap into a substantially normal orientation relative to the tongue free end, whereby the head overlies a the frame transverse portion opposite the tongue free end in spaced relation corresponding to the predetermined range.
THE DRAWINGS
The invention will be further described in conjunction with the attached drawings in which:
FIG. 1 is an oblique view of a limiter structure-featured flexure according to the invention;
FIG. 2 is an oblique view of the invention flexure fixed to a load beam and carrying a slider;
FIG. 3 is a plan view of the invention flexure; and,
FIG. 4 is a view taken on line 4 — 4 in FIG. 3 .
DETAILED DESCRIPTION
The invention uses the flexure, the flexure tongue, the flexure outriggers and other structure in the vicinity of the flexure tongue to define cooperating structure which interacts with the tongue cooperating structure to limit range of the motion of the tongue to facilitate unloading, to avoid lift-off from the dimple in some cases, and to limit movement relative to, e.g. toward and/or away from the disk drive disk, so as to maintain a gimbaling capability over a predetermined range of movement, limited by a limiter that prevents or reduces movement beyond that range.
It will be noted that the central location of the limiter structure and the absence of limiter structure at the edges of the tongue free end enables the invention to uniformly limit the tongue in an unload situation and not possibly rock the tongue and its slider as can happen with dual contact limiters.
With reference now to the Figures, in FIGS. 1-4 the invention comprises a load-unload efficient disk drive suspension 10 comprising a load beam rigid portion 12 having edge rails 14 , and a flexure 16 carrying a slider 18 . The flexure 16 is secured to the load beam rigid portion 12 , and comprises a frame 22 having a proximate first transverse portion 24 , a distal second transverse portion 26 , left and right frame members 28 , 32 linked to the transverse portions to define the frame surrounding an open space 34 . Flexure 16 further comprises a generally planar tongue 36 cantilevered from the frame distal transverse portion 26 to project into the space 34 within the frame 22 . Tongue 36 , typically formed from the same resilient stainless steel material as the frame 22 , has a free end 38 spaced from the surrounding frame portions 24 , 26 and frame members 28 , 32 .
The tongue free end 38 terminates in a tip 42 defined by a final reduction in the tongue free end width and a configuring therefrom of the movable part 44 of the limiter structure 46 in a manner to intersect with the stationary part 48 of the limiter structure opposite the tongue free end 38 and defined by the proximate first transverse portion 24 of the frame 22 . Limiter structure 46 limits the relative movement of the flexure tongue free end 38 and the flexure frame 22 to a predetermined range equal to the gap G (FIG. 2) between the limiter structure movable part 44 and its (relatively) stationary part 48 . The limiter structure 46 is formed at a centrally located portion 52 of the tongue free end 38 , that is inboard of the tongue free end left- and right-hand edges 54 , 56 , and typically in the middle or central one-third of the lateral extent E (FIG. 2) of the tongue free end 38 . In FIG. 2 of the drawings the limiter structure 46 is shown centered on the tongue free end 38 longitudinal axis of revolution L., but it can be located to either side of this axis as long as the location is within the middle third of the tongue free end 38 width or lateral extent E.
Moving part 44 comprises the free end tip 42 cut into a flap 60 and locally deflected or bent to extend out of the predominant horizontal plane of the tongue 36 and generally normal thereto. The movable part 44 is shaped as shown to be hook-like-with a relatively greater dimensioned head 58 and a reduced dimension neck 62 such that the head extends beyond the tongue free end 38 to intersect with the flexure frame first transverse portion 24 at locus 50 (FIG. 1 ), thereby to limit tongue 36 movement relative to the frame 22 . The head 58 is shown as a single panel, but may comprise multiple panels for added breadth of contact, all to be within the central portion 52 (FIG. 1) of the tongue free end 38 .
With particular reference to FIGS. 3 and 4, the limiter structure movable part 44 is defined from the tongue free end tip 42 by making a cut 64 , by etching or otherwise, transversely of the tip and inward of the tongue free end 38 from, e.g., the left-hand edge 54 of the tongue free end 38 partway across the free end to the centrally located portion 52 of the free end to free the flap 60 of material from the tongue free end and leave an uncut remainder 66 to the second or right-hand edge 56 of the tongue free end. Flap 60 is further cut at 68 to define the head 58 , including the tongue free end right-hand edge 56 and the neck 62 of reduced transverse extent relative to the head such that the flap is hook-shaped and its head 58 extends beyond the tongue free end remainder 66 . The flap 60 is bent into a substantially normal orientation e.g. 90°±10-15° relative to the tongue free end 38 to have the head 58 overlie the flexure frame transverse portion 24 opposite the tongue free end in spaced relation across gap G corresponding to the predetermined range that will limit undue travel of the tongue free end 38 during load-unload operations.
In an unload situation, a lifter shifts the load beam and flexure from the disk. Frequently the disk is spinning still and the slider must be forcibly lifted. The invention limiter enables the flexure tongue to lift the slider from the disk against the existing contrary forces while preventing overbending of the tongue and damage to the suspension. The single, central contact of the limiter 46 on the flexure frame 22 blocks rocking of the tongue 36 and flexure 16 that might otherwise occur as in dual limiter constructions, with possible contact of the resultantly tipped slider with the spinning disk. The present invention flexure and limiter is thus more efficient than the prior art.
The foregoing objects are thus met. | A disk drive suspension assembly of a flexure and a flexure support, the flexure having a tongue adapted to carry in gimbaling relation a slider in operating proximity to a disk, the flexure support and the flexure tongue defining cooperating structures which limit motion of the tongue relative to the disk to a predetermined range. | 8 |
RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/293,190 filed Apr. 16, 1999 now U.S. Pat. No. 6,315,065.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to cutting elements for use in earth-boring drill bits and, more specifically, to a means for increasing the life of cutting elements that comprise one or more layers of ultrahard material, such as diamond, affixed to a substrate and having one or more softer, intermediate layer(s) therebetween. Still more particularly, the present invention relates to a polycrystalline diamond enhanced cutter insert including a substrate and a plurality of layers on the substrate, wherein the layers include an ultrahard layer supported on an additional layer, and wherein at least one of the layers is harder and/or more wear resistant than at least one of the layers above it.
BACKGROUND OF THE INVENTION
In a typical drilling operation, a drill bit is rotated while being advanced into a soil or rock formation. The formation is cut by cutting elements on the drill bit, and the cuttings are flushed from the borehole by the circulation of drilling fluid that is pumped down through the drill string and flows back toward the top of the borehole in the annulus between the drill string and the borehole wall. The drilling fluid is delivered to the drill bit through a passage in the drill stem and is ejected outwardly through nozzles in the cutting face of the drill bit. The ejected drilling fluid is directed outwardly through the nozzles at high speed to aid in cutting, flush the cuttings and cool the cutter elements.
The present invention is described in terms of cutter elements for roller cone drill bits. In a typical roller cone drill bit, the bit body supports three roller cones that are rotatably mounted on cantilevered shafts, as is well known in the art. Each roller cone in turn supports a plurality of cutter elements, which cut and/or crush the wall or floor of the borehole and thus advance the bit.
Conventional cutting inserts typically have a body consisting of a cylindrical grip portion from which extends a convex protrusion. In order to improve their operational life, these inserts are preferably coated with an ultrahard material such as polycrystalline diamond. The cutting layer typically comprises a superhard substance, such as a layer of polycrystalline diamond, thermally stable diamond or any other ultrahard material. The substrate, which supports the coated cutting layer, is normally formed of a hard material such as tungsten carbide (WC). The substrate typically has a body consisting of a cylindrical grip from which extends a convex protrusion. The grip is embedded in and affixed to the roller cone and the protrusion extends outwardly from the surface of the roller cone. The protrusion, for example, may be hemispherical, which is commonly referred to as a semi-round top (SRT), or may be conical, or chisel-shaped, or may form a ridge that is inclined relative to the plane of intersection between the grip and the protrusion. The latter embodiment, along with other non-axisymmetric shapes, is becoming more common, as the cutter elements are designed to provide optimal cutting for various formation types and drill bit designs.
The basic techniques for constructing polycrystalline diamond enhanced cutting elements are generally well known and will not be described in detail. They can be summarized as follows: a carbide substrate is formed having a desired surface configuration and then placed in a mold with a superhard material, such as diamond powder and/or its mixture with other materials which form transition layers, and subjected to high temperature and pressure, resulting in the formation of a diamond layer bonded to the substrate surface.
Although cutting elements having this configuration have significantly expanded the scope of formations for which drilling with diamond bits is economically viable, the interface between the substrate and the diamond layer and/or the transition layers continues to limit usage of these cutter elements, as it is prone to failure. Specifically, it is not uncommon for diamond coated inserts to fail during cutting. Failure typically takes one of three common forms, namely spalling/chipping, delamination and wear. External loads due to contact tend to cause failures such as fracture, spalling, and chipping of the diamond layer. Internal stresses, for example thermal residual stresses resulting from the manufacturing process, tend to cause delamination between the diamond layer and the substrate or the transition layer, either by cracks initiating along the interface and propagating outward, or by cracks initiating in the diamond layer surface and propagating catastrophically along the interface. Excessively high contact stresses and high temperatures, along with a very hostile downhole environment, also tend to cause severe wear to the diamond layer.
One explanation for failure resulting from internal stresses is that the interface between the diamond and the substrate or a transition layer is subject to high residual stresses resulting from the manufacturing processes of the cutting element. Specifically, because manufacturing occurs at elevated temperatures, the differing coefficients of thermal expansion of the diamond and substrate material transition layer result in thermally-induced stresses as the materials cool down from the manufacturing temperature. These residual stresses tend to be larger when the diamond/transition-layer/substrate interfaces have smaller radii of curvature. At the same time, as the radius of curvature of the interface increases, the application of cutting forces due to contact on the cutter element produces larger debonding and other detrimental stresses at the interface, which can result in delamination. In addition, finite element analysis (FEA) has demonstrated that during cutting, high stresses are localized in both the outer diamond layer and at the diamond/transition-layers/tungsten carbide interfaces. Finally, localized loading on the surface of the inserts causes rings or zones of tensile stress, which the PCD layer is not capable of handling.
In addition, the cutting elements are subjected to extremes of temperature and heavy loads when the drill bit is in use. It has been found that during drilling, shock waves may rebound from the internal interface between the two layers and interact destructively.
The primary approach used to address the delamination problem in convex cutter elements is the addition of transition layers made of materials with thermal and elastic properties located between the ultrahard material layer and the substrate, applied over the entire substrate protrusion surface. These transition layers have the effect of reducing the residual stresses at the interface and thus improving the resistance of the inserts to delamination. An example of this solution is described in detail in U.S. Pat. No, 4,694,918 to Hall, which is incorporated herein in its entirety.
Transition layers have significantly reduced the magnitude of detrimental residual stresses and correspondingly increased durability of inserts in application. Nevertheless, basic failure modes still remain. These failure modes involve complex combinations of three mechanisms. These mechanisms are wear of the PCD, surface initiated fatigue crack growth, and impact-initiated failure.
The wear mechanism occurs due to the relative sliding of the PCD relative to the earth formation, and its prominence as a failure mode is related to the abrasiveness of the formation, as well as other factors such as formation hardness or strength, magnitude of contact stress, and the amount of relative sliding involved during contact with the formation. The fatigue mechanism involves the progressive propagation of a surface crack, initiated on the PCD layer, into the material below the PCD layer until the crack length is sufficient for spalling or chipping. Lastly, the impact mechanism involves the sudden initiation and propagation of a surface crack or internal flaw initiated in the PCD layer or at the interface, into the material below the PCD layer until the crack length is sufficient for spalling, chipping, or catastrophic failure of the enhanced insert.
All of these phenomena are deleterious to the life of the cutting element during drilling operations. More specifically, the residual stresses, when augmented by the repetitive stresses attributable to the cyclical loading of the cutting element by contact with the formation, may cause spalling, fracture and even delamination of the diamond layer from the transition layer or the substrate. In addition to the foregoing, state of the art cutting elements often lack sufficient diamond volume to cut highly abrasive formations, as the thickness of the diamond layer tends to be limited by the resulting high residual stresses and the difficulty-of bonding a relatively thick diamond layer to a curved substrate surface even with the conventional layout of the transition layers. For example, even within the diamond layer, residual stresses arise as a result of temperature changes. Because these stresses typically increase as the thickness of the layer increases, this factor tends to be viewed as limiting on thickness.
Hence, it is desired to provide a cutting element that provides increased wear resistance and life expectancy without increasing the risk of spalling or delamination.
SUMMARY OF THE INVENTION
The present invention provides a cutting element with increased wear resistance and life expectancy and decreased risk of spalling and delamination. The present cutter element includes at least one transition layer that has mechanical properties that do not lie on a gradient between the mechanical properties of the outermost layer and those of the substrate. The outermost layer or the surface layer may not be the hardest layer in terms of mechanical properties. The present cutter element compensates for the resulting residual stresses that might otherwise occur at the non-intermediate layer by providing an interface geometry that balances the reduction in bending stress that results from an decreased radius of curvature with the increase in interface delamination stresses resulting from a decreased radius of curvature.
The non-intermediate layer of the present invention can be either a discrete layer or can comprise a gradient or portion of a gradient within a single layer, so long as direction of the gradient is reversed with respect to adjacent layers. In each instance, one objective of the present invention is to provide an interruption or reversal of the gradient in at least one of the following properties: the moduli of elasticity, wear resistances, hardnesses, strengths, and coefficients of thermal expansion of the layers so that at least one of the softer and less wear resistant layers is supported by a harder and/or more wear resistant layer.
One preferred embodiment of the present invention comprises a substrate supporting at least three layers, with the layers comprising an ultrahard layer, a relatively soft layer of a material that is less wear resistant than the ultrahard, and a first additional layer, wherein at least one of the layers interrupts a gradient in a mechanical property of the layers. The mechanical properties include the moduli of elasticity, wear resistances, hardnesses, strengths, and coefficients of thermal expansion of the layers.
Another preferred embodiment comprises a substrate having a layer of ultrahard material affixed thereto and a relatively soft layer affixed to the ultrahard layer such that the ultrahard layer is between said substrate and said relatively soft layer.
Still another embodiment comprises a substrate and a layer of PCD, with a cushion layer supporting the PCD layer. The cushion layer has a gradient of hardness such that a first portion of cushion layer next to the substrate is harder than a second portion of said cushion layer that is next to the PCD layer.
Still another embodiment of the invention comprises a method for constructing a cutter element, by providing a substrate having a grip portion and an extending portion and providing a plurality of layers on the extending portion such that at least one of the layers is harder than at least another one of the layers.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of a preferred embodiment of the invention, reference will now be made to the accompanying Figures wherein:
FIG. 1 is a cross sectional view of a cutting element constructed in accordance with a first embodiment of the invention;
FIG. 2 is a cross sectional view of a cutting element constructed in accordance with a second embodiment of the invention;
FIG. 2A is a cross sectional view of a cutting element constructed in accordance with an alternate embodiment of the invention; and
FIG. 3 is a cross-sectional view of a non-axisymmetric cutting element constructed in accordance with an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As used in this specification, the term polycrystalline diamond and its abbreviation “PCD” refer to the material produced by subjecting individual diamond crystals to sufficiently high pressure and high temperature that intercrystalline bonding occurs between adjacent diamond crystals. An exemplary minimum temperature is about 1300° C. and an exemplary minimum pressure is about 35 kilobars. The minimum sufficient temperature and pressure in a given embodiment may depend on other parameters such as the presence of a catalytic material, such as cobalt, with the diamond crystals. Generally such a catalyst/binder material is used to assure intercrystalline bonding at a selected time, temperature and pressure of processing. As used herein, PCD refers to the polycrystalline diamond including cobalt. Sometimes PCD is referred to in the art as “sintered diamond.”
Also as used herein, the terms “beneath” and “above” are used to refer to the relative positions of layers on the substrate. The terms refer to the relative positions as shown in the Figures, wherein the inserts are drawn with their grip portions downward, so that “beneath” refers to positions closer to the substrate and “above” refers to positions that are farther from the substrate.
Referring initially to FIG. 1, a cross sectional view of a cutting element 10 constructed in accordance with a first embodiment of the invention comprises a substrate 12 , and a cutting layer 14 . Substrate 12 comprises a body having a grip portion 16 and an extension portion 18 . Grip portion 16 is typically cylindrical, although not necessarily circular in cross-section, and defines a longitudinal insert axis 17 . Extension portion 18 includes an interface surface 19 , which has an apex 20 . According to one preferred embodiment, substrate 12 comprises tungsten carbide.
Cutting layer 14 is affixed to interface surface 19 and has an outer, cutting surface 15 , which has an apex 22 . Cutting layer 14 comprises at least two layers having differing physical properties. As discussed above, it is known to provide an outermost layer comprising polycrystalline diamond (PCD) and cobalt and one or more transition layers comprising diamond crystals, cobalt and tungsten carbide, so long as the proportion of diamond crystals in the material decreases inwardly towards the substrate and the transition layer(s) provides a gradient, or transition, between the mechanical properties of the substrate and the mechanical properties of the outermost layer. It will be understood that, while apices 20 and 22 are shown coincident with insert axis 17 , the present invention can practiced on inserts for which this is not the case.
It has been discovered, however, that significant advantage can be realized from the placement of a harder layer behind or beneath at least one of the softer and/or less brittle layers. Reference to this layer herein as the “non-intermediate layer” refers to the fact that this layer interrupts the gradient in either the modulus of elasticity, wear resistance, coefficient of thermal expansion, hardness, strength, or any combination of these properties, that would otherwise be formed by the other layers on the cutter element and the substrate body itself. It will be understood that this layer is nevertheless positioned between two other layers or between one layer and the substrate.
By way of example, FIG. 1 shows an outermost PCD layer 26 , beneath which is a transition layer 28 . In one embodiment, transition layer 28 comprises a mixture of diamond crystals, cobalt and precemented tungsten carbide particles. For example, transition layer 28 might comprise between about 20 and about 80 percent by volume diamond crystals, from about 20 to about 60 percent by volume tungsten carbide, and between 5 and 20 percent cobalt. Transition layer 28 may ranges in thickness from zero around its edges to about 100 microns or more at its thickest. One preferred technique for setting or capping the thickness of the transition layer is to define it relative to the insert diameter. For example, the thickness of thickest portion of the layer is preferably no more than 40%, and preferably less than 30%, of the insert diameter and still more preferably less 20% of the insert diameter. It will be understood that the thickness of transition layer 28 may vary across its area, and need not be axisymmetric.
Still referring to FIG. 1, in a preferred embodiment a third, non-intermediate layer 38 is included between transition layer 28 and substrate surface 19 . In accordance with the present invention, third layer 38 is harder and more wear resistant, and has a higher modulus of elasticity or higher hardness than layer 28 . For example, layer 38 can comprise the same PCD material as outermost layer 26 . Alternatively, layer 38 can comprise between about 20 and about 80 percent by volume diamond crystals, from about 20 to about 60 percent by volume tungsten carbide, and between 5 and 20 percent cobalt. In a preferred embodiment, the thickness of layer 38 equal to about 2-30% of the substrate diameter at its thickest point. It will be understood that the thickness of transition layer 38 may vary across its area, and need not be axisymmetric.
When layer 38 comprises PCD, the insert exhibits less residual stress on the interfaces between layers 28 and 38 and also between layers 26 and 28 when a larger radius of curvature is designed over interface surface 19 . The insert also exhibits less Hertz contact tensile stress. In addition, the second diamond layer serves as a back-up wear layer that can extend the life of the insert in the event of failure of the outermost layer. The softer layer 28 serves as a cushion to absorb impact energy and allows the total diamond thickness to be increased without the increase in residual stresses that occur when the thickness of a single diamond layer is increased.
In another alternative embodiment, layer 38 comprises a conventional transition layer and layer 28 comprises a material having a smaller modulus of elasticity and/or decreased wear resistance as compared to layer 38 , such as a transition layer with a higher tungsten carbide and cobalt content. In this embodiment again layer 38 interrupts the gradient in the mechanical properties that is defined by outermost layer 26 and layer 28 .
Referring now to FIG. 2A, in still another alternative embodiment, outermost layer 26 comprises the mixture of tungsten carbide and PCD or another material that is softer than PCD, for example a diamond composite, In this embodiment, it is preferred that layer 28 comprise PCD and layer 38 comprise a second transition layer 39 . In this embodiment, the outermost layer 26 can function to absorb impact energy, while the diamond layer 28 provides stiffness to reduce contact stress and also provides extended wear life after outermost layer is worn away.
An alternative construction to that shown in FIG. 1 is illustrated in FIG. 2, in which transition layers 28 and 38 are replaced by a single layer 48 . Layer 48 comprises a composite of diamond crystals, cobalt and tungsten carbide containing a lesser proportion of diamond crystals near the outer PCD layer 26 and a greater proportion of diamond crystals near the substrate surface 19 . This graded layer can be used in any of the various embodiments described above. While the currently preferred embodiment comprises two distinct layers 28 , 38 , any number of layers can be used, as long at least one layer or portion of a layer interrupts the gradient in mechanical properties between the substrate and at least one layer or portion of a layer above the layer in question.
The various embodiments of the present invention can be used in conjunction with various interface shapes and cutter element shapes. Hence, the cutter element shapes to which the principles of the present invention can be applied are not limited to the embodiments shown. For example, the basic shape of the cutter element need not be axisymmetric and can vary, including SRT, conical, chisel-shaped or relieved shapes, and have positive or negative tangents. An exemplary non-axixymmetric shape is shown in FIG. 3 In addition, the shape of the outer surface of the cutting layer can vary from those illustrated and the thickness of each layer can vary from point to point. In each instance, the present invention contemplates optimizing the shape of the interface between the cutting layer and the substrate so as to balance the residual stresses that result from manufacturing with the stress distribution from mechanical loading. This optimization allows substantial gains to be made in the localized enhancement of the cutting layer, thereby increasing cutter life.
While the cutter elements of the present invention have been described according to the preferred embodiments, it will be understood that departures can be made from some aspects of the foregoing description without departing from the spirit of the invention. For example, while the outer abrasive cutting surface of the cutting element of this invention is described in terms of a polycrystalline diamond layer, other materials, for example, cubic boron nitride, diamond composite, or a combination of superhard abrasive materials, may also be used for the cutting surface of the abrasive cutting element. Likewise, while the preferred substrate material comprises cemented or sintered carbide of one of the Group IVB, VB and VIB metals, which are generally pressed or sintered in the presence of a binder of cobalt, nickel, or iron or the alloys thereof, it will be understood that alternative suitable substrate materials can be used. | A cutter element for use in a drill bit, comprising a substrate and a plurality of layers thereon. The substrate comprises a grip portion and an extending portion. The layers are applied to the extending portion such that at least one of the layers is harder than at least one of the layers above it. The layers can include one or more layers of polycrystalline diamond and can include a layer in which the composition of the material changes with distance from the substrate. | 4 |
This application is a divisional of U.S. patent application Ser. No. 10/628,707 filed Jul. 28, 2003 now abandoned, entitled “Metathesis catalysts”, the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to polymeric transition metal catalysts, to processes for preparing them, to intermediates and also to the use of the transition metal catalysts as catalysts in organic reactions, in particular in olefin metathesis reactions.
2. Brief Description of the Prior Art
Olefin metathesis reactions, for example ring-closing metathesis (RCM), cross-metathesis (CM) and ring-opening metathesis polymerizations (ROMP), are important synthetic methods for forming C—C bonds.
For olefin metathesis reactions, a multiplicity of catalyst systems has been developed, which are described in summary, for example, in T. M. Trnka, R. H. Grubbs, Acc. Chem. Res. 2001, 34, 18-29.
With regard to activity, those catalyst systems which comprise alkoxybenzylidene complexes of transition metals in particular have proven useful. However, the removal and, if possible, the reuse of catalysts is becoming more important, since catalyst metal residues in the product may considerably impair its quality.
For example, Veldhuizen et al., J. Am. Chem. Soc. 2002, 124, 4954-4955 disclose phosphine-alkoxybenzylidene complexes of ruthenium which are suitable as reusable catalysts for the cross-metathesis of tricyclic norbornenes. However, this restriction to specific substrates is a hindrance to industrial use.
Gessler et al., Tetrahedron Lett. 41, 2000, 9973-9976 also describe stable ruthenium complexes which contain dihydroimidazol-2-ylidene and isopropoxybenzylidene ligands. However, the difficult recovery of the catalyst is not satisfactory for industrial applications.
WO 02/14376 A2 describes dendrimeric ruthenium complexes which have dihydroimidazol-2-ylidene and isopropoxybenzylidene ligands and can advantageously be removed from the reaction products in the catalytic reaction mixtures which result from olefin metathesis reactions. However, a disadvantage of these catalysts is the complicated synthesis of the dendritic framework.
There was therefore still a need for easily obtainable catalysts which have high activity even on reuse and can easily be removed from the catalytic reaction mixtures.
SUMMARY OF THE INVENTION
Surprisingly, polymeric compounds have now been found which contain at least
structural units of the formula (Ia),
where
M is a transition metal of the 8 th transition group of the Periodic Table,
X 1 and X 2 are the same or different and are each chlorine, bromine or iodine,
L is an N-heterocyclic carbene ligand of the formula (II)
where the direction of the arrow is intended to represent the bond to M and where
B is a 1,2-ethanediyl or 1,2-ethenediyl radical which is optionally mono- or disubstituted by C 1 -C 4 -alkyl, C 6 -C 15 -arylalkyl or C 5 -C 14 -aryl and
R 6 and R 7 are each independently C 1 -C 20 -alkyl or C 5 -C 24 -aryl,
R 1 is cyclic, straight-chain or branched C 1 -C 20 -alkyl or C 5 -C 24 -aryl and
R 2 , R 3 and R 4 are each independently hydrogen, C 1 -C 20 -alkyl, C 5 -C 24 -aryl, halogen, C 1 -C 4 -fluoroalkyl, C 1 -C 4 -alkoxy, C 5 -C 14 -aryloxy, (C 1 -C 8 -alkyl)OCO—, (C 1 -C 8 -alkyl)CO 2 —, (C 5 -C 14 -aryl)OCO— or (C 5 -C 14 -aryl)CO 2 — and/or
in each case two radicals in an ortho-arrangement to one another from the group of R 2 , R 3 and R 4 are part of a cyclic system which consists of a carbon framework having 5 to 22 carbon atoms, one or more carbon atoms of the cyclic system optionally being replaced by heteroatoms from the group of sulphur, oxygen or nitrogen, and the cyclic system also being optionally mono- or polysubstituted by radicals selected from the group of halogen, C 1 -C 4 -fluoroalkyl, (C 1 -C 4 -alkyl)OCO—, (C 1 -C 8 -alkyl)CO 2 —, (C 6 -C 10 -aryl)OCO— or (C 5 -C 14 -aryl)CO 2 — and
A is oxygen, sulphur, sulphoxyl, sulphonyl or CR 8 R 9 where R 8 and R 9 are each independently hydrogen or C 1 -C 4 -alkyl and
D is C 1 -C 8 -alkylene, [(C 1 -C 8 -alkylene)-O—] n where n=1 to 12, (C 1 -C 8 -alkylene)CO 2 —, (C 1 -C 8 -alkylene)-OCO—(C 1 -C 8 -alkylene), (C 1 -C 8 -alkylene)CO 2 —(C 1 -C 8 -alkylene), (C 1 -C 8 -alkylene)CONR 10 —, (C 1 -C 8 -alkylene)NR 10 CO—, (C 1 -C 8 -alkylene)CONR 10 —(C 1 -C 8 -alkylene) or (C 1 -C 8 -alkylene)NR 10 CO—(C 1 -C 8 -alkylene) where R 10 is hydrogen or C 1 -C 4 -alkyl
and structural units of the formula (Ib)
where A, D, R 1 , R 2 , R 3 and R 4 each independently have the same definitions and fulfil the same conditions as specified under the formula (Ia) and
optionally structural units of the formula (Ic)
where
A has the same definition and fulfils the same conditions as specified under formula (Ia) and
R 11 is C 1 -C 8 -alkyl, [(C 1 -C 8 -alkylene)-O—] n —(C 1 -C 8 -alkyl) where n=1 to 12, (C 1 -C 8 -alkylene)CO 2 —(C 1 -C 8 -alkyl), (C 1 -C 8 -alkylene)-OCO—(C 1 -C 8 -alkyl), (C 1 -C 8 -alkylene)-OCO—(C 5 -C 14 -aryl), (C 1 -C 8 -alkylene)CO 2 —(C 5 -C 14 -aryl), (C 1 -C 8 -alkylene)CONR 10 —(C 1 -C 8 -alkyl), (C 1 -C 8 -alkylene)NR 10 CO—(C 1 -C 8 -alkyl), (C 1 -C 8 -alkylene)CONR 10 —(C 5 -C 14 -aryl) or (C 1 -C 8 -alkylene)NR 10 CO—(C 5 -C 14 -aryl) where R 10 is hydrogen or C 1 -C 4 -alkyl.
DETAILED DESCRIPTION OF THE INVENTION
Within the scope of the invention, all radical definitions and illustrations listed in general or within areas of preference may be combined with each other, i.e. the particular areas and areas of preference may also be combined as desired.
Wavy lines in formulae are intended to emphasize that in each case both possible isomers are intended to be encompassed by the representation.
For the purposes of the invention, alkyl, alkylene and alkoxy each independently represent a straight-chain, cyclic, branched or unbranched alkyl, alkylene and alkoxy radical respectively, each of which may optionally be further substituted by C 1 -C 4 -alkoxy radicals. The same applies to the alkylene moiety of an arylalkyl radical.
In all contexts, C 1 -C 4 -alkyl is preferably, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl and tert-butyl, C 1 -C 8 -alkyl is additionally neopentyl, n-pentyl, cyclohexyl, n-hexyl, n-heptyl, n-octyl and isooctyl, and C 1 -C 20 -alkyl is further additionally, for example, n-decyl, n-dodecyl, n-hexadecyl and n-octadecyl.
In all contexts, C 1 -C 4 -alkylene is preferably, for example, methylene, 1,1-ethylene, 1,2-ethylene, 1,1-propylene, 1,2-propylene, 1,3-propylene, 1,1-butylene, 1,2-butylene, 2,3-butylene and 1,4-butylene, and C 1 -C 8 -alkylene is additionally 1,5-pentylene, 1,6-hexylene, 1,1-cyclohexylene, 1,4-cyclohexylene, 1,2-cyclohexylene and 1,8-octylene.
For the purposes of the invention, aryl is a carbocyclic radical or heteroaromatic radical in which no, one, two or three framework atoms per cycle, although at least one framework atom in the entire radical, is a heteroatom which is selected from the group of nitrogen, sulphur and oxygen. The carbocyclic aromatic radicals or heteroaromatic radicals may also be substituted by up to five identical or different substituents per cycle, selected, for example, from the group of hydroxyl, chlorine, fluorine, nitro and C 1 -C 12 -alkyl. For the purposes of the invention, aryl is preferably an above-defined carbocyclic radical.
The same applies to the aryl moiety of an arylalkyl radical. C 6 -C 15 -Arylalkyl is, for example, and with preference, benzyl.
For the purposes of the invention, fluoroalkyl is in each case independently a straight-chain, cyclic, branched or unbranched alkyl radical which may be singly, multiply or fully substituted by fluorine atoms.
For example and with preference, C 1 -C 4 -fluoroalkyl is in all contexts preferably trifluoro-methyl, 2,2,2-trifluoroethyl, pentafluoroethyl and nonafluorobutyl.
The polymeric compounds containing at least the structural units of the formula (Ia) and (Ib) and optionally (Ic) may also contain structural units which are derived from olefins which are suitable for ring-opening metathesis polymerization. These are sufficiently well known from the literature (e.g. from T. M. Trnka, R. H. Grubbs, Acc. Chem. Res. 2001, 34, 18-29 and the literature cited there).
Polymeric compounds containing structural units of the formulae (Ia) and (Ib) and optionally structural units of the formulae (Ic) are preferably those which have a degree of polymerization (numerical average) of 6 to 2000, particularly preferably 10 to 500.
It is pointed out that the scope of the invention also encompasses polymeric compounds in which the structural units of the formulae (Ia) and/or of the formulae (Ib) and/or optionally the structural units of the formulae (Ic) may in each case have different definitions for A and D or M, L, X 1 , X 2 or R 1 , R 2 , R 3 , R 4 or R 11 , although preference is given to those polymeric compounds in which M, L, X 1 and X 2 in the structural units of the formula (Ia), and likewise R 1 , R 2 , R 3 and R 4 in the structural units of the formula (Ia) and (Ib), and R 11 in any structural units of the formula (Ic) present and likewise A and D in the structural units of the formula (Ia) and (Ib) and any structural units of the formula (Ic) present are in each case identical.
Preference is further given to those polymeric compounds in which the proportion of the structural units of the formula (Ia) and of the formula (Ib) and any structural units of the formula (Ic) present (average proportion by weight) is 80% or more, preferably 90% or more and particularly preferably 98% or more.
The ratio of structural units of the formula (Ia) to structural units of the formula (Ib) in the polymer is preferably 1:2 to 1:500, particularly preferably 1:8 to 1:200.
When the polymeric compound also contains structural units of the formula (Ic), the ratio of structural units of the formula (Ia) to structural units of the formula (Ic) is in addition preferably 10:1 to 1:200, particularly preferably 1:1 to 1:100 and very particularly preferably 1:10 to 1:50.
D in the structural units (Ia) and (Ib) is preferably bonded via the ortho-position to the olefin or to the ylidene unit.
M in formula (Ia) is preferably ruthenium or osmium, particularly preferably ruthenium.
X 1 and X 2 are preferably identical and are each chlorine or bromine, particularly preferably chlorine.
L in formula (Ia) is an N-heterocyclic carbene ligand of the formula (II).
B in formula (II) is preferably 1,2-ethanediyl or 1,2-ethenediyl.
R 6 and R 7 in formula (II) are preferably and in each case independently, although preferably identically, a primary C 5 -C 20 -alkyl radical, with the proviso that the carbon atom bonded to the nitrogen atom bears a tertiary alkyl radical, or are each a secondary C 3 -C 20 -alkyl radical, a tertiary C 4 -C 20 -alkyl radical or a phenyl radical which is further mono- or polysubstituted, although at least in an ortho-position, by C 1 -C 4 -alkyl radicals.
R 6 and R 7 in the formula (III) are particularly preferably identical and are each isopropyl, sec-butyl, tert-butyl, 1-methylbutyl, 1-ethylpropyl, 1,1-dimethylpropyl, 1,2-di-methylpropyl, 1-methylpentyl, 1,1-dimethylbutyl, 1,2-dimethylbutyl, 1,3-dimethylbutyl, 1-ethylbutyl, 1,1,2-trimethylpropyl, 1,2,2-trimethylpropyl, 1-ethyl-1-methylpropyl, cyclopentyl, cyclohexyl, cycloheptyl, neopentyl, adamantyl, norbornyl, o-tolyl, 2,6-dimethylphenyl, 2-ethyl-6-methylphenyl, 2,6-diisopropylphenyl, o-anisyl, 2,6-dimethoxyphenyl, mesityl and isityl.
R 1 is preferably a radical which is selected from the group of ethyl, isopropyl, tert-butyl, neopentyl, cyclohexyl and cyclopentyl, and even greater preference is given to isopropyl. R 2 , R 3 and R 4 are preferably each independently hydrogen, C 1 -C 4 -alkyl, fluorine, chlorine or C 1 -C 4 -fluoroalkyl, and are particularly preferably identical and are each hydrogen. A is preferably oxygen or CH 2 , and even greater preference is given to oxygen. D is preferably [(C 1 -C 4 -alkylene)-O—] n where n=1 or 2, or (C 1 -C 4 -alkylene)CO 2 —, particularly preferably (C 1 -C 4 -alkylene)-O— and very particularly preferably CH 2 O. R 11 is preferably (C 1 -C 4 -alkylene)-O—] n —(C 1 -C 4 -alkyl) where n=1 or 2, (C 1 -C 4 -alkylene)CO 2 —(C 1 -C 4 -alkyl) or (C 1 -C 4 -alkylene)CO 2 —(C 5 -C 14 -aryl), particularly preferably CH 2 O 2 C—(C 1 -C 4 -alkyl) or CH 2 OCO—(C 5 -C 14 -aryl), and very particularly preferably CH 2 OCOphenyl or CH 2 OCO(o-methylaminophenyl), which may be used as a fluorescence marker.
Very particularly preferably, the polymeric compounds according to the invention contain structural units of the formula (Ia):
where R 6 and R 7 are identical and are each isopropyl, sec-butyl, tert-butyl, 1-methylbutyl, 1-ethylpropyl, 1,1-dimethylpropyl, 1,2-dimethylpropyl, 1-methylpentyl, 1,1-dimethylbutyl, 1,2-dimethylbutyl, 1,3-dimethylbutyl, 1-ethylbutyl, 1,1,2-trimethyl-propyl, 1,2,2-trimethylpropyl, 1-ethyl-1-methylpropyl, cyclopentyl-, cyclohexyl-, cycloheptyl-, neopentyl, adamantyl, norbornyl, o-tolyl, 2,6-dimethylphenyl, 2-ethyl-6-methylphenyl, 2,6-diisopropylphenyl, 2,6-dimethoxyphenyl and mesityl.
Very particularly preferably, the polymeric compounds according to the invention contain as structural units of the formula (Ib):
When the polymeric compounds according to the invention contain structural units of the formula (Ic), very particular preference is given to the following:
The polymeric compounds according to the invention containing structural units of the formulae (Ia) and (Ib) and optionally (Ic) are accessible by a process which is likewise encompassed by the invention.
This is a process for preparing polymeric catalysts, which is characterized in that compounds of the formula (IIIa) and/or (IIIb)
where
R 1 , L, X 1 and X 2 each have the definition and areas of preference specified under formula (Ia) and ortho-arylene is an ortho-phenylene or ortho-naphthylene radical, for example 1,2-naphthylene, and the radicals mentioned may also be substituted by one, two, three or four radicals per cycle which are selected from the group of C 1 -C 4 -alkyl, C 5 -C 14 -aryl and C 1 -C 4 -alkoxy and Ar is C 5 -C 14 -aryl and R 12 , R 13 and R 14 are each independently C 1 -C 8 -alkyl or C 5 -C 14 -aryl
are reacted
with at least one compound of the formula (IV)
where
R 1 , R 2 , R 3 , R 4 , A and D have the definition and areas of preference specified under formula (Ia).
and optionally with at least one compound of the formula (V)
where
R 11 and A each have the definition and areas of preference specified under formula (Ic)
and optionally with one or more further olefins which can be polymerized by ring-opening metathesis.
The compounds of the formula (IV) are hitherto unknown and therefore likewise encompassed by the invention.
In formula (IIIa), ortho-arylene is preferably ortho-phenylene.
In formula (IIIb), aryl is preferably phenyl.
Also, R 12 , R 13 and R 14 in formula (IIIb) are preferably identical and each C 1 -C 8 -alkyl or C 5 -C 14 -aryl, particularly preferably identical and each cyclohexyl.
A particularly preferred compound of the formula (IV) is (7-oxa-2-norborn-2-en-5-yl-methyl) (2-isopropoxy-3-ethenylphenyl) ether (IVa).
The compounds of the formula (IIIa) and (IIIb) are known from the literature or can be prepared in a similar manner to methods known from the literature (see in particular Veldhuizen et al., J. Am. Chem. Soc. 2002, 124, 4954-4955).
The compounds of the formulae (IV) and (V) may be prepared in a similar manner to the literature methods. As an example, the synthetic sequence for the compound of the formula (IVa) is given.
Preference is given to carrying out the process according to the invention in an organic solvent. Examples of useful organic solvents include amides, for example dimethylformamide, N-methylpyrrolidinone, halogenated aliphatic or optionally halogenated, aromatic solvents having up to 16 carbon atoms, e.g. toluene, o-, m-, p-xylene, chloroform, dichloromethane, chlorobenzene, the isomeric dichlorobenzenes, fluorobenzene, nitriles, e.g. acetonitrile and benzonitrile, sulphoxides such as dimethyl sulphoxide or mixtures thereof.
Preferred organic solvents are toluene and dichloromethane.
The reaction temperature may be, for example −30° C. to 100° C., preferably 10 to 40° C.
The reaction time may be, for example, 2 minutes to 24 hours, preferably 5 min to 1 h.
When using compounds of the formula (IIIb), it is advantageous also to use compounds which are capable of scavenging phosphines. These are preferably copper salts, in particular CuCl 2 and CuCl which are also preferably used in an equimolar amount or in a molar excess.
Depending on the choice of the molar ratios of the monomeric compounds (IIIa) and/or (IIIb), (IV) and any (V), a corresponding average molar composition is achieved in the polymeric compounds according to the invention. The areas of preference specified above for the ratios of the structural units of the formulae (Ia), (Ib) and any (Ic) consequently apply correspondingly to the preferred ranges of the ratios of monomeric compounds to be used.
The workup can be effected in such a way, for example, that any insoluble constituents present are filtered out and the filtrate is concentrated, the residue is subsequently washed with organic solvent and then optionally dried under reduced pressure.
In this way, the polymeric compounds according to the invention comprising the structural units of the formulae (Ia) and (Ib) and any (Ic) can be obtained in high yields. These polymeric compounds according to the invention are suitable, for example, as metathesis catalysts, in particular for ring-closing metatheses, ring-opening metatheses, cross-metatheses and ring-opening metathesis polymerizations.
The invention therefore also encompasses a process for preparing olefins by catalytic olefin metathesis, which is characterized in that the catalysts used are the polymeric compounds according to the invention containing the structural units of the formulae (Ia) and (Ib) and optionally (Ic).
An example of a possible procedure is to react the reactant olefin, optionally in an organic solvent, with the polymeric compounds according to the invention and in this way to obtain catalytic reaction mixtures which contain the product.
The reaction temperature may be, for example, −30 to 100° C.
In a preferred embodiment, the polymeric compounds according to the invention are removed from the catalytic reaction mixtures and reused for the preparation of olefins by catalytic olefin metathesis. The procedures of removal and reuse can be repeated once or more than once.
In a further preferred embodiment of the process according to the invention, the removal can be effected in such a way that sufficient aliphatic hydrocarbons, preferably having 5 to 12 carbon atoms, and/or diethyl ether are added to the catalytic reaction mixtures to at least partially precipitate out the polymeric compounds. Subsequently, the polymeric compounds according to the invention can be removed by filtration and/or decanting from the product solution.
Aliphatic hydrocarbons having 5 to 12 carbon atoms are, for example and with preference, n-pentane and n-hexane.
The polymeric compounds according to the invention are suitable in particular as catalysts, preferably as catalysts in metathesis reactions, for example cross-metatheses, ring-closing metatheses and ring-opening metathesis polymerizations, optionally with subsequent cross-metathesis.
They are notable for their high activities for a multiplicity of different substrates, for example ring-closing metatheses at low catalyst loading result in quantitative conversions even in a short time and at low temperatures.
The polymeric compounds according to the invention can also be removed easily and in high yields from the catalytic reaction mixtures and only have a small loss of activity on reuse.
EXAMPLES
Example 1
Preparation of methyl 7-oxanorborn-2-en-5-ylcarbonate
Furan and methyl acrylate were distilled before use.
A mixture of furan (22.6 ml, 311 mmol) and methyl acrylate (20.0 ml, 222 mmol) was cooled to −20° C. under nitrogen. AlCl 3 (8.880 g, 67 mmol) was added to this mixture in four portions, likewise under nitrogen. The reaction mixture was stirred for 30 min and subsequently allowed to heat to room temperature within 2 h. The crude reaction mixture was admixed with ethyl acetate (30 ml) and filtered. The filtrate was washed with saturated NH 4 Cl solution (50 ml) and dried over magnesium sulphate and concentrated under reduced pressure.
The crude product was purified by flash chromatography (using 50:50 cyclohexane:ethyl acetate as the eluent) to obtain the pure product 16.2 g (55% of theory) as a 55:45 mixture of the exo- and endo-isomers.
δ H (200 MHz, CDCl 3 , E1=exo-isomer, E2=endo-isomer): 6.40-6.46 (1H, m, H-5 E2), 6.32-6.40 (2H, m, H-5, 6 E1), 6.22 (1H, dd, J 2, 15 Hz, H-6 E2), 5.12-5.20 (2H, m, H-1, 4 E2), 4.98-5.08 (2H, m, H-1, 4 E1), 3.72 (3H, s, CH 3 E1), 3.62 (3H, s, CH 3 E2), 3.10 (1H, quint., J 6 Hz, H-3 E1), 2.42 (1H, dd, J 3, 8 Hz, H-3 E1), 2.04-2.22 (1H, m, H-2 E1), 1.48-1.70 (2H, m, H-3 E2), 1.20-1.30 (1H, t, 6 Hz, H-2 E2).
Example 2
Preparation of 7-oxanorborn-2-en-5-ylmethanol
A solution of methyl 7-oxanorborn-2-en-5-ylcarbonate (16.163 g, 105 mmol, see Example 1) in THF (75 ml) was added dropwise with stirring and under nitrogen to a suspension of lithium aluminium hydride (4.376 g, 115 mmol) in anhydrous THF (100 ml), in such a way that the solution boiled gently. The reaction mixture was subsequently stirred at room temperature for another 12 h and then quenched by cautiously adding an ice-water mixture. The organic phase was removed and the aqueous phase extracted with ethyl acetate (3×200 ml). The combined organic phases were washed with water (600 ml) and saturated sodium chloride solution (600 ml), dried over sodium sulphate and concentrated under reduced pressure.
The crude product was purified by flash chromatography (using a 50:50 mixture of cyclohexane and ethyl acetate). 3.7 g (32% of theory) of the pure product were obtained.
δ H (500 MHz, CDCl 3 , E1=exo-isomer, E2=endo-isomer): 6.38 (1H, dd, J 1.5, 5.9 Hz, H-5 E2), 6.32 (2H, br s, H-5, 6 E1), 6.28 (1H, dd, J 1.0, 5.9 Hz, H-6 E2), 5.01 (1H, d, J 3.7 Hz, H-1 E2), 4.93 (2H, m, H-1, 4 E1), 4.87 (1H, s, H-4 E2), 3.75 (1H, dd, J 5.1, 10.4 Hz, H CHOH E2), 3.52-3.59 (2H, m, C H 2 OH E1), 3.19 (1H, t, J 10.1 Hz, HC H OH E2), 2.44 (1H, m, H-2 E2), 1.97-2.00 (1H, m, H-3 E2), 1.76-1.81 (1H, m, H-2 E1), 1.34-1.39 (2H, m, H-3 E1), 0.70 (1H, dd, J 4.1, 11.3 Hz, H-3 E2).
Example 3
Preparation of 7-oxanorborn-2-en-5-yl-methyl bromide
Tetrabromomethane (1.161 g, 3.50 mmol) was added to a solution of 7-oxanorborn-2-en-5-ylmethanol (0.305 g, 2.50 mmol, from Example 2) in CH 2 Cl 2 (12.5 ml). The solution was cooled to 0° C. and admixed with triphenylphosphine (1.836 g, 7 mmol). The reaction mixture was allowed to warm to room temperature and stirred for 12 h. The solvent was removed under reduced pressure and the remaining solid was taken up in cyclohexane. The crude product was purified by flash chromatography (using a 98:2 mixture of cyclohexane and ethyl acetate). 0.3 g (59% of theory) of the pure product were obtained. The product was stored under cool conditions with the exclusion of light.
δ H (200 MHz, CDCl 3 , E1=exo-isomer, E2=endo-isomer): 6.46 (1H, dd, J 2, 6 Hz, H-5 E2), 6.35 (2H, br s, H-5, 6 E1), 6.36 (1H, dd, J 2, 8 Hz, H-6 E2), 4.96-5.08 (2H, m, H-1, 4 E2), 4.99 (1H, d, J 4 Hz, H-1 E1), 4.86 (1H, s, H-4 E1), 3.42-3.49 (2H, m, C H 2 Br E1), 3.36 (1H, dd, J 7, 10 Hz, H CHBr E2), 3.19 (1H, t, J 10 Hz, HC H Br E2), 2.58-2.68 (1H, m, H-2 E2), 2.06-2.12 (1H, m, H-3 E2), 2.00-2.06 (1H, m, H-2 E1), 1.37-1.43 (1H, m, H-3 E1), 1.36 (1H, dt, J 4, 12 Hz, H-3 E1), 0.80 (1H, dd, J 4, 12Hz, H-3 E2).
Example 4
Preparation of 2-hydroxy-3-acetoxybenzaldehyde
A solution of 2,3-dihydroxybenzaldehyde (4.000 g, 28.96 mmol) and acetic anhydride (3.260 g, 32.00 mmol) in acetic acid (40 ml) was heated to reflux under a nitrogen atmosphere for 72 h.
After cooling, the reaction mixture was poured into ice-water, and a white solid precipitated out.
After extraction with CH 2 Cl 2 (2×100 ml), the combined organic phases were rapidly washed with ice-cold water (2×100 ml) and saturated sodium chloride solution (100 ml). After drying over magnesium sulphate and concentrating to a volume of approx. 70 ml, hexane (50 ml) was added and the mixture was concentrated again under reduced pressure until the commencement of crystallization. The mixture was aerated and cooled to 0° C. After one hour at 0° C., the precipitated solid was filtered off with suction and dried under high vacuum.
3.95 g (76% of theory) of 2-hydroxy-3-acetoxybenzaldehyde were obtained as a colourless crystalline solid.
δ H (500 MHz, CDCl 3 ): 11.12 (1H, s, CHO), 9.92 (1H, s, OH), 7.49 (1H, dd, J 1.5, 7.7 Hz), 7.32 (1H, dd, J 0.7, 7.9 Hz), 7.03 (1H, dd, J 7.7, 7.9 Hz), 2.86 (3H, s, OCOMe).
Example 5
Preparation of 2-isopropoxy-3-hydroxybenzaldehyde
A 100 ml round-bottomed flask was charged with dried molecular sieve 4 A mol (approx. 1 g) and dried (130° C., 12 h) K 2 CO 3 (5.520 g, 40.00 mmol) and charged under a nitrogen atmosphere with a solution of 2-hydroxy-3-acetoxybenzaldehyde (3.600 g, 19.98 mmol, from Example 3) in dried DMF (50 ml). After stirring for 30 minutes, 2-bromopropane (13.00 ml, 138.88 mmol) was added via a cannula and the resulting yellow solution was heated to 50° C. for 12 h. After cooling to room temperature, water (100 ml) was added. The biphasic mixture was extracted with diethyl ether (3×200 ml). The combined organic phases were washed with water (5×100 ml), dried over magnesium sulphate and concentrated under reduced pressure.
1 H NMR analysis showed a 92:8 mixture of mono- and bis-alkylated products. To hydrolyse the 3-acetoxy group, the residue was taken up in methanol (20 ml) and admixed with a 30% solution of sodium methoxide in methanol until the resulting yellow solution gained no more colour intensity on further addition.
The methanolic solution was concentrated under reduced pressure to dryness and the remaining residue was taken up in water (40 ml). The yellow solution of the phenoxide was extracted with MTBE (2×20 ml), in order to remove the undesired bis-alkylated by-product. Subsequently, acetic acid was added to the aqueous phase until decolorization.
Subsequently, extraction was effected using MTBE (5×50 ml), and the combined organic phases were dried over magnesium sulphate and concentrated under reduced pressure.
The yellow residue was purified by column chromatography (eluent CH 2 Cl 2 ). 2.66 g (74% of theory) of the product were obtained as a colourless solid.
δ H (500 MHz, CDCl 3 ): 10.25 (1H, s, CHO), 7.37 (1H, dd, J 1.4, 7.7 Hz), 7.20 (1H, dd, J 1.4, 7.9 Hz), 7.11 (1H, dd, 7.7, 7.9 Hz), 5.96 (1H, s, OH), 4.33 (1H, septet, J 6.1 Hz C H (CH 3 ) 2 ), 1.38 (6H, d, J 6.1 Hz, CH(C H 3 ) 2 ).
Example 6
Preparation of 7-oxa-2-norborn-2-en-5-ylmethyl 2-isopropoxy-3-formylphenyl ether
7-Oxanorborn-2-en-5-ylmethyl bromide (1.0 g, 5.3 mmol from Example 3) and potassium carbonate (0.498 g, 3.6 mmol) were added to a solution of 2-isopropoxy-3-hydroxybenzaldehyde (0.317 g, 1.8 mmol from Example 5) in dry DMF (6 ml) and the reaction mixture was stirred at 50 to 60° C. for 12 h. After cooling to room temperature, water (10 ml) was added. The resulting biphasic mixture was extracted with MTBE (3×20 ml). The combined organic phases were washed with water (5×30 ml) and sodium hydrogencarbonate solution (30 ml), dried over magnesium sulphate and concentrated under reduced pressure. The crude product was purified by flash chromatography (eluent CH 2 Cl 2 ). 0.4 g (76% of theory) of the pure product was obtained.
δ H (500 MHz, CDCl 3 , E1=exo-isomer, E2=endo-isomer): 10.45 (1H, s, CHO), 7.42 (1H, dd, J 1.9, 7.5 Hz, ArH), 7.02-7.14 (2H, m, ArH), 6.45 (1H, dd, J 1.6, 5.9 Hz, H-6 E2), 6.38 (2H, ddd, J 1.5, 5.9, 13.1 Hz, H-5, 6 E1), 6.31 (1H, dd, J 1.3, 5.8 Hz, H-5 E2), 5.13 (2H, d, J 4.2 Hz, H-1 E2), 5.01 (2H, d, J 3.3 Hz, H-4 E2), 4.96-5.01 (2H, m, H-4, 1 E1), 4.62-4.68 (1H, m, C H (CH 3 ) 2 ), 4.00-4.04 (2H, m, C H 2 O E1), 3.93 (1H, dd, J 6.4, 9.1 Hz, H CHO E2), 3.54 (1H, t, J 9.1 Hz, HC H O E2), 2.76-2.81 (1H, m, H-2 E2), 2.10-2.15 (2H, m, H-3 E1 & E2), 1.51-1.54 (1H, m, H-3 E1), 1.56 (1H, dd, J 8, 12 Hz, H-2 E1), 1.36 (6H, d, J 6.1 Hz, CH(CH 3 ) 2 ), 0.86 (1H, dd, J 4.1, 11.4 Hz, H-3 E2).
Example 7
Preparation of 7-oxa-2-norborn-2-en-5-ylmethyl 2-isopropoxy-3-ethenylphenyl ether
Potassium tert-butoxide (0.218 g, 1.94 mmol) was added at 0° C. in one portion to a suspension of methyltriphenylphosphonium bromide (0.694 g, 1.94 mmol) in dry diethyl ether (5 ml) and the reaction mixture was stirred for 10 min. Subsequently, a solution of 7-oxa-2-norborn-2-en-5-ylmethyl 2-isopropoxy-3-formylphenyl ether (0.280 g, 0.97 mmol from Example 6) in diethyl ether (3.6 ml) was added and the mixture was stirred at 0° C. for a further 20 min. Afterwards, the mixture was quenched by adding saturated ammonium chloride solution. The aqueous phase was extracted using diethyl ether (3×10 ml) and, after washing with water (30 ml) and saturated sodium chloride solution (30 ml), the combined organic phases were dried over magnesium sulphate and concentrated under reduced pressure.
The crude product was purified by flash chromatography (eluent CH 2 Cl 2 ). 0.22 g (79% of theory) of the pure product was obtained.
δ H (500 MHz, CDCl 3 , E1=exo-isomer, E2=endo-isomer): 7.09-7.15 (2H, m, ArH), 6.95-6.97 (1H, m, ArH), 6.73 (1H, d, J 8.0 Hz, ArCH), 6.43 (1H, dd, J 1.3, 5.8 Hz, H-6 E2), 6.36 (2H, s, H-5, 6 E1), 6.27 (1H, dd, J 0.8, 5.8 Hz, H-5 E2), 5.71 (1H, d, J 17.8 Hz, H CH═CH), 5.26 (1H, dd, J 0.9, 11.1 Hz, HC H ═CH), 5.15 (1H, d, J 3.7 Hz, H-1 E2), 4.97-4.99 (3H, m, H-4 E2 & H-4, 1 E1), 4.45 (1H, septet, J 6.1 Hz, C H (CH 3 ) 2 ), 3.94-4.02 (2H, m, C H 2 O E1), 3.91 (1H, dd, J 6.1, 9.1 Hz, H CHO E2), 3.49 (1H, t, J 9.1 Hz, HC H O E2), 2.75-2.81 (1H, m, H-2 E2), 2.08-2.13 (2H, m, H-3 E1 & E2), 1.50 (1H, dd, J 8.1, 11.5 Hz, H-3 E1), 1.56 (1H, dt, J 11.5, 3.9 Hz, H-2 E1), 1.32 (6H, d, J 6.1 Hz, CH(C H 3 ) 2 ), 0.84 (1H, dd, J 4.1, 11.4 Hz, H-3 E2).
Example 8
Preparation of 7-oxa-2-norborn-2-en-5-yl-methyl benzoate
A solution of benzoyl chloride (0.93 ml, 8 mmol) in CH 2 Cl 2 (8 ml) was added dropwise at 0° C. to a mixture of 7-oxanorborn-2-en-5-ylmethanol (0.505 g, 4.0 mmol from Example 2), 4-dimethylaminopyridine (0.049 g, 0.4 mmol) and triethylamine (2.2 ml, 16 mmol) in CH 2 Cl 2 (8 ml). The reaction mixture was stirred at room temperature and the progress of the reaction was followed by thin-layer chromatography (eluent 80:20 ethyl acetate:cyclohexane). After 2.5 h, the reaction mixture was quenched by adding water (20 ml). The product was extracted using CH 2 Cl 2 (3×20 ml). The combined organic phases were washed with dilute hydrochloric acid, 10% NaHCO 3 -solution (60 ml), water (60 ml) and concentrated sodium chloride solution (60 ml), dried over magnesium sulphate and concentrated under reduced pressure.
The crude product was purified by flash chromatography (eluent 70:30 to 90:10 CH 2 Cl 2 :cyclohexane). 0.68 g (74% of theory) of the pure product was obtained.
δ H (500 MHz, CDCl 3 , E1=exo-isomer, E2=endo-isomer): 8.03-8.07 (2H, m, ArH), 7.55-7.57 (1H, m, ArH), 7.43-7.47 (2H, m, ArH), 6.41 (1H, dd, J 1.4, 5.8 Hz, H-5 E2), 6.33-6.36 (3H, m, H-5, 6 E1 & H-6 E2), 5.06 (2H, d, J 3.7 Hz, H-1 E2), 4.98-5.01 (2H, m, H-1, 4 E1), 4.92 (1H, s, H-4 E2), 4.48 (1H, dd, J 6.0, 10.8 Hz, H CHO E1), 4.27 (1H, dd, J 6.2, 11.1 Hz, H CHO E2), 3.87 (1H, t, J 10.8 Hz, H CHO E1), 3.87 (1H, t, J 11.1 Hz, HC H O E2) 2.66-2.71 (1H, m, H-2 E2), 2.03-2.14 (2H, m, H-3 E2 & H-2 E1), 1.48 (1H, dd, J 7.9, 11.5Hz, H-3 E1), 1.41 (1H, dt, J 4.0, 8.0Hz, H-3 E1), 0.87 (1H, dd, J 4.1, 11.3 Hz, H-3 E2).
Example 9
Preparation of a Polymeric Catalyst
A solution of dichlorobenzylidene-(N,N-bismesitylimidazolinylidene) tricyclohexylphosphine-ruthenium (II) (7.4 mg, 0.0087 mmol) in CH 2 Cl 2 (2 ml) was added via a cannula to a solution of 7-oxa-2-norborn-2-en-5-ylmethyl 2-isopropoxy-3-ethenylphenyl ether (25 mg, 0.087 mmol from Example 7) and 7-oxa-2-norborn-2-en-5-ylmethyl benzoate (60 mg, 0.261 mmol from Example 8) in CH 2 Cl 2 (3 ml) in a 5 ml round-bottomed flask under a nitrogen atmosphere and with vigorous stirring. After 10 min, the 1 H NMR analysis of the red reaction solution showed the complete conversion of the reactants, recognizable by the disappearance of the olefinic norbornene signals at 6.2-6.5 ppm. After adding CuCl (1 mg, 0.101 mmol), the resulting solution was heated to reflux for one hour, resulting in a pale green solution.
After cooling, the reaction solution was concentrated under reduced pressure to dryness and the residue was taken up in a 1:1 mixture of hexane and CH 2 Cl 2 . The insoluble copper salts were removed by filtration through a Pasteur pipette filled with cotton wool.
The clear, green solution was concentrated to dryness under reduced pressure and the solid residue was washed successively with hexane (10 ml) and diethyl ether (10 ml). After drying under high vacuum, the polymeric product (74.5 mg, 93% of theory) was obtained as a pale green, adhesive solid. The catalyst loading of the polymeric product can be determined by integration of the 1 H NMR signals at 16.67 and 7.99 ppm.
δ H (500 MHz, CDCl 3 ): 16.67 (1H, bs, Ru═C H , 7.99 (60H, bs, o-Ar ester), 7.50 (31H, bs), 7.38 (62H, bs), 7.04 (18H, bs), 6.91 (9H bs), 6.74 (9H, bs), 5.7-5.6 (90H, bs) 5.21 (10H, bs), 4.7-3.7 (180H, m), 2.78 (20H, bs), 2.37 (61H, bs), 2.01 (50H, bs) 1.23 (60H, bs);
N.B.: the overlapping and very broad signals cause some integrals of the high-field signals to become closer together, but nevertheless consistent for different polymer charges.
Examples 10-24
General Procedure for Carrying Out Metathesis Catalysis Using the Polymeric Catalyst from Example 9
The substrate (compounds 14 to 21) (0.12 mmol) CH 2 Cl 2 (1.6 ml) was added at room temperature to a solution of the polymeric catalyst from Example 9 (1.2×10 −3 mmol) in CH 2 Cl 2 (1 ml) under a nitrogen atmosphere. The resulting pale green solution was stirred until the substrate had been quantitatively converted according to the 1 H NMR spectrum or thin-layer chromatography. After the reaction, the catalyst can be removed as a green adhesive material from the catalytic reaction mixture by adding cold diethyl ether (7 ml). Alternatively, the addition of cold hexane or a diethyl ether-hexane mixture leads to the precipitation of the catalyst as a green solid. The products (compounds 22 to 29) could subsequently be obtained by filtering and removing the solvent.
The catalysis results are compiled in Tables 1 and 2.
TABLE 1
Activity of the polymeric catalyst from Example 9 in metathesis reactions.
Example
Substrate
Product/(reaction time)
Conversion (%)
10
>98
11
>98
12
>98
13
>98
14
>98
15
>98
16
>98
17
>98
TABLE 2
Recyclability of the polymeric catalyst from Example 9 in the
ring-closing metathesis of toluenesulphonyl-N,N-diallylamide
Example
Cycle
Time (min)
Conversion (%)
18
1
60
>98
19
2
60
>98
20
3
60
>98
21
4
60
>98
22
5
60
>98
23
6
120
>98
24
7
240
>98 | The invention relates to polymeric transition metal catalysts, to processes for preparing them, to intermediates and also to the use of the transition metal catalysts as catalysts in organic reactions, in particular in olefin metathesis reactions. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to catalytic asymmetric hydrogenation of olefins to synthesize chiral alpha-amino phosphonates and selected novel chiral alpha-amino phosphonates. The chiral alpha-amino phosphonates are either useful as biocides, antibiotics and/or useful in the preparation of phosphorus-containing analogs of peptides, i.e., phosphono peptides or pseudopeptides having known uses. For example, such phosphorus-type compounds have been shown to be effective as antibiotics, antibiotic enhancers, or enzyme inhibitors.
In the past desired stereoisomers have been difficult to obtain. Laborious and expensive processes such as those using fractional crystallization and recycle loops have been common in procedures involving a resolution step to obtain a desired stereoisomer. More recently some olefins have been subjected to asymmetric hydrogenation over rhodium and other metal coordination catalysts having optically active ligands.
Such asymmetric hydrogenation for the preparation of selected enantiomers is shown by the following references:
U.S. Pat. No. 4,939,288;
U.S. Pat. No. 4,277,420;
East German Application Nos. 280,527; 280,528; 280,529; 240,372 described in corresponding Derwent Abstract Numbers 90-362220/49, 90-362221/49, 90-362222/49, 87-057083/09, respectively;
Int. J. Peptide Protein Res. 41, 1988, 269-280;
U.S. Pat. No. 4,912,221;
EP Application No. 90307750.1;
U.S. Pat. No. 4,906,773;
U.S. Pat. No. 4,916,252;
U.S. Pat. No. 4,316,847;
EP Application No. 89403599.7;
Japanese Number 3002152A described in WPI Acc No. 91-048825;
German Appl. No. 140-036 described in Derwent Abstract No. 34661C/20.
Some (1-Aminoalkyl)phosphonic acids, the phosphonic acid analogs of amino acids, and particularly the selected enantioselective synthesis of optically pure aminophosphonic acids and phosphonopeptides have been prepared by resolution and by asymmetric synthesis using chiral auxiliaries. This is exemplified by the following references:
Schollkoph et al, Liebigs Ann. Chem., 1985, 555-559;
Aboujaoude et al, Phosphorus Sulfur, 1983, 18(1-2-3), pp. 133-6;
Bissane et al, Pept. 1990 Proc. Eur. Pept. Symp. 21st, Meeting Date 1990, pp. 438-9,
Glowak et al, Khim. Primen. Fosfororg. Soedin., Tr. Yubileinoi Kong., 6th Meeting Date 1977, 1981, pp.2251-3;
Ornstein, J. Org. Chem., 1989, 54(9), pp. 2251-2;
Sauveur et al, Phosphorus Sulfur. 1983, 14(3), pp.341-6;
Growiak and Sawka-Dobrowolska, Tetrahedron Letters, 1977, No. 45, pp. 3965-8; and
Parsons et al, J. Med. Chem. 1988, No. 31, pp. 1772-8.
Schollkoph et al report that "attempts to hydrogenate 3a" (which is N-[1-(dimethoxyphosphoryl)ethenyl]formamide) at room temperature, normal pressure) in the presence of (R,R)-DIPAMP failed." Schollkoph et al disclose the reduction of certain dehydro alpha-amino phosphonates by catalytic asymmetric hydrogenation in the presence of rhodium (+) DIOP catalyst. Thus, surprisingly, both the chemical yield and the asymmetric induction providing enantiomeric enhancements (ee) of the present invention process provide essentially pure compounds of a particular stereoisomeric form including selected chiral compounds now essentially pure not previously known. Further, Genet et al, Tetrahedron letters. 1986, Vol. 27, No. 38, pp 4573-76, provide comparisons of DIOP and DIPAMP in a different asymmetric allylation consistent with Schollkoph.
Reported diastereomeric mixtures of 1-aminoalkylphosphono type compounds are found in numerous references of which the following are examples:
Baylis et al, J. Chem. Soc. Perkin Trans I 1984, 1984,2845-53;
Yuan and Qi, Synthesis, 1988, June, 472-4 disclose 1-amino-substituted benzyl phosphonic acids where the benzyl includes various substituents.
U.S. Pat. No. 4,016,148 discloses peptide derivatives having a moiety characterized by the replacement of the carboxyl group of a naturally occurring L alpha-amino acid by a phosphorus group including a --P(O)(OH) 2 group.
Recent reviews disclosing the preparation of selected diastereomeric and chiral alpha-amino phosphonates are found in the following references respectively:
Kukhar and Solodenko, Russ. Chem. Rev. 1987, pp. 1504-32; and
Dhawan and Redmore, Phosphorus and Sulfur, 1987, 32, pp. 119-44.
The following additional references disclose various specific chiral alpha-amino phosphonates:
Sawamura et al, Tetrahedron Letters. 1989, Vol. 30, No. 17, pp 2247-50;
Sting and Steglich, Synthesis, 1990, February, pp. 132-4;
Solodenko et al, Tetrahedron. 1991, Vol 47, No. 24, pp. 3989-98;
Kafarski and Lejczak, Can. J. Chem. 1983, 61, pp. 2425-30;
Atherton et al, Antimicrobial Agents and Chemotherapy, 1979, May, pp. 677-83;
Atherton et al, J. Med. Chem., 1986, 29 pp. 29-40;
Scholkoph and Schutze, Liebigs Ann. Chem., 1987, pp. 45-9;
Bartlett and Lamden, Bioorganic chemistry, 1986, 14, pp. 45-9;
Huber and Vasella, Helvetica Chimica Acta, 1987, 70, pp. 1461-76.
The interesting biological properties of α-aminophosphonates make them attractive analogues of α-amino acids, [(a) Redmore, D. Top. Phosphorus Chem., 1976, 8, 515; (b) Petrov, K. A.; Chauzov, V. A.; Erokhina, T. S. Russ. Chem. Rev. 1974, 43, 984; (c) Kafarski, P.; Mastarlerz, P. Aminophosphonates: Natural Occurance, Biochemistry and Biological Properties, Bertrage zur Wirkstofforschung, Ak. Ind. Kompl. DDR. 1984, 21.] While they resemble their carbon counterparts, the tetrahedral phosphorus also allows them to function as transition state analogues. These pharmaceutically-interesting compounds [Certain phosphorus analogues of α-amino phosphonates are being investigated by the pharmaceutical industry as antibiotics, see; (a) Atherton, F. R.; Hall, M. J.; Hassall, C. H.; Lambert, R. W.; Llod, W. J.; Ringrose, P. S. Antimicrob. Agents Chemother., 1979, 15, 696; (b) Chakravarty, P. K.; Greenlee, W. J.; Parsons, W. H.; Patchett, A. A.; Combs, P.; Roth, A.; Busch, R. D.; Mellin, T. N. J. Med. Chem., 1989, 32, 1886 and references therein.] have been synthesized by various racemic routes, but the need to develop a practical asymmetric method still exists. The 35 present invention now successfully fulfills this need.
α-Amino phosphonates have recently been reported to serve as starting materials for the preparation of potent inhibitors of HIV-1 protease. (Dreyer, G. B. New diamino phosphinic acid derivatives are aspartic protease inhibitors used to treat viral infections especially HIV type 1. Patent Application W09200954-A1, Jan. 23, 1992, assigned to SmithKline Beecham Corp.) This application is incorporated herein by reference to provide the basis for utility for the present invention process and its intermediates. Since the α-amino phosphonate employed by Dreyer et al was racemic (Dreyer, G. B.; Choi, J. K.; Meek, T. D.; Tomaszek, T. A.; Jr. 203rd American Chemical Society Meeting, San Francisco, Calif. Apr. 5-10, 1992, Medicinal Chemistry #179), the inhibitor was made as a mixture of isomers necessitating a tedious chromatographic separation in order to isolate the most active constituent. The most active isomer was derived from the phosphorus analogue of phenylalanine with the L(R) absolute configuration. Not only would the methodology described herein be adaptable to the preparation of the most active isomer of the SKB HIV-protease inhibitor, but to a wide variety of analogues as well, Intermediates of U.S. Pat. No. 4,946,833 and each of European Application Nos. 89401595.7 and 90402226.6 are related to the novel compound I of the present invention. German Application 4029444A abstracted in Derwent Abstract No. 91-095191/14 discloses compounds for regulating plant growth related to the novel compounds of Formula II of the present invention. Further, EP 207,890A disclosed in Derwent Abstract No. 87-001565/01 includes 1-amino-2-phenylethylophosphorus acid derivatives as microbiocidal and biocidal agents.
The flexibility of the present synthesis permits the synthesis of very unique analogues of α-amino phosphonates that are related to known compounds having biological properties relative to molecules available by more demanding syntheses. The literature is replete with examples of novel amino acid side chains designed to impart improved biological properties to analogous molecules.
BRIEF SUMMARY OF THE INVENTION
The present invention is a novel compound of the formula (I') ##STR1## wherein R 1 ' is (1) cyclopentyl, cyclopentylmethyl, cyclohexyl, or cyclohexylmethyl;
(2) alkyl of from one to six carbons substituted by one or two hydroxyl, chloro, or fluoro;
(3) phenyl substituted by one to three substituent(s) consisting of
(a) halogen consisting of fluoro, chloro, bromo, iodo,
(b) alkoxy of from one to three carbons,
(c) nitro,
(d) amido,
(e) mono- or di- alkyl (of from one to four carbons) amido;
(f) hydroxy with the proviso that when the substituent is one or two hydroxy then one of hydroxy can not be in the position para to the phenyl bond,
(4) tolyl;
(5) tolyl substituted by one to three substituents consisting of
(a) alkyl of from one to four carbons,
(b) halogen consisting of fluoro, chloro, bromo. iodo,
(c) alkoxy of from one to three carbons,
(d) nitro,
(e) amido,
(f) mono- or di- alkyl (of from one to four carbons) amido;
(g) hydroxy;
(6) naphthyl optionally attached through a CH 2 group and optionally substituted by one to three substituents consisting of
(a) alkyl of from one to four carbons,
(b) halogen consisting of fluoro, chloro, bromo or iodo,
(c) alkoxy of from one to three carbons,
(d) nitro,
(e) amido,
(f) mono- or di- alkyl (of from one to four carbons) amido,
(g) hydroxy; or
(7) indol-3-yl, indol-2-yl, or imidazol-4-yl, or indol-3-ylmethyl, indol-2-ylmethyl or imidazol-4-ylmethyl;
(8) NHA wherein A is
(a) trityl,
(b) hydrogen,
(c) alkyl of from one to six carbons,
(d) R 10 CO wherein R 10 is (A)hydrogen, (B) alkyl of from one to three carbons optionally substituted with hydroxyl, chloro, or fluoro, (C) phenyl or naphthyl; unsubstituted or substituted with one to three of (i) alkyl of from one to three carbons, (ii) halogen where halogen is F, Cl, Br, or I, (iii) hydroxy, (iv) nitro, (v) alkoxy of from one to three carbons, (vi) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons, or (D) a 5 to 7 member heterocycle such as indolyl, pyridyl, furyl or benzisoxazolyl;
(e) phthaloyl wherein the aromatic ring is optionally substituted by one to three of (A) alkyl of from to three carbons, (B) halogen where halogen is F, Cl, Br, or I, (C) hydroxy, (D) nitro, (E) alkoxy of from one to three carbons, (F) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons,
(f) R 12 (R 13 R 14 C) m CO wherein m is one to three and R 12 ,R 13 , and R 14 are independently (A) hydrogen, (B) chloro or fluoro, (C) alkyl of from one to three carbons optionally substituted by chloro, fluoro, or hydroxy, (D) hydroxy, (E) phenyl or naphthyl optionally substituted by one to three of (i) alkyl of from to three carbons, (ii) halogen where halogen is F, Cl, Br, or I, (iii) hydroxy, (iv) nitro, (v) alkoxy of from one to three carbons, (vi) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons, (F) alkoxy of from one to three carbons, (G) 5 to 7 member heterocycle such as indolyl, pyridyl, furyl, or benzisoxazolyl, or (H) R 12 ,R 13 , and R 14 are independently joined to form a monocyclic, bicyclic, or tricyclic ring system each ring of which is a cycloalkyl of from three to six carbons; except that only one of R 12 , R 13 and R 14 can be hydroxy or alkoxy on the same carbon and can not be hydroxy, chloro or fluoro when m is one;
(g) R 12 (R 13 R 14 C) m W wherein m is independently 1 to 3 and W is OCO or SO 2 and R 12 ,R 13 , and R 14 are independently as defined above;
(h) R 20 W wherein R 20 is a 5 to 7 member heterocycle such as indolyl, pyridyl, furyl, or benzisoxazolyl;
R 21 W wherein R 21 is phenyl or naphthyl; unsubstituted or substituted by one to three substituents of (i) alkyl of from one to three carbons, (ii) halogen where halogen is F, Cl, Br, or I, (iii) hydroxy, (iv) nitro, (v) alkoxy of from one to three carbons, (vi) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons;
(j) R 12 (R 13 R 14 C) m P(O) (OR 22 ) wherein R 22 is alkyl of from one to four carbons or phenyl and R 12 , R 13 and R 14 are independently as defined above;
(k) R 20 P(O)(OR 22 ) wherein R 21 and R 22 are as defined above;
(1) R 21 P(O)(OR 22 ) wherein R 21 and R 22 are as defined above;
(9) R 12 (R 13 R 14 C) m V wherein V is O or NH and R 12 , R 13 and R 14 are independently as defined above;
(10) N(R 11 ) 2 wherein R 11 is independently as defined above;
(11) NR 15 NR 16 wherein R 15 and R 16 are joined to form a 4 to 6 membered saturated nitrogen containing heterocycle which is (i) azetidinyl, (ii) pyrrolidinyl, (iii) piperidinyl, or (iv) morpholinyl;
(12) R 17 OCH 2 O wherein R 17 is
(a) alkyl of from one to six carbons,
(b) R 21 wherein R 21 is independently defined as above; or
(c) CH 2 Q 1 wherein Q 1 is phenyl, naphthyl or a 5 to 7 membered heterocycle independently as defined above;
(13) R 17 OCH 2 CH 2 OCH 2 wherein R 17 is independently as defined above;
(14) alkynyl of from two to six carbons optionally substituted with R 21 where in R 21 is independently as defined above;
(15) alkenyl of from two to six carbons optionally substituted with R 21 where in R 21 is independently as defined above;
R 2 and R 5 are independently hydrogen, alkyl, lower cycloalkyl, or ar wherein ar is an aromatic group, preferably unsubstituted or substituted phenyl;
R 3 ' is hydrogen, an amino acid radical or a protecting group such as a substituted or unsubstituted acyl; and
R 4 is hydrogen and with the proviso that when R 3 ' is hydrogen, then R 1 ' cannot be (1) alkyl substituted by hydroxy, (2) phenyl substituted by halogen, hydroxy or alkoxy, (3) 2-indolyl, (4) 4-imidazolyl, or (5) alkoxycarbonyl.
The present invention is also a compound of the formula (II) ##STR2## wherein R 1 , R 2 , R 3 , R 4 and R 5 are all as defined herein.
The present invention is also a process comprising the treatment of a compound of the formula (II) ##STR3## wherein R 1 is (1) hydrogen;
(2) alkyl of from 1 to 6 carbons optionally substituted by one or two hydroxyl, chloro or fluoro;
(3) cycloalkyl of from 3 to 7 ring carbons;
(4) ar 4 which is a group such as phenyl, or phenyl substituted by one to three substituent(s) consisting of
(a) alkyl of from one to four carbons,
(b) halogen consisting of fluoro, chloro, bromo, iodo,
(c) alkoxy of from one to three carbons,
(d) nitro,
(e) amido,
(f) mono- or di- alkyl (of from one to four carbons) amido;
(g) hydroxy;
(5) ar 5 which is a group such as tolyl;
(6) ar 6 which is a group such as tolyl substituted by one to three substituents consisting of
(a) alkyl of from one to four carbons,
(b) halogen consisting of fluoro, chloro, bromo, iodo,
(c) alkoxy of from one to three carbons,
(d) nitro,
(e) amido,
(f) mono- or di- alkyl (of from one to four carbons) amido,
(g) hydroxy;
(7) ar 7 which is a group optionally attached through a CH 2 and is naphthyl or naphthyl substituted by one to three substituents consisting of
(a) alkyl of from one to four carbons,
(b) halogen consisting of fluoro, chloro, bromo, iodo,
(c) alkoxy of from one to three carbons,
(d) nitro,
(e) amido,
(f) mono- or di- alkyl (of from one to four carbons) amido,
(g) hydroxy; or
(8) ar 8 which is a group such as indol-3-yl, indol-2-yl, or imidazoly-4-yl or indol-3-ylmethyl, indol-2-ylmethyl or imidazol-4-ylmethyl (preferably unsubstituted or substituted phenyl or indol-3-yl);
(9) NHA wherein A is
(a) trityl,
(b) hydrogen,
(c) alkyl of from one to six carbons,
(d) R 10 CO wherein R 10 is (A)hydrogen, (B) alkyl of from one to six carbons optionally substituted with hydroxyl, chloro, or fluoro, (C) phenyl or naphthyl unsubstituted or substituted with one to three of (i) alkyl of from one to three carbons, (ii) halogen where halogen is F, Cl, Br, or I, (iii) hydroxy, (iv) nitro, (v) alkoxy of from one to three carbons, (vi) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons, or (D) a 5 to 7 member heterocycle such as indolyl, pyridyl, furyl or benzisoxazolyl;
(e) phthaloyl wherein the aromatic ring is optionally substituted by one to three of (A) alkyl of from one to three carbons, (B) halogen where halogen is F, Cl, Br, or I, (C) hydroxy, (D) nitro, (E) alkoxy of from one to three carbons, (F) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons,
(f) R 12 (R 13 R 14 C) m CO wherein m is one to three and R 12 , R 13 , and R 14 are independently (A) hydrogen, (B) chloro or fluoro, (C) alkyl of from one to three carbons optionally substituted by chloro, fluoro, or hydroxy, (D) hydroxy, (E) phenyl or naphthyl optionally substituted by one to three of (i) alkyl of from to three carbons, (ii) halogen where halogen is F, Cl, Br, or I, (iii) hydroxy, (iv) nitro, (v) alkoxy of from one to three carbons, (vi) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons, (F) alkoxy of from one to three carbons, (G) 5 to 7 member heterocycle such as indolyl, pyridyl, furyl, or benzisoxazolyl, or (H) R 12 , R 13 , and R 14 are independently joined to form a monocyclic, bicyclic, or tricycle ring system each ring of which is a cycloalkyl of from three to six carbons; except that only one of R 12 , R 13 and R 14 can be hydroxy or alkoxy on the same carbon and can not be hydroxy, chloro or fluoro when m is one;
(g) R 12 (R 13 R 14 C) m W wherein m is independently 1 to 3 and W is OCO or SO 2 and R 12 , R 13 , and R 14 are independently as defined above;
(h) R 20 W wherein R 20 is a 5 to 7 member heterocycle such as pyridyl, furyl, or benzisoxazolyl;
(i) R 21 W wherein R 21 is phenyl or naphthyl; unsubstituted or substituted by one to three substituents of (i) alkyl of from one to three carbons, (ii) halogen where halogen is F, Cl, Br, or I, (iii) hydroxy, (iv) nitro, (v) alkoxy of from one to three carbons, (vi) CON(R 11 ) 2 wherein R 11 is independently hydrogen or alkyl of from one to four carbons;
(j) R 12 (R 13 R 14 C) m P(O)(OR 22 ) wherein R 22 is alkyl of from one to four carbons or phenyl and R 12 , R 13 and R 14 are independently as defined above;
(k) R 20 P(O)(OR 22 ) wherein R 20 and R 22 are as defined above;
(1) R 21 P(O)(OR 22 ) wherein R 21 and R 22 are as defined above;
(10) R 12 (R 13 R 14 C) m V wherein V is O or NH and R 12 , R 13 and R 14 are independently as defined above;
(11) N(R 11 ) 2 wherein R 11 is independently as defined above;
(12) NR 15 NR 16 wherein R 15 and R 16 are joined to form a 4 to 6 membered saturated nitrogen containing heterocycle which is (i) azetidinyl, (ii) pyrrolidinyl, (iii) piperidinyl, or (iv) morpholinyl;
(13) R 17 OCH 2 O wherein R 17 is
(a) alkyl of from one to six carbons,
(b) R 21 wherein R 21 is independently defined as above; or
(c) CH 2 Q 1 wherein Q 1 is phenyl, naphthyl or a 5 to 7 membered heterocycle as defined above;
(14) R 17 OCH 2 CH 2 OCH 2 wherein R 17 is independently as defined above;
(15) alkynyl of from two to six carbons optionally substituted with R 21 where in R 21 is independently as defined above;
(16) alkenyl of from two to six carbons optionally substituted with R 21 where in R 21 is independently as defined above;
R 2 and R 5 are independently hydrogen, alkyl, lower cycloalkyl, or an aromatic group, preferably unsubstituted or substituted phenyl;
R 3 is a protecting group such as a substituted or unsubstituted acyl; and
R 4 is hydrogen or lower cycloalkyl; with the overall proviso that one of R 1 and R 4 must be hydrogen;
with hydrogen in the presence of rhodium (R,R)(1,2-ethanediyl bis[(orthomethoxyphenyl) phenylphosphine] (H 2 RhDiPAMP) in a deoxygenated solvent; optionally (1) deprotecting the nitrogen or (2) deprotecting the nitrogen and further treating to add an amino acid radical to the nitrogen, to obtain a compound of the formula (I) ##STR4## wherein R 1 , R 2 , R 4 and R 5 is as defined above; and R 3 ' is hydrogen, amino acid radical or a protecting group.
The present invention is also the process comprising the condensation of a compound of the formula (III) ##STR5## wherein R 1 is as defined above with a compound of the formula (IV) ##STR6## wherein R 5 is as defined and R 8 is a protecting group; in the presence of titanium tetrachloride; to obtain a compound of the formula (V and VA) ##STR7## and then V and VA are treated with a solution of trifluoroacetic acid in an inert solvent such as methylene chloride in the presence of molecular sieves to obtain the mixture of the formula (VI and VIA) ##STR8## which is treated with diphenylphosphoryl azide at about 0° C., extracted and warmed to effect Curtius rearrangement; and treated with an alcohol, such as para-methoxybenzyl alcohol, tert-butyl alcohol or benzyl alcohol or the like, to trap the incipient isocyanate and to obtain compound of the formula (II) ##STR9## wherein R 1 , R 2 , R 3 , R 4 and R 5 are as defined above.
Optionally this immediately preceding process to obtain the compound II may also include a further step wherein the compound of formula II is further treated with hydrogen in the presence of rhodium (R,R)(1,2-ethanediyl bis[(orthomethoxyphenyl) phenylphosphine] in a deoxygenated solvent; and optionally (1) treated to deprotect the nitrogen, (2) and to add an amino acid radical on the nitrogen to obtain a compound of the formula (I) ##STR10## wherein R 1 , R 2 , R 3 ', R 4 , and R 5 is as defined above.
The preferred process is for the preparation of the phosphorus analog of L-phenylalanine.
DETAILED DESCRIPTION OF THE INVENTION
The terms in the present invention generally have the following meaning.
Alkyl means an alkyl of from one to six carbons such as methyl, ethyl, propyl and the like and isomers thereof.
An aromatic group means a phenyl, substituted phenyl, tolyl, substituted tolyl, naphthyl, indol-3-yl, indol-2-yl, a 5 to 7 membered heterocycle group such as pyridyl, furyl, or benzisoxazolyl and the like. The latter heterocyclic group is usually attached through one of the carbon atoms of the ring.
Substituted phenyl and substituted tolyl means each of phenyl or tolyl is substituted with from one to three substituents such as alkyl, carboxyl, hydroxyl (and base salts thereof), alkoxy, halogen, acyloxy, aryloxy, aralkoxy, amino, alkyl amido (both mono and di alkylamido), nitro, cyano or sulfonyl.
Acyl means such groups as acetyl, benzoyl, formyl, propionyl, butyryl, toluyl, and may include substituted such groups, for example nitrobenzoyl, and the like; and may also include groups composing urethano groups with the nitrogen, such as carbalkoxy groups, for example, carbethoxy, and the like or other acyl variants commonly used as blocking groups in peptide synthesis. In other words the blocking groups in the present invention are commonly acyl groups.
Lower cycloalkyl means cyclic hydrocarbon groups containing 3 to 6 carbon atoms, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl.
The compounds and the processes of the present invention include an asymmetric carbon adjacent to the carbon on which the nitrogen and phosphorus group are attached. In the compound of the formula I or of the compound of the formula I' the stereo configuration of this carbon is the same as the carbon in an analogous naturally occurring peptide configuration and is essentially optically pure. In other words the present invention provides a novel synthesis for obtaining optically pure compounds and selected novel optically pure compounds of the synthesis corresponding to an analogous naturally occurring peptide.
Consequently, an ordinarily skilled artisan can determine pharmacological activity for selected compounds within the formula I' and also ascertain the usual and customary dosage forms or dosages by the use of analogous means as applied to the naturally occurring peptide.
Likewise use of the compounds of the formula I as intermediates in the preparation of compound which are derivatives of the compounds of formula I are also within the skill of the ordinary artisan.
The compounds of the invention may contain other isomeric moieties within its substituents. Thus, the invention includes the individual isomers and mixtures thereof. The individual isomers of this type may be prepared or isolated by methods known in the art.
Chiral means optically active.
The compounds of Formula I' which manifest pharmacologically activity are useful both in the free base and the free acid form or in the form of base salts thereof, as well as, in the form of acid addition salts. All forms are within the scope of the invention. In practice, use of the salt form amounts to use of the free acid or free base form. Appropriate pharmaceutically acceptable salts within the scope of the invention are those derived from mineral and organic acids or those derived from bases such as suitable organic and inorganic bases. For example, see "Pharmaceutical Salts", J. Pharm. Sci., 66(1), 1-19(1977). The acid addition salts of said compounds are prepared either by dissolving the free base of compound I' in aqueous or aqueous alcohol solution or other suitable solvents containing the appropriate acid or base and isolating the salt by evaporating the solution, or by reacting the free base of Compound I" having an acid group thereon with a base such that the reactants are in an organic solvent, in which case the salt separates directly or can be obtained by concentration of the solution.
The base salts of compounds of Formula I described above are prepared by reacting the appropriate base with a stoichiometric equivalent of the acid compounds of Formula I to obtain pharmacologically acceptable base salts thereof.
Specifically, the present invention is a process as shown in Scheme 1.
The process of Scheme 1 may generally be carried out at from about 1 to 100 psig and at a temperature from about 0° C. to 60° C., preferably at about room temperature and at a pressure about 40 psig, in inert solvents such as methanol, ethanol, tetrahydrofuran, dichloromethane, acetonitrile and the like or mixtures thereof. ##STR11##
Evaluation of the results may be accomplished by standard methods, such as vapor phase chromatography on a chiral capillary column, or by HPLC (high performance liquid chromatography) on a chiral column or by evaluation of the optical rotation of a solution of the compound.
More particularly the process of Scheme 1 may be accomplished be the following general procedure.
A Fisher-Porter bottle is charged with the appropriate substrate II dissolved in deoxygenated methanol along with 0.1-1.0 mol percent rhodium (R, R)-DiPAMP (R,R)-(1,2-ethanediy) bis[(o-methoxyphenyl) phenylphosphine]. After 5 nitrogen purges (40 psig) the solution was purged 5 times with hydrogen (40 psig) and then allowed to hydrogenate at room temperature for 1-24 h. The hydrogen was replaced with nitrogen and the contents of the bottle concentrated in vacuo. The catalyst residue was separated from the chiral alpha-amino phosphonate I by dissolving the product in iso-octane. The catalyst residue is not soluble in iso-octane.
A general procedure for the hydrolysis of chiral N,O-protected alpha-amino phosphonates of the formula I wherein R 3 ' is a protecting group is as follows. A sample of the chiral N,O-protected alpha-amino phosphonate derivative is refluxed for 24 h with 12 N hydrochloric acid. The solvent is removed in vacuo. The residue is taken up in water and reconcentrated in vacuo. After thoroughly drying under vacuum the hydrochloride salt is converted to the free amine by treatment with excess propylene oxide. The precipitated amino acid is then isolated by filtration and optionally recrystallized from water/methanol.
An evaluation is made of optical purity by chiral vapor phase chromatography. The N,O-protected chiral alpha-amino phosphonate derivatives are analyzed by chiral gas chromatography for optical purity. A solution of the racemic amino acid derivative in dichloromethane is separated into the two enantiomers by a 25 meter Chirasil Val III capillary column with flame ionization detection. After conditions for separation of the two enantiomers are established, each chiral hydrogenation product is evaluated for the extent of optical purity.
Specifically, when R 1 is hydrogen and R 2 is C 6 H 5 CH 2 OCO in the above described hydrogenation of the compound of the formula II at 40 psig in methanol at room temperature gives the product of the formula I wherein R 1 is hydrogen and R 2 is C 6 H 5 CH 2 OCO in a yield of 98% after two hours and evaluation of the optical purity of the compound of the formula I by vapor phase chromatography on a chiral capillary column revealed that the L-isomer was formed to the extent of 95% purity.
Variations in these conditions and evaluations for different compounds within the definitions of the formula I are within the skill of an ordinarily skilled artisan.
The compounds of the formula II are known or can be prepared from compounds that are known by methods known in the art or for compounds of the above formula II can be prepared by the following methods. ##STR12##
Condensation of the compound of the formula III with the compound of the formula IV in the presence of titanium tetrachloride gives the expected Knovenagel, (Lehnert, W., Tet. Lett. 1970 pp. 4723-4; Lehnert, W., Tetrahedron, 1973, 29, pp. 635-8), product along with the aldol condensation product in good yield (V and VA). Treatment of this mixture with a solution of trifluoroacetic acid in methylene chloride in the presence of molecular sieves results in dehydration and the formation of a 3:1 mixture of Z:E isomers (VI and VIA). Treatment of this mixture with diphenylphosphoryl azide at about 0° C. followed by extractive work-up gives the corresponding acyl azide. The acyl azide is then diluted with toluene and warmed to 90° C. to effect Curtius rearrangement. The incipient isocyanate is then trapped in situ with benzyl alcohol to produce the corresponding N-protected dehydro alpha-amino phosphonate of the formula II as a single (E) geometrical isomer. ##STR13##
More particularly these processes may be accomplished by the following general procedures.
A general procedure for the Knovenagel condensation of tert-butyl O,O-dimethylphosphono acetate IV with aldehydes III is as follows. A 3-necked round bottomed flask is fitted with a nitrogen inlet, provisions for magnetic or mechanical stirring and a serum cap. The flask is then charged with anhyd. tetrahydrofuran (THF) and the solution is cooled to 0° C. in an ice/salt bath. Titanium tetrachloride (2 equivalents per aldehyde) is dissolved in carbontetrachloride and added dropwise to the THF solution A solution of the appropriate aldehyde (1 equivalent) III in a small amount of THF is then added to the above solution followed by a solution of tert-butyl O,O-dimethylphosphono acetate (1 equivalent) IV in THF. Finally, N-methylmorpholine (4 equivalent) is added slowly to this stirring solution, after the addition is complete the solution is allowed to warm to room temperature and stirred for 24 h. The solution is then cooled to about 0° C. and treated with water dropwise over a few minutes. The solution is diluted with ether, poured into a separatory funnel and the aqueous phase extracted with ether 3 times. The combined ethereal solution is washed with NaHCO 3 , brine, dried over anhyd. MgSO 4 , filtered and concentrated in vacuo. The crude product, V and VA, is then purified by flash chromatography.
The general procedure for removal of a protecting group, such as the tert-butyl ester is as follows. A sample of the Knovenagel product, V and VA, is dissolved in dichloromethane and treated with an equal (volume) amount of trifluoroacetic acid at 0° C. The solution is allowed to warm to room temperature and the progress of the reaction monitored by TLC. When the reaction is finished the solvents are removed in vacuo and the residue purified by crystallization or flash chromatography on silica gel. This procedure produces the (Z) and (E)-2-substituted 1-carboxy-1-dimethoxyphosphono ethylene derivatives, VI and VIA.
CURTIUS REARRANGEMENT OF (E)-2-SUBSTITUTED 1-CARBOXY-1-DIMETHOXYPHOSPHONO ETHYLENE DERIVATIVES
Preparation of dehydro alpha-amino phosphonates is as follows. The (Z) and (E)-2-substituted 1-carboxy-1-dimethoxyphosphono ethylene derivatives, VI and VIA, and 1 equivalent of triethylamine is dissolved in dichloromethane and then treated with diphenylphosphoryl azide at 0° C. for a period of 1 h. The solution is then poured into a separatory funnel and washed with 1N KHSO 4 , sat. aq. NaHCO 3 , dried over anhyd. MgSO 4 , filtered and concentrated in vacuo. The acyl azide thus produced is diluted with toluene and warmed to 90° C. for ca. 1 h to effect Curtius rearrangement. This solution is then treated with a mixture of triethylamine (1.5 equivalents) and benzyl alcohol (1.05 equivalents) and allowed to stir at 90° C. for an additional 1 h. The contents of the flask are then poured into a separatory funnel and washed with 1N KHSO 4 , sat. aq. NaHCO 3 , brine, dried over anhyd. MgSO 4 , filtered and concentrated in vacuo to give the desired dehydro alpha-amino acid, II, which was purified by flash chromatography over silica gel.
Variations in these conditions and evaluations for different compounds within the definitions of the formula are within the skill of an ordinarily skilled artisan. For example, substituents may include groups also recognized as requiring protective groups and, of course, these are readily prepared and removed as needed.
The compounds of the formula III and IV are known or can be prepared from compounds that are known by methods known in the art.
The catalytic asymmetric hydrogenation as described above for Scheme I is carried out on the dehydro alpha-amino phosphonate of the formula II in the presence of rhodium (R,R)-DiPAMP to produce the desired compound of the formula I.
When the appropriate corresponding starting materials are used the L-alpha-amino phosphonate analogue of phenylalanine is obtained in excellent yield with very high optical purity. The enantiomeric excess of this latter named reaction is found to be greater than 98%.
The following examples illustrate of the present invention processes using compounds of the above described processes. Various other compounds within the processes of the present invention are readily prepared by these or variations of these examples. That is, the following examples are not meant to be limiting.
EXAMPLE 1
AMINOMETHYLENEBIS(PHOSPHONIC ACID)
Formamide (54g, 1.2 mol) is added dropwise to a solution of phosphorus acid (100g, 1.2 mol) and phosphorus trichloride (500g, 3.6 mol). The solution is warmed to 70° C. for 2 h and then diluted cautiously with 300 mL of water. The solution is then allowed to stand overnight and then concentrated on a rotary evaporator with the bath temperature at 90° C. Upon cooling, the solution solidifies and the product is isolated by filtration on a Buchner funnel. The filter cake is washed thoroughly with a mixture of methanol and water (1:1 v:v) and dried in vacuo to give 100g, 44% of material with mp 255°-265° C.
N-[BIS(DIMETHOXYPHOSPHORYL)METHYL]FORMAMIDE
A mixture of the aminomethylenebis(phosphonic acid) as prepared above (45g, 0.39 mol), trimethyl orthoformate (250g, 2.4 mol) and p-toluenesulfonic acid (2g) are diluted with 500 mL of dry dimethylformamide and stirred at 120° C. for 2 days or until an appropriate assay indicates the reaction is complete. The solution is then filtered and concentrated in vacuo to give a semisolid. This material is recrystallized from acetone to give 64g, 60% of material, mp 95° C.
N-[1(DEMETHOXYPHOSPHORYL)-4-PHENYLETHENYL]FORMAMIDE
A solution of N-[bis (dimethoxyphosphoryl)methyl]formamide (3.50g, 12.7 mmol) is dissolved in 20 mL of dry methanol and treated with a solution of sodium methoxide (from 14 mmol of sodium metal) in methanol under nitrogen. The mixture is stirred at room temperature for 30m and then treated with a solution of benzaldehyde (135g, 12.7 mmol) in 5 mL of methanol. The solution is stirred at room temperature for 24 h and then concentrated in vacuo. The residue is extracted 3× with dichloromethane, the combined extracts dried over anhyd. MgSO 4 , filtered, and concentrated in vacuo to give an oil that is purified by radial chromatography over silica gel eluting with dichloromethane to 10% methanol in dichloromethane. The appropriate fractions are combined and concentrated to give 2.31g, 76% of the desired product as an oil. 1-tert-butyl-1-dimethylphosphonyl-(E)-3-(4)-benzyloxyphenyl) propenoate.
ASYMMETRIC HYDROGENATION OF N-[1-{DIMETHOXYPHOSPHORYL)-4-PHENYLETHENYLFORMAMIDE: PREPARATION OF N-[1-(R)-(DIMETHOXYPHOSPHORYL)-4-PHENYLETHYL]FORMAMIDE
A solution of N-[1-(Dimethoxyphosphoryl)-4-phenylethenyl]formamide (2.31 g, 9.7 mmol) is dissolved in 30 mL of degassed methanol in a Fisher-Porter bottle is treated with rhodium (R,R)-DiPAMP (50 mg, 0.067 mmol). The solution is flushed with nitrogen 5× and then with hydrogen 5× and hydrogenated at 40 psig for 16 h. The solution is then concentrated in vacuo and the residue purified by radial chromatography on silica gel eluting with 5% methanol in dichloromethane to give 1.00 g, 86% of material that is taken on the next step.
HYDROLYSIS OF N-[1-(R)-DIMETHOXYPHOSPHORYL)-4-PHENYLETHYL]FORMAMIDE: PREPARATION 1(R)-AMINO-2-PHENYLETHANEPHOSPHONIC ACID, (L-PHOSPHONO PHENYLALANINE)
A solution of N-[1(R)-(Dimethoxyphosphoryl)-4-phenylethyl]formamide (500 mg, 2.1 mmol) in 40 mL of 6N HCl is heated to reflux for 48 h and then concentrated in vacuo. The residue is dissolved in ethyl acetate and water and treated with 1 mL of propylene oxide. The phases are separated and the aqueous phase extracted with ethyl acetate 3×. The combined ethyl acetate solution is dried over anhydrous MgSO 4 , filtered, and concentrated to give 374 mg, 89% of a white solid, mp 264°-267° C.,[α] D @25° C.=-46 (c=0.5, 2N NaOH). IR(KBr) 1951, 1516 cm -1 . High resolution mass spectrum, calc'd for C 8 H 12 O 3 NP: 202.0812. Found: 202.0633.
KNOVENAGEL CONDENSATION OF 4-BENZYLOXY BENXYALDEHYDE WITH TERT-BUTYL P,P-DIMETHYLPHOSPHONOACETATE: PREPARATION OF 1-TERT-BUTYL-1-DIMETHYLPHOSPHONYL-(E)-3-(4-BENZYLOXYPHENYL) PROPENOATE ##STR14##
Procedure: a 2-neck, 500-mL, round bottom flask equipped with a nitrogen inlet and pressure-equalizing addition funnel is charged with THF (50 mL) and cooled in an ice bath. Titanium tetrachloride (8.46 g, d 1.730, 4.89 mL, 44.6 mmol) in CCl 4 (12 mL) is subsequently added dropwise via the addition funnel over 30 minutes resulting in the formation of a copious, yellow precipitate (TiCl 4 . 2THF). The 4-benzyloxybenzaldehyde (4.73 g, 22.3 mmol) in THF (8 mL) is added next via syringe over 5-10 minutes followed by the t-butyl P,P-dimethylphosphonoacetate (5.00 g, d 1.137, 4.40 mL, 22.3 mmol). N-methylmorpholine (9.02 g, d 0.920, 9.81 mL, 89.2 mmol) in THF (15 mL) is finally added via the addition funnel. The mixture is permitted to stir at 0° C. for 5 h before quenching with water (25 mL). The product is isolated by extracting the reaction mixture several times with ether. The combined ether layer is washed with saturated sodium bicarbonate and brine before drying over anhydrous magnesium sulfate. Filtration and evaporation of the solvent in vacuo revealed the crude product which is recrystallized from CH 2 cl 2 /iso-octane to give 6.0 grams of white crystals (64% yield). 1 H NMR: (CDCl 3 , 300 MHz) ∂ 7.49 (m, 8H, aromatic and olefinic protons); 6.99 (d, J=8.9 Hz, 2H, p-subst. aromatic); 5.13 (s, 2H, benzyl CH 2 ); 3.84 (d, J=1l.4 Hz, 2 eq. OCH 3 's split by P); 1.54 (s, 9H, t-butyl). 13 C NMR: (CDCl 3 , 75.6 MHz) ∂ 160, 147.5, 147, 136, 131, 129, 128, 127, 126.7, 126.4, 115, 82.7, 70.1, 52.9 and 52.8 (P-OCH 3 ), 27.8. 31 P NMR: (CDCl 3 ) ∂ 20.0. MS: (FAB) m/e (relative intensity) 425 [(M+Li)+, 5%], 369 [(M+ Li-C 4 H 8 )+, 100%].
SELECTIVE DEPROTECTION OF THE TERT-BUTYL ESTER: PREPARATION OF 1-DIMETHOXYPHOSPHONYL (E)-3-(4-BENXYLOXYPHENYL) PROPENOIC ACID AND 1-DIMETHYOXYPHOSPHONYL (Z)-3-(4-BENZYLOXYPHENYL) PROPENOIC ACID
Procedure: The starting ester (3.7 g, 8.8 mmol) is dissolved in anhydrous dichloromethane (18 mL) under N 2 . ##STR15##
Trifluoroacetic acid (6.0 g, d 1.480, 4.1 mL, 53 mmol) is subsequently added dropwise at room temperature via syringe. The resulting red solution is permitted to stir overnight at room temperature. The solvent is then removed under reduced pressure, and saturated sodium bicarbonate is added to the residue. The aqueous layer is extracted several times with ethyl acetate to remove unreacted starting material before acidifying with conc. HCl. The carboxylic acid is subsequently extracted into ethyl acetate, and the ethyl acetate layer is washed with brine before drying over anhydrous magnesium sulfate. Filtration and evaporation of the solvent in vacuo revealed a bright yellow solid (2.85 g, 90% yield) which is identified as a mixture of olefins by proton NMR; the two isomers were not separated.
1 H NMR for E-olefin: (CDCl 3 , 300 MHz) ∂ 9.5 (br s, 1H, acid OH); 7.61 (overlapping pair of d's: J=8.8 Hz, 2H, p-subst. aromatic); 7.38 (m, 5H, aromatic); 6.98 (d, J=8.8 Hz, 2H, p-subst. aromatic); 5.10 (s, 2H, benzyl CH 2 ); 3.87 (d, J=11.4 Hz, 6H, 2 eq. OCH 3 's split by P).
1 H NMR for Z-olefin: (CDCl 3 , 300 MHz) d 9.5 (br s, 1H, acid OH); 8.91 (d, J=42.3 Hz, olefinic proton); 7.76 (d, J=8.9 Hz, p-subst. aromatic); 7.38 (m, 5H, aromatic); 7.05 (d, J=8.9 Hz, p-subst aromatic); 5.18 (s, 2H, benzyl CH 2 ); 3.75 (d, J=11.8 Hz, 6H, 2 eq. OCH 3 's split by P).
Formation of acyl azide: Preparation of dimethyl 1-azidocarbonyl 2(E)-(4-benzyloxyphenyl) ethenephosphonate and dimethyl 1-azidocarbonyl 2(Z)-(4-benzyloxyohenyl) ethenephosphonate ##STR16##
Procedure: To an ice-cooled solution of the acid mixture (2.73 g, 7.53 mmol) in dry toluene (11 ML) under nitrogen is added triethylamine (0.762 g, d 0.726, 1.05 mL, 7.53 mmol) and diphenylphosphoryl azide (2.07 g, d 1.277, 1.62 mL, 7.53 mmol). The resulting solution is stirred for 4 h at room temperature. The acyl azide products are isolated by diluting the solution with cold water and extracting with ether. The organic layer is dried over anhydrous magnesium sulfate, filtered, and evaporated under reduced pressure to reveal the crude product mixture which is immediately taken onto the next step.
Curtius rearrangement of acyl azide: Preparation of dimethyl 1-benzyloxycarbonylamino 2(E)-(4-benzyloxyphenyl) ethene phosphonate ##STR17##
Procedure: The crude acyl azide mixture is redissolved in anhydrous toluene (11 mL), and the solution is heated to reflux under nitrogen After heating for 1 h, benzyl alcohol (0.78 mL, 7.53 mmol) is added dropwise. The resulting mixture is permitted to stir overnight at reflux before diluting with ethyl acetate, washing with sat. NaHCO 3 (3 times), 1N HCl (2 times), and brine, and drying over anhydrous magnesium sulfate. Filtration and evaporation of the solvent in vacuo revealed an oil which is purified by flash column chromatography on silica gel initially using CH 2 Cl 2 until the phenol by-product eluted, then switching to 1% MeOH/CH 2 Cl 2 to elute the desired product (R f =0.33, 5% MeOH/CH 2 Cl 2 ) Recrystallization with CH 2 Cl 2 /iso-octane afforded a 56% yield of white crystals.
1 H NMR: (CDCl 3 , 300 MHz) ∂ 7.52 (d, J=8.8 Hz, 2H, p-subst. aromatic); 7.37 (m, 11H, aromatic and 1 olefinic); 6.92 (d, J=8.8 Hz, 2H, p-subst. aromatic); 5.92 (br s, 1H, NH); 5.14 (s, 2H, benzyl CH 2 ); 5.11 (s, 2H, benzyl CH 2 ); 3.78 (d,J=11 Hz, 6H, 2 eq. OCH 3 's split by P).
13 C NMR: (CDCl 3 , 75.6 MHZ) ∂ 160, 140.7, 140.3, 132, 128.6, 128.5, 128.2, 128.1, 127, 126, 115, 70.0, 67.5, 52.9 (d).
MS: (FAB) m/e (relative intensity) 468 (MH+, 65% ); 359 (M+-PO(OMe) 2 , (45%). ##STR18##
Asymmetric hydrogenation of dimethyl 1-benzyloxycarbonylamino 2(E)-4-benzyloxyohenyl) ethene phosphonate: Preparation of dimethyl (1(R)-benzyloxycarbonylamino 2-(4-benzyloxyphenyl) ethane phosphonate, (dimethyl N-Cbz-L-O-benzyl phosphonotyrosine)
Procedure: The starting material (700 mg, 1.5 mmol) and the rhodium (R, R) diPAMP catalyst (approximately 10-20 mg) are placed in a Fischer-Porter tube and flushed with nitrogen (5 times). Degassed methanol is subsequently added, and the tube is flushed 5 more times with nitrogen followed by 5 times with hydrogen before pressurizing to a final volume of 45 p.s.i. The reaction is then permitted to stir at room temperature for 48 h. Typically the chiral products are filtered through silica gel to remove the catalyst.
Preparation of Dimethyl N-Cbz-L-Phosphonoalanine ##STR19##
Dimethyl Acetylphosphonate. Trimethyl phosphite (57.1 g, 0.46 mol) is added dropwise to an ice cold solution of acetyl chloride (36.2, 0.26 nol) at a rate that the internal temperature did not rise above 5° C. The ice bath is removed and the solution warmed to room temperature and then heated to 100° C. for 1 hour. The solution is then vacuum distilled through a 12-inch Vigeraux column to give 30.87 g, 44% of a clear liquid with bp 57°-60° C. at 0.5 mm. H and C nmr are consistent with the assigned structure. This procedure is adapted from the published method of McConnell, R. L., Coover, H. W.,Jr. J. Am. Chem. Soc., 1956, 78, 4450-4452. ##STR20##
Preparation of Dimethyl 1-Benzyloxycarbonylamino-1-etheneohosphonate
Dehydrophosphonopeptide synthesis: Method A. A 250 mL round bottomed flask equipped with a reflux condenser is charged with dimethyl acetylphosphonate (15.2 g, 0.1 mol), benzyl carbamate (15.1 g, 0.1 mol) and 60 mL of dry toluene. The solution is then treated with 1 g of camphor sulfonic acid and then heated to reflux for 12 h. TLC on silica get eluting with 3:1 hexane:ethyl acetate shows the desired product is formed and had R f =0.14. The solution is concentrated and purified by chromatography on a Prep-500 instrument with two silica gel cartridges eluting with hexane and ethyl acetate. The appropriate fractions are combined and concentrated to give 9.58 g, 31% of pure product that slowly crystallized on standing, mp 50°-52° C. This is essentially the method published by Zon, J. Synthesis, 1981, 324.
Dehydrophosphonopeptide synthesis: Method B. A solution of dimethyl acetylphosphonate (12.4 g, 0.081 mol), benzyl carbamate (12.33 g, 0.081 mol) and 260 mL of dry toluene is treated with phosphorus oxychloride (30.3 mL, 0.33 mol). The solution is then warmed to 70° C. for 1 h and then cooled to room temperature. The solution is then poured into a solution of sat. aq. NaHCO 3 , the pH of the solution is maintained between 6.9 and 7.3 by the addition of additional solid NaHCO 3 . The phases are separated and the aqueous phase extracted with two 500 mL portions of ethyl acetate. The combined organic phase is dried with anhyd. MgSO 4 , filtered, and concentrated in vacuo to give an oil 19.0 g, which was purified by chromatography on a Prep-500 as described above to give the pure product 7.7 g, 30%. ##STR21##
Asymmetric hydrogenation of N-Cbz-dehydroalanine (Dimethyl 1(R)-Benzyloxycarbonylamino-1-ethanephosphonate): Preparation of N-Cbz-L-phosphonoalanine
A Fischer-Porter bottle is charged with N-Cbz-dehydroalanine (5.00 g, 16.0 mmol) in 20 mL of degassed methanol. To this solution is added rhodium (R,R) DiPAMP (20 mg, 0.026 mmol). The solution is then flushed with nitrogen five times and then with hydrogen five times and hydrogenated t 40 psig for 4 h. The bottle is opened and the solution concentrated in vacuo to give an oil, 5.03 g, 100% of product that is purified by flash chromatography over silica gel to give 4.89 g, 97% of N-Cbz-L-phosphonoalanine as an oil. Evaluation of the optical purity of this product by chiral vapor phase chromatography on a Chirasil Val III 25 meter column revealed that 95% of the material was (R) and 5% was (S), for an enantiomeric excess of 90%.
Using analogous method with appropriate corresponding starting materials the following compounds are prepared using the processes of the present invention.
TABLE 1______________________________________R.sub.1 R.sub.2 % Yield % ee______________________________________H C.sub.6 H.sub.2 CH.sub.2 OCO 95 90C.sub.6 H.sub.5 -- HCO 86 100C.sub.6 H.sub.5 C.sub.6 H.sub.2 CH.sub.2 OCO 93 98p-C.sub.6 H.sub.5 CH.sub.2 OC.sub.6 H.sub.4 -- C.sub.6 H.sub.2 CH.sub.2 OCO 93 98(CH.sub.3).sub.2 CH C.sub.6 H.sub.2 CH.sub.2 OCO 97 881-naphthyl C.sub.6 H.sub.2 CH.sub.2 OCO 97 98cyclohexyl C.sub.6 H.sub.5 CH.sub.2 OCO 95 91______________________________________ | This invention is selected novel chiral (essentially pure) alpha-amino phosphonates, process for the preparation which is a catalytic asymmetric hydrogenation of olefins and novel intermediates therefor. The alpha-amino phosphonates are useful as antibiotics and/or as intermediates in the preparation of phosphorus-containing analogs of peptides, i.e., phosphonopeptides or pseudopeptides having known uses, such as in antibiotics, antibiotic enhancers, or enzyme inhibitors. | 2 |
FIELD OF THE INVENTION
This invention relates to electron beam tube arrangements comprising resonant cavities, and more particularly, but not exclusively, to output resonant cavity circuits of such arrangements from which high frequency energy is extracted.
The present invention is particularly applicable to inductive output tetrode devices (hereinafter referred to as "IOT's") such as those referred to by the trade name Klystrode (registered trademark, Varian Associates Inc.).
BACKGROUND OF THE INVENTION
An IOT device includes an electron gun arranged to produce a linear electron beam and an input resonant cavity at which an r.f. signal to be amplified is applied to produce modulation of the beam at a grid of the electron gun. The resultant interaction between the r.f. energy and the electron beam causes amplification of the high frequency signal which is then extracted from an output resonant cavity circuit.
One problem faced by designers and operators of IOT devices is that the dimensions of the arrangement, particularly the resonator cavities included at the input and output parts of the device, must be precisely chosen for a particular band of operating frequencies. The resonant frequency of resonant cavities may be altered using tuning doors, or movable tuning plates, to change their volume. However coupling efficiency between primary and secondary resonant cavities may be adversely affected when operated at the extremes of the frequency band, even to the extent that it may be impracticable to use the device. In such cases, a second tube suitable for use over a different range of frequencies may be required.
The present invention arose from the particular consideration of the output cavity arrangement of IOT devices but it is also applicable to other electron beam tube arrangements in which coupling between resonant cavities is employed, such as, for example, klystrons.
SUMMARY OF THE INVENTION
According to the invention, there is provided an electron beam tube arrangement comprising: a resonant cavity circuit comprising two cavities, means for coupling high frequency energy between them, and a coupling dome projecting into one of the cavities from a wall thereof, the dome comprising a base portion adapted to be joined to a dome completion member of a set of one or more dome completion members, whereby coupling between the two cavities is adjustable depending on selection of the dome completion member.
By employing the invention, it is possible to provide efficient coupling over a wide range of operating frequencies by selecting different dome completion members as appropriate for use in co-operation with the base portion.
In one preferred embodiment of the invention, the coupling dome comprises a base portion which is used in conjunction with a selected one of a set of dome completion members to provide a variable dome configuration which may be assembled by a user of the equipment. The dome completion members may be of different thicknesses and diameters so as to essentially alter the configuration of the cavity in which they are located, hence changing inductance and capacitance within the cavity and thus affecting the coupling characteristics.
Thus, the use of the invention enables increased flexibility in operating characteristics to be achieved without the need to use a separate device. The extra parts required compared to a conventional arrangement are relatively small and easy to manufacture and do not add greatly to the total cost of the arrangement.
In one preferred embodiment of the invention, each dome completion member is joined to the base portion by co-operating screw thread arrangements giving a good electrical connection between them. In another arrangement, fixing means, such as screws, are located through the base portion and into a dome completion member.
In one preferred embodiment of the invention, the base portion is in a form of a closed cylinder on which the selected dome completion member is mounted. The cylinder may be of circular symmetry or some other configuration. For example it could have a square transverse section. In another embodiment the base portion is an open-ended cylinder, the dome completion member being attached to its inner or outer wall surface.
Preferably, the coupling dome is substantially circularly cylindrical although other configurations may be employed. For example, the dome may take the form of a block having square or rectangular faces. Advantageously, the base portion is removable from the wall. This enables different dome completion members to be easily removed and fitted.
Although in a preferred embodiment, the coupling dome is a base portion which must be used in conjunction with a dome completion member, in another embodiment of the invention, the base portion is itself capable of operating as a complete coupling dome. Thus, one arrangement in accordance with the invention may comprise a base portion and a single dome completion member, which is either selected for combination with the base portion or not depending on what operational performance is required. Of course, two or more completion members may be available for use with a base portion capable of acting as a complete coupling dome.
In one advantageous embodiment of the invention, coupling between the first and second cavities is achieved by a coupling arrangement which includes an electrically conductive member, such as a block, located within one of the cavities. The coupling dome may be arranged within the same cavity and aligned with the conductive block with a gap between them such that the end faces of the block and dome face one another. In such a configuration the coupling dome is particularly direct in its effect on coupling between the first and second cavities. The gap between the dome and conductive member may be altered by selecting different dome completion members.
The invention is particularly applicable to output resonant cavity circuits of electron beam devices such as IOT's and klystrons. However, it could also be implemented in other arrangements involving coupling between resonant cavities, such as at the input resonant cavity circuit in those arrangements which use two input cavities.
BRIEF DESCRIPTION OF DRAWINGS
Some ways in which the invention may be performed are now described by way of example with reference to the accompanying drawings in which:
FIG. 1 schematically illustrates an IOT comprising a coupling dome configuration in accordance with the invention;
FIG. 2 schematically illustrates the coupling dome of FIG. 1 including alternative dome completion members fastened to a base portion of the coupling dome by fastening means including threads;
FIG. 3 illustrates the arrangement of FIG. 1 with a different dome completion member;
FIG. 4 schematically illustrates a coupling dome including alternative dome completion members having fastening means different from those in FIG. 2;
FIG. 5 schematically illustrates a coupling dome in which the base member itself is capable of acting as a complete coupling dome; and
FIG. 6 schematically illustrates a coupling dome having a planar base portion and alternative dome completion members.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, an IOT comprises an electron gun 1 which includes a cathode 2 and grid 3 arranged to produce a linear electron beam along the longitudinal axis X--X of the arrangement. The IOT includes drift tubes 4 and 5 via which the electron beam passes before being collected by a collector (not shown). A cylindrical input resonant cavity 6 is arranged coaxially about the electron gun 1 and includes an input coupling 7 at which an r.f. signal to be amplified is applied. A primary output cavity 8 surrounds the drift tubes 4 and 5 and includes a coupling loop 9 via which an amplified r.f. signal is extracted and coupled into a secondary output cavity 10 and from the IOT via an output coupling 11.
During operation of the device, the cathode 2 and the grid 3 are maintained at potentials of the order of 30 kV, the grid 3 being maintained at a dc bias voltage of about 100 volts less than the cathode potential. The input high frequency signal applied at input coupling 7 results in an r.f. voltage of a few hundred volts introduced between the cathode 2 and the grid 3 to produce modulation of the electron beam.
The coupling loop 9 in the primary cavity 8 is connected via a conductive post 12 to a cylindrical block 13 which is also electrically conductive. The conductive post 12 is surrounded by insulating material 14 and is rotatable to permit the orientation of the loop 9 to be changed, thus altering the coupling between the primary and secondary cavities 8 and 10.
A coupling dome indicated generally at 15 is located in one of the walls of the secondary cavity 10 and is arranged opposite the conductive block 13. The coupling dome 15 is electrically conductive and comprises a base portion 16 which is a cylindrical flanged member mounted to project into the cavity 10. A dome completion member 17 is fixed to the end of the base portion 16 so that it faces the block 13. The dimensions of the completion member 17 are such that a particular desired gap of spacing D exists between the conductive block 13 and the dome 15. The dome completion member 17 is generally circularly cylindrical in configuration and has a diameter d which, in combination with the spacing D provides efficient coupling between the primary and secondary cavities 8 and 10.
FIG. 2 illustrates parts of the dome 15 in greater detail. The base portion 16 includes a region of reduced width at the end which, in use, is remote from the wall of the secondary cavity. In this embodiment, the outer surface of the region of reduced width includes a screw thread 18. The dome completion member 17, shown separately, includes a cylindrical cavity 19, the side wall of which includes a screw thread 20 which cooperates with the thread 18 of the base portion 16. Thus, in order to utilise this particular dome completion member, it is simply screwed into position onto the base portion 16. The base portion 16 also includes fins 21 which extend outwardly or externally of the secondary cavity 10 (see FIG. 1) and over which cooling air flows during operation of the device.
If it is desired to use the IOT over a different range of operating frequencies, the coupling dome 15 is removed from the secondary cavity 10 (see FIG. 1). The dome completion member 17 is then unscrewed from the base portion 16 and replaced by another dome completion member 22, also shown in FIG. 2. Dome completion member 22 includes a cavity 23 which is configured to cooperate with the base portion 16 and the thread 18 so that together a coupling dome of larger diameter and greater depth is assembled. The configuration of the dome completion member 22 differs from that of the first member 17 in that its side walls 24 are substantially normal to the end face 25. As can be seen, the side walls of the first member 17 are generally curved.
When the second member 22 is added to the base member 16, the completed dome is inserted into the secondary cavity 10 (see FIG. 1) and because of the change in configuration and dimensions permits efficient coupling to be achieved over a different range of frequencies compared to that obtained with the first dome completion member 17.
FIG. 3 illustrates schematically the IOT of FIG. 1 in which the first dome completion member 17 has been replaced by the second one 22. Identical reference numerals present in FIGS. 1 and 3 refer to identical parts as previously described in connection with FIG. 1.
The coupling dome as shown in FIGS. 1 and 3 is at particular specified distances from the end face of the conductive block 13 depending on which completion member is used. The particular configuration chosen is dependent on the applications and the frequencies involved. In some arrangements the gap between the end face of the dome and the block, or other conductive portion such as a wall if a block is not included, may be the same for different dome completion members In other arrangements, the gap may be different for alternative completion members.
The coupling dome of FIG. 2 is shown with two alternative end members to form the complete dome. However, a larger number of such completion members may be included in a set supplied with a particular IOT or other device to enable the user to choose between them depending on his requirements.
The coupling dome illustrated in FIG. 2 has a base portion and end portions, or dome completion members which are connected by a screw thread fitting. However, other fastenings may be employed. For example, as shown in FIG. 4, the alternative dome completion members are attached by fastenings 26 and 27 passing through the base portion and fixing the end completion members thereto.
In the arrangements so far described with reference to the previous FIGS. 1-4, the coupling dome consists of a base portion to which appropriate dome completion members are attached. FIG. 5 schematically illustrates an alternative arrangement in which a coupling dome comprises a base portion 28 which in itself effectively acts as a complete coupling dome over a certain range of frequencies without the need to add completion members. The base portion 28 is adapted to receive an additional end dome completion member 29 when operation is required over a different range of frequencies. Again, several end members may be supplied as a set for use with the base portion 28.
As seen particularly in FIGS. 4 and 5, the end dome completion members may define respective completion member cavities which are configured to receive the base portion therein.
In the illustrated arrangements, the coupling dome is located opposite a conductive block, and both the coupling dome and the conductive block are located within the secondary output cavity. In other arrangements, the conductive block may be omitted and other forms of coupling may be employed. For example, the coupling loop 9 within the primary cavity 8 may be connected to a second coupling loop within the secondary output cavity 10.
With reference to FIG. 6, in another arrangement in accordance with the invention, a coupling dome comprises a base portion 30 and several alternative dome completion members, two of which 31 and 32 are illustrated. In this arrangement, the base portion 30 is a substantially planar disc having cooling fins 33 projecting from one surface which in use is external to the cavity in which the coupling dome is arranged to project. The completion members 31 and 32 are fixed to the base portion 30 by screws but other fixation means could be employed. For example, the base portion could include a threaded cylindrical wall of relatively small axial extent with which the dome completion members are adapted to co-operate.
In the embodiment shown in FIG. 6, the dome completion members are hollow to save weight and reduce material requirements. However, they could be solid in other embodiments of the invention. | An electron beam tube arrangement in an inductive output tetrode. The arrangement comprises a resonant cavity circuit having two cavities, and includes an element for coupling high frequency energy between the two cavities. The coupling element includes a coupling dome projecting into one of the two cavities from a wall thereof. The coupling dome has a base portion which is adapted to be connected to a dome completion member selected from a set comprising at least one dome completion member for adjusting a coupling level between the two cavities. | 7 |
CROSS-REFERENCE T RELATED APPLICATION
[0001] This application claims priority to German Parent Application No. 102 51 574.3. filed Nov. 6, 2002, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an apparatus provided in a spinning preparation machine, such as a carding machine, a cleaner, or the like, for measuring distances between a sensor and clothing surfaces, where a clothed roll (main carding cylinder) cooperates with clothed flat bare which glide on slide guides by means of flat bar slide elements.
[0003] The distances between the clothing of the main carding cylinder and clothings which face same are of substantial significance as concerns machine and fiber technology. The carding result, that is, the cleaning, nep formation and fiber shortening, is to a large measure dependent from the carding clearance, that is, from the distance between the clothing of the main carding cylinder and the clothings of the traveling flats. The guidance of air about the main carding cylinder and the removal of heat are also dependent from the distance between the clothing of the main carding cylinder and the clothed flat bars. The distances are affected by various, partly opposed influences. The wear of racing clothing leads to an increase of the carding clearance which involves an increase of the nap number and a decrease o the fiber shortening. An increase of the rpm of the main carding cylinder, for example, for intensifying the cleaning effect, causes, by virtue of centrifugal forces, an expansion of the main carding cylinder, including its clothing, and thus results in a decrease of the carding clearance. A temperature increase when processing large fiber quantities and certain fiber types, such as chemical fibers, also causes the main carding cylinder to expand, so that for this reason too, the distances decrease. The carding clearance is affected particularly by the machine settings, on the one hand, and by the condition of the clothing, on the other hand. The most important carding clearance of the traveling flats type carding machine is located in the principal carding zone, that is, between the main carding cylinder and the traveling flats assembly. In most cases both clothings which border the working distance are in motion.
[0004] In practice, the quality of the flat bar clothing is regularly optically examined by an attendant. A wear results in an increase of the carding clearance. In a known apparatus described in German Patent Document DE-OS 199 23 419, the distance between a sensor and the points of the flat bar clothing in determined. The stationary sensor is associated with the traveling flats and is facing the flat bars as they are guided along their return path.
SUMMARY OF THE INVENTION
[0005] It is an object of the invention to improve an apparatus of the type described above for measuring the distances at the clothing of the carding machine.
[0006] Embodiments of the invention include an arrangement in a spinning preparation machine. The arrangement has a clothed roll having clothing presenting free ends; flat bar elide elements; clothed flat bars having clothing presenting free ends and cooperating with the clothing of the clothed roll, the flat bars having slide guides which glide on the flat bar slide elements; and a measuring apparatus comprising at least one sensor arranged for detecting a distance between a reference surface and at least one of the free ends of the clothing of the clothed roll and the free ends of the clothing of the clothed flat bars.
[0007] The measures according to the invention permit a simple and direct determination of the distance between the clothing points and the slide surface of the flat bar slide elements (for example, flat bar pins). In this manner, on the one hand, a quality monitoring concerning the uniformity of the flat bars may be obtained and, on the other hand, a simpler and more accurate setting of the distance between the points of the flat bar clothing and the main carding cylinder may be effected. It is a particular advantage to determine the wear, that is, the consumption of the flat bar clothing, particularly after a long running period. Upon a change in the carding clearance, the effect of the change of the flat bar clothing is determined directly as concerns wear and also indirectly as concerns the distance change relative to the main carding cylinder, particularly due to the wear of the clothing of the main carding cylinder, the expansion of the main carding cylinder effected by centrifugal forces and temperature change. In this manner an optimal setting of the carding clearance is feasible, namely, related to a desired value. Measuring is possible during operation.
[0008] It is a further advantage that the geometrically tallest flat bar is found. Furthermore, an adjustment of the flat bar after the grinding of the flat bar clothing is possible,
[0009] Expediently, the height/distance sensor determines the distance “c” between the free ends of the flat bar clothing and the slide surfaces of the flat bar slide elements. In practice slight manufacturing tolerances of the flat bars and the clothing may appear which may be ascertained in this manner. This makes possible a determination of a mid value for the distance “c” for a plurality or for all of the flat bars, thus obtaining a uniform carding clearance. Furthermore, determining the distance “c” yields a magnitude with which the carding clearance gal may be directly calculated. Advantageously, the height/distance sensor may determine the distance “b” between the free ends of the clothing of the main carding cylinder and the slide guide for the flat bar slide elements. As a result, a further magnitude is made available in a simple manner for directly calculating the carding clearance “a”.
[0010] Due to the fact that the slide faces of the flat bar slide elements glide on the slide guide, the slide faces correspond to the slide guide. The distance “a” (carding clearance) between the free ends of the flat bar clothing and the free end of the clothing of the main carding cylinder is preferably determined in accordance with the relationship “a”=“b”−“c”. The determination is effected expediently by computation, for which preferably an electronic regulating and control device may be used. In this manner, at the same time, a predetermined optimal carding clearance may be automatically set by a device which is connected to the electronic control and regulating device. The computed carding clearance may, however, also be outputted to an indicating device, a monitor, a printer or the like. Thus the carding clearance may be set by a control with an inputting device or may be set manually in a mechanical manner.
[0011] The invention permits a determination of the important distance between the slide surface of the flat bar heads and the free ends (points) of the flat bar clothing. Further, by the measures according to the invention, an accurate adjustment of the flat bar heads with respect to the clothing points is effected and thus the correct distance between the clothing points and the clothing of the main carding cylinder (carding clearance) is obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention is explained below in further detail with the aid of exemplary embodiments shown in the drawings, wherein;
[0013] [0013]FIG. 1 shows a schematic side view of a carding machine including an apparatus according to the invention;
[0014] [0014]FIGS. 2 a and 2 b show a side view and section through clothed flat bars, a part of a slide guide and a flexible bend and the distance between the clothing of the flat bars and the clothing of the main carding cylinder;
[0015] [0015]FIG. 3 shows a front view of a returning flat bar and three apparatuses according to the invention;
[0016] [0016]FIG. 4 shows a side view of three returning flat bars and a stationary measuring apparatus;
[0017] [0017]FIG. 5 shows a laser beam of a light section sensor in the zone of a flat bar head;
[0018] [0018]FIG. 6 shows a top view of a measuring flat bar having two light section sensors;
[0019] [0019]FIG. 7 shows a laser beam of a light section sensor the zone of a flat bar head of a measuring flat bar; and
[0020] [0020]FIG. 8 shows a block diagram of an electronic regulating and control device to which at least a stationary sensor, a moved sensor and a setting device for displacing the slide guides are connected.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] [0021]FIGS. 1, 2 a and 2 b show a carding machine, for example, a Trützschler high-performance carding machine DX 903, including a feed roll 1 , a feed table 2 , licker-ins 3 a , 3 b, 3 c, a main carding cylinder 4 , a doffer 5 , a stripping roll 6 , crushing rolls 7 , 8 , a web guiding element 9 , a sliver trumpet 10 , calendar rolls 11 , 12 , traveling flats 13 having clothed flat bars 14 , a coiler can 15 and a sliver coiler 16 . The rotary directions of the rolls are indicated by curved arrows. The working direction is designated at arrow A. Stationary carding elements 33 and 34 face the main carding cylinder clothing 4 a. The apparatus 24 according to the invention is arranged facing the clothing of the returning flat bars 14 ′.
[0022] According to FIG. 2 a , a flexible bend 17 a, having a plurality of non-illustrated set screws, is secured to the machine stand., laterally on each side of the carding machine. The flexible bend 17 a has a convex outer surface 17 1 and an underside 17 2 . A slide guide 20 , made, for example, of a low-friction plastic material is arranged above the flexible bend 17 a. The slide guide 20 has a convex outer surface 20 1 and a concave inner surface 20 2 . The concave inner surface 20 2 lies on the convex outer surface 17 1 and may glide thereon in the direction of arrows B, C. A slide guide 20 and a convex outer surface 17 are provided to support each end of the flat bars (shown as 20 a , 20 b, 17 a and 17 b in FIG. 2 b ). Each flat bar 14 which may be structured, for example, in accordance with European Patent Application EP 0 567 747 A1, is formed of a back part 14 a and a carrier body 14 b. The carrier body 14 b has a foot surface, two side surfaces and two upper surfaces. Each flat bar 14 has, a: both ends, a respective flat bar head 14 I , 14 II (see FIG. 2 b ) each having two steel pins 14 1 , 14 2 and, respectively, 14 3 , 14 4 which are, with one part, axially affixed to the flat bar. The parts of the steel pins 14 1 , 14 2 projecting beyond the end faces of the carrier body 14 b glide on the convex outer surface 20 1 of the slide guide 20 in the direction of the arrow D.
[0023] A clothing strip 18 , having clothing 19 , is mounted on the underface of the carrier body 14 b. The circle circumscribing the points of the flat bar clothing 19 is designated as 21 . The main carding cylinder 4 has on its periphery a main carding cylinder clothing 4 a, such as a saw tooth clothing. The circle circumscribing the points of the main carding cylinder clothing 4 a is designated as 22 . The distance between the circles 21 and 22 is designated by “a” and is, for example, {fraction (3/1000)}″. The distance between the convex outer surface 20 1 and the circle 22 is designated by “b”. The radius of the convex outer surface 20 1 is designated as r 1 , and the radius of the circle 22 is designated as r 2 . The radii r 1 and r 2 are taken from the axis M of the main carding cylinder 4 .
[0024] [0024]FIG. 3 shows a flat bar 14 ′ whose steel pins 14 1 , 14 2 and 14 3 , 14 4 glide on stationary supports 29 a and 29 b , respectively, during the return travel on that side of the traveling flats 13 (see FIG. 1) which is opposite the slide guide 20 , Three light section sensors 24 a, 24 b and 24 c, for example, SICK light section sensors DMH, functioning as height/distance sensors face at a distance the clothing 19 of the flat bar 14 ′. Light sensors 24 a , 24 b , and 24 c produce light beams 25 3 , 25 4 and 25 5 , respectively. The light section sensors are sensors having a large measuring range. The provision of the three sensors 24 a through 24 c allows conclusions to be drawn concerning the wear of the flat bar 14 as viewed over the length 1 (see FIG. 2 b ).
[0025] According to FIGS. 4 and 5, three flat bars 14 ′, 14 ″, 14 ′″ have clothing 19 ′, 19 ″, 19 ′″, respectively. Flat bar 14 ″ glides with surfaces 14 ** of the slide pins 14 1 through 14 4 in the direction E over the stationary support 29 a. The measuring surface 24 ′ of the stationary sensor 24 faces at a distance d the points of the clothing 19 ″ of the flat bar 14 ″. The light section sensor 24 generates, in the direction of the flat bar length (see FIG. 5), a laser beam 25 which impinges on the slide surfaces 14 * of the slide pins 14 1 through 14 4 as well as on the flat bar clothing 19 ″. As the flat bars 14 pass under the sensor 24 , the height profile shown in FIG. 5 is obtained. For an evaluation, the measured value of the two slide pins 14 3 , 14 4 is deducted from the maximum value which is to be filtered out via the constant pin distance. The height difference c thus obtained is utilized for checking the flat bars 14 (uniformity check) and/or for setting the carding clearance “a”. The distance between the free ends of the flat bar clothing 19 ″ and the slide surfaces 14 * of the flat bars 14 1 through 14 4 is designated as “c”. The distance between the sensor 24 ′ and the slide surfaces 14 * of the flat bars 14 1 through 14 4 is designated as “f”. The distance between the sensor 24 ′ and the free ends of the flat bar clothing 19 ″ is designated as “d”.
[0026] As shown in FIG. 6, the flat bar heads of a measuring flat bar 26 glide on the outer surfaces 20 1 of the slide guides 20 a and 20 b, respectively (see FIGS. 2 a, 2 b ). In the regions of the two ends of the measuring flat bar 26 , respective light section sensors 24 1 and 24 2 as height/distance sensors are arranged between the two pins of the respective flat bar heads. The light section sensors 24 1 and 24 2 generate, in the length direction of the flat bars (axial direction), laser beams 25 1 and 25 2 which impinge on the outer surfaces 20 1 and 20 2 as well as on the surface of the clothing 4 a of the main carding cylinder 4 . As the measuring flat bar 26 passes over the outer surfaces 20 1 , 20 1 and the main carding cylinder clothing 4 a, a height profile is obtained which is evaluated and which yields a height difference “b” (see FIGS. 2 a, 2 b ).
[0027] According to FIG. 7 the distance between the sensor 24 1 and the slide surface 20 1 (outer surface) of the slide guide 20 is designated as “g”. The distance between the sensor 24 1 and the points of the main carding cylinder clothing 4 a is designated as “h”. The height difference between “h” and “ 9 ” results in “b”. It is noted in this connection that the slide surfaces 14 * of the slide pins 14 1 through 14 4 lie on the outer surfaces 20 1 , 20 1 and glide thereon.
[0028] As a result, the distance “a” (carding clearance) is obtained between the free ends of the fat bar clothing 19 and the free ends of the main carding cylinder clothing 4 a by the relationship “a”=“b”−“c”.
[0029] In practice at least one of the flat bars 14 ′, 14 ″, 14 ′″ is replaced by the measuring flat bar 26 for the duration of the measuring process. Thus, the measuring flat bar 26 circulates endlessly—like the flat bars 14 —by means of two (non-illustrated) toothed belts on either side of the carding machine.
[0030] The measuring flat bar 26 may also be advantageously installed stationarily relative to the clothing 19 of the returning flat bars 14 as shown in FIG. 4.
[0031] According to FIG. 8 an electronic control and regulating device 27 , for example a microcomputer, is provided to which, for example, the stationary sensor 24 ′ and the circulating sensor 24 1 are connected. The carding clearance “a” is calculated from the measuring results yielded by the sensors 24 ′ and 24 1 . The computed carding clearance “a” is compared with a stored (pre-given) carding clearance a′. Further, to the electronic control and regulating device 27 an automatic setting device 28 for the carding clearance “a” is connected which is known, for example, from German Patent Document DE-OS 196 51 894.
[0032] It is to be understood 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 within the principles of the invention.
[0033] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the arc the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that the invention may be practiced otherwise than as specifically described. | An arrangement in a spinning preparation machine Is provided. The arrangement has a clothed roll having clothing presenting free ends; flat bar slide elements; clothed flat bars having clothing presenting free ends and cooperating with the clothing of the clothed roll, the flat bars having slide guides which glide on the flat bar slide elements; and a measuring apparatus comprising at least one sensor arranged for detecting a distance between a reference surface and at least one of the free ends of the clothing of the clothed roll and the free ends of the clothing of the clothed flat bars. | 3 |
TECHNICAL FIELD
[0001] The invention relates to a step ladder comprising a tool carrier. The tool carrier serves to accommodate and carry tools, which step ladder is adapted for increasing the working height, e.g. on a building site, in a workshop, or in an assembly hall, but also in private households.
PRIOR ART
[0002] A tool box comprising a stool is disclosed in DE 296 09 524 U1, in which the stool is lowered over a drawer cabinet, by which means the drawers are held in a closed position.
[0003] A step ladder in the form of a stable, hollow box is disclosed in DE 2 127 666 A1, in which the top step forms a lid for a container situated beneath it.
[0004] A multi-purpose step ladder is disclosed in DE 81 33 640 U1, in which tool bags can be attached inside the tubular frame of said ladder.
[0005] It is an object of the present invention to further develop a step ladder in such a way that the tool carrier is fully closed when the step ladder has been fitted thereon such that accidental opening of the step ladder is prevented and that a collapsible step ladder is provided that is sufficiently stable to fulfill the requirements of official authorities or the standards for step ladders in general.
DESCRIPTION OF THE INVENTION
[0006] The step ladder of the invention comprising a tool carrier consists of two ladder parts comprising a top step, the two ladder parts being foldably connected by means of a hinge in the region of the top step.
[0007] At least one ladder part comprises a folding step pivotally disposed about a bearing between lateral uprights of the ladder part, said folding step being movable in the direction of the uprights of the ladder part when the step ladder is in a collapsed position, and to a position extending toward the other ladder part parallel to the top step when the step ladder is in an opened position. The tool carrier comprises a base and at least one tool carrier wall that is disposed thereon and extends away from the base and is adapted to be enclosed by the ladder parts. The tool carrier wall comprises a guide surface and/or a guide point for the folding step, disposed on a side facing away from the base, which guide surface and/or guide point interacts with the folding step and guides the folding step from the opened position parallel to the top step to the position in the direction of the uprights when the ladder part comprising the folding step is lowered onto the tool carrier from above. A hinged strut possessing high compressive and tensile rigidity is provided on the folding step at a distance from the bearing, is rotatably joined to the opposing ladder part, and has a length and bearing points that are dimensioned such that the ladder parts can be moved from the opened position to the collapsed position and vice versa when the folding step is being pivoted.
[0008] Therefore, in the collapsed position, a tool box is created consisting of the step ladder and the tool carrier, for ease of transport. In the opened position, the step ladder and the tool carrier represent two separate pieces of equipment that can be used individually. Since the ladder parts collapse automatically and the folding steps fold down when being mounted onto the tool carrier, all openings are covered and the tool box is closed to the environment.
[0009] It is advantageous when each ladder part comprises a single step. In this case it is possible to ascend the step ladder on either side and a safety bar is not required, as may be the case with single-sided ladders.
[0010] It is advantageous when the tool carrier wall is eccentrically disposed on the base by means of the guide surface and/or guide point, and when an inner wall comprises a more centrally disposed inner guide surface or inner guide point. The inner guide surface or inner guide point may be disposed above the guide surface or the guide point of the tool carrier wall. Thus subdivision of the path of movement is possible, and the different positions of the ladder parts relatively to each other can be accommodated in a simple manner.
[0011] It is advantageous when the guide surface of the tool carrier wall is at an angle of from 35 to 60 degrees, preferably 45 degrees, and when the guide surface of the inner wall is at an angle of from 10 to 30 degrees, preferably from 15 to 20 degrees. For practical purposes, within said range of angles the geometric ratios are sufficiently well accounted for the purpose of effecting secure closing.
[0012] It is advantageous when the ladder part comprises a closed wall section below the folding step and the side wall of the ladder part is completely closed when in the collapsed position.
[0013] It is advantageous when the tool carrier has a handle on the side facing away from the base, which handle is guided longitudinally displaceably along a sliding rail on the inner wall and/or on the tool carrier wall and is transversely tiltable relatively to the sliding rail in an upper position. As a result, the tool carrier is able to hold tools in its central region.
[0014] It is advantageous when the step ladder has a recess for the handle in the top step in the region of the hinge, the handle being guarded against tilting by means of contact surfaces on the top step when the step ladder is mounted. This facilitates transportation and handling of the tool box.
[0015] It is advantageous when the handle is entirely retractable when the step ladder is mounted, resulting in it being flush with the surface of the step. The space required to store the tool box is thus minimized.
[0016] It is advantageous when the base has a groove for the purpose of receiving and laterally retaining the ladder part on at least two opposing edges by means of a bottom wall section entering the groove. This prevents spreading of the ladder parts when the ladder is mounted.
[0017] It is advantageous when the ladder part comprising the folding step comprises a support on the inner side of the upright on which the folding step rests in the opened position. Stabilization is thereby achieved and the opening angle further restricted.
[0018] It is advantageous when the strut on the ladder parts is in each case attached below the bearing of the folding step so that, when the step ladder is in an opened position, the strut assumes an angle of from 5 to 45 degrees, preferably from 15 to 20 degrees. Such an arrangement of the strut facilitates smooth opening and closing of the ladder during everyday use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention is explained below with reference to the drawings, in which:
[0020] FIG. 1 shows a step ladder 1 for mounting on a tool carrier in an upper position;
[0021] FIG. 2 shows the step ladder of FIG. 1 lowered over the tool carrier 2 to assume a lower position;
[0022] FIG. 3 shows the step ladder of FIGS. 1 and 2 with the ladder parts fully closed;
[0023] FIG. 4 shows the tool carrier as viewed from above;
[0024] FIG. 5 is a side view of the tool carrier;
[0025] FIG. 6 illustrates the forced coupling of the ladder parts and the folding steps;
[0026] FIG. 7 is a diagrammatic view of the collapsed step ladder;
[0027] FIG. 8 shows supports for varying and supporting the opened folding steps;
[0028] FIG. 9 shows the ladder part comprising the step and the folding step resting on a support;
[0029] FIG. 10 shows a handle mounted on the inner wall in a first, rotated position;
[0030] FIG. 11 shows the handle of FIG. 10 in a partly recessed, second position;
[0031] FIG. 12 is a perspective view of the folded step ladder mounted on the tool carrier.
EXEMPLARY EMBODIMENT
[0032] FIG. 1 shows a step ladder 1 for mounting on a tool carrier 2 , said step ladder comprising two ladder parts 3 , 4 each comprising a top step 5 , 6 , which two ladder parts are interconnected by means of a hinge 7 and are adapted to close toward, or open away from, each other. Each ladder part 3 , 4 comprises a folding step 11 , 12 pivotally disposed about a bearing 10 between the lateral rails 8 , 9 of the ladder parts 3 , 4 , said folding step being in the opened position of the step ladder 1 as shown, parallel to the top step 5 , 6 and thus extending toward the other ladder part 3 , 4 .
[0033] The step ladder 1 is symmetrically constructed about a central axis 13 , the hinge 7 being disposed on said central axis 13 . The tool carrier 2 comprises a base 21 and a tool carrier wall 22 disposed on, and extending away from, said base 21 , said tool carrier wall being laterally enclosed by the ladder parts 3 , 4 when the ladder is mounted as illustrated in FIG. 3 and described below with reference thereto.
[0034] The tool carrier wall 22 is eccentrically disposed on the base 21 , that is to say, at a distance from the central axis 13 , and an inner wall 23 is provided at a shorter distance from the central axis 13 . The inner wall 23 comprises a guide surface 24 , 25 on its upper side facing away from the base 2 , which guide surface slopes outwardly, that is to say, away from the central axis 13 , and is adapted to interact with the folding step 11 , 12 when the opened step ladder is mounted on the tool carrier 2 from above.
[0035] Instead of the outwardly and downwardly sloping guide surface 24 , 25 , a guide point or support point may be used, upon which the folding step 11 , 12 initially rests when the step ladder 1 is mounted and along which it glides when the step ladder 1 is lowered. However, the use of a guide surface 24 , 25 has the advantage over a guide point (not shown) that a defined support having a larger flat surface may be created, at least for a single, intermediate position. However, this is not absolutely necessary.
[0036] In the upper position of the step ladder 1 in relation to the tool carrier 2 , as shown in FIG. 1 , the folding steps 11 , 12 still rest against the guide surfaces 24 , 25 of the inner wall 23 , and the step ladder is still shown in a maximally opened position, the angle shown at this point being 15 degrees per ladder part, that is to say, 30 degrees in all.
[0037] The direction of movement of the step ladder 1 and the tool carrier 2 in relation to each other is indicated by the arrow 26 oriented along the central axis 13 .
[0038] In addition to the guide surfaces 24 , 25 on the inner wall 23 , the tool carrier wall 22 also comprises a guide surface 31 disposed below the guide surface 24 of the inner wall 23 , that is to say, closer to the base 21 and at a more outward position. The guide surface 31 is at a more acute angle than the guide surface 24 , but also slopes outwardly and downwardly. The function of the guide surface 31 on the tool carrier wall 22 is explained below in detail with reference to the figures.
[0039] FIG. 1 further shows a circular recess 41 communicating with an elongated sliding rail 43 formed by a further recess 42 . Said recesses 41 , 42 serve to accommodate a handle (not shown) and to enable tilting thereof to an upper position and to enable the insertion and fixation of the handle to prevent it from tilting in the region of the sliding rail 43 .
[0040] The base 21 has a locating slot 51 disposed near its outer edge 52 . Said slot serves to receive and secure the ladder part 3 when the closed step ladder 1 is totally fitted over the tool carrier 2 .
[0041] FIG. 2 shows how the step ladder 1 is further lowered toward the base 21 in the direction of the arrow 26 , in order to be fitted over the tool carrier 2 . To this end, the folding steps 11 , 12 have been guided entirely past the guide surfaces 24 , 25 to rest on the guide surface 31 of the tool carrier wall 22 . The two ladder parts 3 , 4 have moved toward one another and the opening angle of the step ladder 1 has decreased due to a forced coupling of the two ladder parts 3 , 4 with the folding step 11 , 12 (shown and explained below with reference to FIG. 6 ), that is to say, the step ladder has incipiently closed around the central axis 13 . In this position, the steps 5 , 6 have also approached one another around the joint 7 .
[0042] FIG. 3 shows the step ladder 1 in the fully collapsed position of the ladder parts 3 , 4 prior to reaching the final position, complete closure being effected by further lowering of the unit toward the base 21 . The folding steps 11 , 12 have been fully raised, at least approximately, by sliding along the guide surface 31 and thus lie in the plane of the outer surfaces of the ladder parts 3 , 4 . The lower edge of the ladder parts 3 , 4 is close to being docked in the locating slot 51 disposed at the outer edge 52 of the base 21 . When the closed step ladder 1 is completely fitted over the tool carrier 2 , the ladder parts 3 , 4 are accommodated and secured in said slot 51 . For the purpose of facilitating the docking action, outward protrusions 53 are formed on the tool carrier wall 22 that act as glide slopes and guide the lower edge of the ladder parts 3 , 4 prior to their reaching the final position.
[0043] FIG. 4 shows the tool carrier 2 as viewed from above and illustrates the base 21 comprising the edge 51 and the groove 52 contained therein, the edge 51 being only required on two oppositely disposed sides of the base. The tool carrier wall 22 is disposed on the base 21 in a central region around the central axis (not shown), allowing a view of the guide surface 31 . Such a tool carrier wall 22 is basically sufficient, but two oppositely disposed tool carrier walls are provided for the purpose of increasing the storage capacity to allow for the tidy storage of tools. The inner wall 23 is disposed between the two tool carrier walls, the guide surfaces 24 , 25 being located on the upper surface of the inner wall, facing the viewer.
[0044] FIG. 5 shows the tool carrier 2 in a side view not including the step ladder nor the inner surfaces. The guide surfaces 31 disposed on each of the oppositely disposed tool carrier walls 22 on either side of the central axis 13 are shown, as is the base 21 having the edge 52 and the groove 51 contained therein. This embodiment is sufficient to enable raising of the folding steps 30 when the step ladder is being mounted.
[0045] FIG. 6 illustrates the forced coupling of the ladder parts 3 , 4 and the folding steps 11 , 12 . A hinged strut 61 , 62 possessing high compressive and tensile rigidity is provided on each of the folding steps 11 , 12 at a distance from the bearing 10 , rotatably joined to the oppositely disposed ladder parts 4 , 3 , the length 1 of which and the bearing points 63 , 64 in the ladder part 3 , 4 being dimensioned such that the ladder parts 3 , 4 can be moved from the opened position to the collapsed position, and vice versa, by swiveling the folding step 11 , 12 .
[0046] The distance of the bearing of the folding step 11 , 12 from the hinge 7 connecting the two ladder parts 3 , 4 is identified as radius R. The strut 61 , 62 is fixed to the bearing points 65 , 66 in the folding steps 11 , 12 . If one of the folding steps 11 , 12 is moved about the hinge 10 from the opened position (as shown) of the step ladder to the position identified by dashed lines, indicated as 11 ′, 12 ′ (shown in FIG. 7 below), the process of raising the folding step 11 , 12 enables a pulling force to be applied to the strut, causing the opposing ladder part to move toward the ladder part accommodating the folding step, thus closing the step ladder.
[0047] FIG. 7 is a diagrammatic view of the closed step ladder, the struts 61 , 62 being attached inside the step ladder and thus concealing the mechanism and preventing external interference. In the collapsed position shown below, the struts 61 , 62 further ensure that the folding steps 11 , 12 are approximately flush with the surface of the ladder parts 3 , 4 and that they are also braced against external pressure. The present embodiment also shows that supports 67 , 68 are provided on the inner surfaces of the ladder rails 8 , 9 of the ladder parts 3 , 4 , supporting the opened folding steps 11 , 12 , shown in detail in FIG. 8 , the struts not being shown for the sake of clarity.
[0048] FIG. 9 shows the ladder part 4 comprising the step 6 and the folding step 12 resting on the support 68 , that is to say, with the ladder being in an opened position.
[0049] FIGS. 10 and 11 show the manner in which a handle 71 can be mounted on the inner wall 23 for the purpose of making it rotatable and retractable. FIG. 10 shows the handle 71 in an extended position and tilted sideways relatively to the central axis 13 . Set in said position is an extension tongue 73 supporting the actual hand piece 72 comprising a lug 74 in the region of the circular recess 41 having a diameter such that the lug 74 may be accommodated in its entire length. The lug 74 comprises guide surfaces 75 interacting with the elongated sliding rail 43 comprising the further recess 42 in a position not shown.
[0050] Said position is shown in FIG. 11 , the handle 71 comprising the hand piece 72 and the extension tongue 73 slightly protruding beyond the steps 5 , 6 after the step ladder 1 has been mounted, that is to say, to such an extent that an opening 76 is still accessible into which a lock (not shown) can be set for the purpose of locking the mounted step ladder against removal of the tool carrier, the inner wall 23 of which is shown. Although the recess 41 with fully extended handle 71 cannot itself prevent tilting of the handle, the handle 71 together with contact areas 77 , 78 mounted on the steps 5 , 6 is stabilized in the region of an opening 79 of the hinge. In the partly inserted position shown, the hand piece 71 is further secured against tilting in the region of the sliding rail 43 in the recess 42 by means of the guiding cam 74 , even when the step ladder 1 is not mounted.
[0051] The handle 71 can be wholly countersunk in the tool box formed by the step ladder mounted on the tool carrier, with the result that the upper surface of the hand piece 72 is flush with the steps 5 , 6 .
[0052] FIG. 12 is a perspective view of the collapsed step ladder 1 mounted on the tool carrier 2 and ready for transportation, the handle 71 being extended. In this position, the folding step 12 is flush with the side wall of the ladder part 4 comprising a closed wall section 81 , the two ladder rails 8 , 9 being of such widths that they are in contact with each other. The step ladder 1 thus completely encloses the tool carrier 2 above the base 21 .
[0053] The lowest wall section 82 is partly sunk into the base 2 or, more specifically, is engaged thereby, thus safeguarding said wall section from spreading.
[0054] If the tool carrier and the step ladder are being used independently of each other, they can be inter-adjusted for the purpose of achieving an ergonomic working height for the removal of tools from the tool carrier. For the purpose of stabilizing such adjustment, the underside of the tool carrier base may comprise a connecting element allowing for a positive connection with an appropriately designed connecting element on the upper surface of the step ladder, for example a tongue and groove connection in the form of ribs and protrusions. | A stepladder which is placed on a tool carrier and which is folded up when in the transport position with the handle extracted, has a folding step which in this position is flush with the side wall of the ladder part. The stepladder surrounds the tool carrier above the level of a base. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an analog-to-digital (A/D) converter, and more particularly, to an A/D converter having charge-coupled device (CCD) pipelines.
2. Description of the Related Art
As A/D converters, sequential successive approximation A/D converters have been broadly used.
A first prior art sequential successive approximation A/D converter includes a sample/hold circuit for storing a signal voltage, a D/A converter for generating a reference voltage, a comparator for comparing the signal voltage with the reference voltage, and a control circuit for controlling the D/A converter in accordance with the output signal of the comparator to generate an encoded digital signal. This will be explained later in detail.
In the above-described first prior art A/D converter, however, since the sample/hold circuit continues to hold one signal voltage until its encoded digital signal is determined, the A/D conversion speed (throughput) is substantially reduced. In this case, the throughput is mainly dependent upon N times of a setting time of the D/A converter, where N is the number of bits of the encoded digital signal.
In a second prior art sequential successive approximation A/D converter, a signal CCD pipeline for passing successive analog signals therethrough is provided instead of the sample/hold circuit of the first prior art A/D converter, and also, a plurality of D/A converters and a plurality of comparators are provided, thus substantially enhancing the throughput (see: U.S. Pat. No. 4,326,192). This will be also explained later in detail.
In the above-described second prior art A/D converter, however, even when the comparators can be operated at a high speed, the settling time of each of the D/A converters is required, so that there is a limit in the operation speed of the A/D conversion. In other words, a large throughput cannot be expected.
Also, in the second prior art A/D converter, the transfer efficiency of each stage of the signal CCD pipeline is not always 100%, so that a charge transferred through the stages of the signal CCD pipeline is changed. Therefore, particularly when the signal CCD pipeline is long, an error of the A/D conversion becomes large, and in addition, it is impossible to correct such an error.
Further, the transfer efficiency of each stage of the signal CCD pipeline may be brought close to 100%, to reduce the above-mentioned error of the A/D conversion; however, in this case, the manufacturing cost of the A/D converter is increased.
SUMMARY OF THE INVENTION
It is an object of the present invention to enhance the throughput of a pipelined A/D converter.
Another object is to reduce the error of a pipelined A/D converter.
According to the present invention, a pipelined A/D converter includes a signal CCD pipeline formed by stages for passing analog signals therethrough, and a plurality of reference CCD pipelines each for passing reference signals therethrough. A plurality of comparators are provided for comparing output analog signals from the stages of the signal CCD pipeline with respective output signals of the reference CCD pipelines. An encoded digital signal is obtained in accordance with the output signals of the comparators.
Thus, the reference CCD pipelines serve as the D/A converters of the prior art A/D converter which require a settling time. Therefore, no settling time is necessary to enhance the throughput.
Also, the operation characteristics of the reference CCD pipelines are similar to those of the signal CCD pipeline, for example, the transfer efficiecy of the reference CCD pipelines is similar to that of the signal CCD pipeline. Therefore, the characteristics of the analog signal through the signal CCD pipeline are similar to those of the reference signals through the reference CCD pipelines. As a result, even when the transfer efficiency of the signal CCD pipeline and the reference CCD pipelines is low, errors in the A/D conversion can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more clearly understood from the description as set forth below, as compared with the prior art, with reference to the accompanying drawings, wherein:
FIG. 1 is a block circuit diagram illustrating a first prior art sequential successive approximation A/D converter;
FIG. 2 is a table showing the digital signal of the A/D converter of FIG. 1;
FIG. 3 is a block circuit diagram illustrating a second prior art sequential successive approximation A/D converter;
FIG. 4 is a circuit diagram illustrating a first embodiment of the A/D converter according to the present invention;
FIG. 5A is a longitudinal cross-sectional view of the charge input portion and the signal CCD pipeline of FIG. 4;
FIG. 5B is a traverse cross-sectional view taken along the line B--B of FIG. 5A;
FIG. 6 is a cross-sectional view of a modification of the charge input portion of FIG. 5A;
FIG. 7 is a longitudinal cross-sectional view of the charge input portion and the reference CCD pipeline of FIG. 4;
FIG. 8 is a circuit diagram of the comparator of FIG. 4;
FIG. 9 is a circuit diagram of the boundary detecting circuit, the delay circuit and the encoder circuit of FIG. 4;
FIG. 10 is a table showing a relationship among the output signals of the comparators, the boundary detecting circuits and the encoder circuit of FIG. 9;
FIG. 11 and 12 are circuit diagrams illustrating modifications of the circuit of FIG. 9;
FIG. 13 is a circuit diagram illustrating a second embodiment of the A/D converter according to the present invention; and
FIG. 14 is circuit diagram illustrating modifications of the circuit of FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before the description of the preferred embodiments, prior art sequential successive approximation A/D converters will be explained with reference to FIGS. 1 and 2.
In FIG. 1, which illustrates a first prior art A/D converter, reference numeral 101 designates a sample/hold circuit for sampling a signal voltage V in and holding it, and 102 designates a D/A converter for generating a reference voltage V R . A comparator 103 compares the signal voltage V in with the reference voltage V R . A control circuit 104 receives the output signal of the comparator 103 to control the content of a sequential approximation register 105 to change the reference voltage V R . Finally, the control circuit 104 generates an N-bit digital signal. Note that N times of comparison operations by the comparator 103 are performed upon the same signal voltage V in to obtain the N-bit digital signal. For example, if N is 3, the 3-bit digital signal denoted by D0, D1 and D2 is as shown in FIG. 2.
The operation of the A/D converter of FIG. 1 will explained next. In this case, assume that N is 3 and V in is 4.7 V.
First, the control circuit 104 sets "011" corresponding to 3.5 V in the register 105, so that the output voltage V R of the D/A converter 102 is 3.5 V. As a result, the comparator 103 compares the signal voltage V in (=4.7 V) with the reference voltage V R (=3.5 V). Therefore, since V in>V R , the comparator 103 generates "1" and transmits it to the control circuit 104. Thus, the most significant bit (MSB) D2 is caused to be "1".
Next, the control circuit 104 generates either "001" corresponding to 1.5 V or "101" corresponding to 5.5 V in accordance with the first comparison result D2. In this case, since the first comparison result D2 is "1", the control cirucit 104 generates "101". That is, the control circuit 104 sets "101" corresponding to 5.5 V in the register 105, so that the output voltage V R of the D/A converter 102 is 5.5 V. As a result, the comparator 103 compares the signal voltage V in (=4.7 V) with the reference voltage V R (=5.5 V). Therefore, since V in<V R , the comparator 103 generates "0" and transmits it to the control circuit 104. Thus, the second significant bit D1 is caused to be "0".
Finally, the control circuit 104 generates either "000" corresponding to 0.5 V, "010" corresponding to 2.5 V, "100" corresponding to 4.5 V, or "111" corresponding to 6.5 V in accordance with the first comparison result D2 and the second comparison result D1. In this case, since the first comparison result D2 is "1" and the second comparison result D1 is "0", the control circuit 104 generates "100". That is, the control circuit 104 sets "100" corresponding to 4.5 V in the register 105, so that the output voltage V R of the D/A converter 102 is 4.5 V. As a result, the comparator 103 compares the signal voltage V in (=4.7 V) with the reference voltage V R (=4.5 V). Therefore, since V in >V R , the comparator 103 generates "1" and transmits it to the control circuit 104. Thus, the least significant bit (LSB) D0 is caused to be "1".
Thus, the 3-bit code (D2, D1, D0)=(1, 0, 1) is obtained.
In the art A/D converter of Fig. 1, however, since the sample/hold circuit 101 continues to hold one signal voltage V in until its encoded digital signal (D2, D1, D0) is determined, the A/D conversion speed (throughput) is substantially reduced, since the throughput is mainly dependent upon 3 times a settling time of the D/A converter 102.
In FIG. 3, which illustrates a second prior art A/D converter (see: U.S. Pat. No. 4,326,192), a signal CCD pipeline 201 formed by three CCD stages 2011, 2012 and 2013 corresponds to the sample/hold circuit 101 of FIG. 1, three D/A converters 2021, 2022 and 2023 correspond to the D/A converter 102 of FIG. 1, and three comparators 2031, 2032 and 2033 correspond to the comparator 103 of FIG. 1. Also, delay circuits 2041, 2042 and 2043 correspond to the control circuit 104 and the register 105 of FIG. 1. That is, the output voltage V R .spsb.1 of the D/A converter 2021 is constant, while the output voltages V R .spsb.2 and V R .spsb.3 of the D/A converters 2022 and 2023 are variable. In more detail, the output voltage V R .spsb.2 of the D/A converter 2022 is determined by the first comparison result of the comparator 2031 via the delay circuit 2041, and the output voltage V R .spsb.3 of the D/A converter 2023 is determined by the first comparison result of the comparator 2031 via the delay circuits 2041 and 2042 and the second comparison result of the comparator 2032 via the delay circuit 2043. Therefore, a settling time is unnecessary for the D/A converter 2021, while a settling time is necessary for each of the D/A converters 2022 and 2023.
In the A/D converter of FIG. 3, while an A/D conversion is performed upon one signal voltage, another A/D conversion is performed upon another signal voltage. That is, although three comparsion operations are required for each signal voltage in the same way as in the A/D converter of FIG. 1, A/D conversions are performed upon three signal voltages simultaneously. In other words, an A/D conversion upon one signal voltage is completed for one comparison time by the comparators 2031, 2032 and 2033. Thus, the throughput of the A/D converter of FIG. 3 is three times that of the A/D converter of FIG. 1.
In the A/D converter of FIG. 3, however, even when the comparators 2031, 2032 and 2033 can be operated at a high speed, the settling time of each of the D/A converters 2022 and 2023 is required, so that there is a limit in the operation speed of the A/D conversion. In other words, a large throughput cannot be expected.
Also, in the A/D converter of FIG. 3, the transfer efficiency of each of the CCD stages 2011, 2012 and 2013 of the signal CCD pipeline 201 is not always 100%, so that a charge transferred through the CCD stages 2011, 2012 and 2013 of the signal CCD pipeline 201 is changed. Therefore, particularly when the number of CCD stages of the signal CCD pipeline 201 is increased, an error of the A/D conversion becomes large, and in addition, it is impossible to correct such an error.
Further, the transfer efficiency of each stage of the signal CCD pipeline may be brought close to 100%, to reduce the above-mentioned error of the A/D conversion; however, in this case, the manufacturing cost of the A/D converter of FIG. 3 is increased.
In FIG. 4, which illustrates a first embodiment of the present invention, reference numeral 1 designates a signal CCD pipeline formed by seven (7=2 3 -1) CCD stages 11, 12, 13, . . . , 17. The signal CCD pipeline 1 receives a signal voltage V in from a charge input portion 10 and passes a charge corresponding to the signal voltage V in therethrough.
Also, seven reference CCD pipelines 21, 22, 23, . . . , 27 are provided. In this case, the reference CCD pipeline 21, which is formed by one CCD stage, receives a reference voltage V R .spsb.1 from a charge input portion 210 and passes a charge corresponding to the signal voltage V R .spsb.1 therethrough. Also, the reference CCD pipiline 22, which is formed by two CCD stages 221 and 222, receives a reference voltage V R .spsb.2 from a charge input portion 220 and passes a charge corresponding to the signal voltage V R .spsb.2 therethrough. Further, the reference CCD pipiline 23, which is formed by three CCD stages 231, 232 and 233, receives a reference voltage V R .spsb.3 from a charge input portion 230 and passes a charge corresponding to the signal voltage V R .spsb.3 therethrough. Similarly, the reference CCD pipeline 27, which is formed by seven CCD stages 271, 272, 273, . . . , 277, receives a reference voltage V R .spsb.7 from a charge input portion 270 and passes a charge corresponding to the signal voltage V R .spsb.7 therethrough. Note that the reference voltages V R .spsb.1, V R .spsb.2, V R .spsb.3, . . . , V R .spsb.7 satisfy the following condition: V R .spsb.1 <V R .spsb.2 <V R .spsb.3 <. . . <V R .spsb.7
The output signals of the CCD stages 11, 12, 13, . . . , 17 of the signal CCD pipeline 1 are supplied to buffers 31, 32, 33, . . . , 37, respectively. On the other hand, the output signal of the reference CCD pipeline 21, the output signal of the last CCD stage 222 of the reference CCD pipeline 22, the output signal of the last CCD stage 233 of the reference CCD pipeline 23, . . . , and the output signal of the last CCD stage 277 of the reference CCD pipeline 27 are supplied to buffers 41, 42, 43, . . . , and 47, respectively.
The output signals of the buffers 31, 32, 33, . . . , 37, i.e., the output signals of the CCD pipeline 1 are supplied to respective inputs of comparators 51, 52, 53, . . . , 57, respectively. On the other hand, the output signals of the buffers 41, 42, 43, . . . , and 47, i.e., the output signals of the reference CCD pipelines 21, 22, 23, . . . , 27 are supplied to respective inputs of the comparators 51, 52, 53, . . . , 57, respectively.
Therefore, for a signal voltage V in , the comparator 51 compares the signal voltage V in with the first reference voltage V R .spsb.1 at a first timing, the comparator 52 compares the signal voltage V in with the second reference voltage V R .spsb.2 at a second timing, the comparator 53 compares the signal voltage V in with the third reference voltage V R .spsb.3 at a third timing, the comparator 54 compares the signal voltage V in with the fourth reference voltage V R .spsb.4 at a fourth timing, the comparator 55 compares the signal voltage V in with the fifth reference voltage V R .spsb.5 at a fifth timing, the comparator 56 compares the signal voltage V in with the sixth reference voltage V R .spsb.6 at a sixth timing, and the comparator 57 compares the signal voltage V in with the seventh reference voltage V R .spsb.7 at a seventh timing.
That is, at the i-th timing, the i-th comparator compares a charge corresponding to the signal V in which has passed through the number i of CCD stages with a charge corresponding to the i-th reference voltage V Ri which has passed through the number i of CCD stages. Therefore, even when the characteristics of the charge input portions 10, 210, 220, 230, . . . , 270, the CCD stages 11, 12, 13, . . . , 17, 21, 221, 222, 231, 232, . . . , 271, 271, 273, . . . , and the output portions of the CCD stages are deteriorated, the characteristics are similar to each other. Therefore, comparison operations of the comparators 51, 52, 53, . . . , 57 are hardly affected by the characteristics of the CCD pipelines 1, 21, 22, 23, . . . , 27 and the like. In other words, even when the transfer efficiency of the CCD pipelines 1, 21, 22, 23, . . . , 27 is low, errors in A/D conversions can be reduced.
Further, the D/A converters of FIG. 3 which require a settling time are not provided in FIG. 4, thus enhancing the throughput.
The output signals of the comparators 51, 52, 53, . . . , 57 are supplied to a boundary detecting circuit 6, a delay circuit 7 and an encoder circuit 8, thus obtaining a 3-bit digital signal (D2, D1, D0).
An example of A/D conversion is explained next. Here, assume that
V R .spsb.1 =0.5 V,
V R .spsb.2 =1.5 V,
V R .spsb.3 =2.5 V,
:
:
V R .spsb.7 =6.5 V
Also, the signal voltage V in can be ranged from 0 V to 7 V, and in this case, is 4.2 V. Further, assume that the gain of the input/output transfer characteristics of each of the charge input portions 10, 210, 220, 230, . . . , 270 and the CCD stages of the CCD pipelines 1, 21, 22, 23, . . . , 27 is 1.
The comparator 51 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.1 (=0.5 V), so that the output signal CMP1 is high (="1"). The comparator 52 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.2 (=1.5 V), so that the output signal CMP2 is high (="1"). The comparator 53 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.3 (=2.5 V), so that the output signal CMP3 is high (="1"). The comparator 54 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.4 (=3.5 V), so that the output signal CMP4 is high (="1"). The comparator 55 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.5 (=4.5 V), so that the output signal CMP5 is low (="0"). The comparator 56 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.6 (=5.5 V), so that the output signal CMP6 is low (="0"). The comparator 57 compares the signal voltage V in (=4.2 V) with the reference voltage V R .spsb.7 (=6.5 V), so that the output signal CMP7 is low (="0"). Thus, the comparison result (CMP1, CMP2, CMP3, CMP4, CMP5, CMP6, CMP7) is (1, 1, 1, 1, 0, 0, 0), which is called a thermometer code.
The comparison result (CMP1, CMP2, CMP3, . . . , CMP7) is supplied to the boundary detecting circuit 6 which generates a boundary code signal (H1, H2, H3, . . . , H7). Each element of the boundary code signal (H1, H2, H3, . . . , H7) is synchronized by a delay circuit 7 and is supplied to an encoder circuit 8 which generates a 3-bit digital signal (D2, D1, D0)=(1, 0, 0).
Each portion of the A/D converter of FIG. 4 will be explained next.
FIG. 5A a longitudinal cross-sectional view of the charge input portion 10 and the signal CCD pipeline 1 of FIG. 4, and FIG. 5B is a traverse cross-sectional view taken along the line B--B in FIG. 4. In FIGS. 5 and 6, reference numeral 501 designates a P-type monocrystalline silicon substrate on which an insulating layer 502 made of silicon oxide is formed. Also, transfer electrodes 503-1, 503-2, . . . , 503-13 made of polycrystalline silicon are formed on the insulating layer 502 and within the insulating layer 502. The transfer electrodes 503-1, 503-5, 503-9 and 503-13 are clocked by a clock signal P1, the transfer electrodes 503-2, 503-6 and 503-10 are clocked by a clock signal P2, the transfer electrodes 503-3, 503-7 and 503-11 are clocked by a clock signal P3, the transfer electrodes 503-4, 503-8 and 503-12 are clocked by a clock signal P4. In this case, the clock signals P1, P2, P3 and P4 are shifted by 90 degrees from each other, so that the signal CCD pipeline 1 is four-phased.
Also, seven sensing electrodes 504-1, 504-2, . . . , 504-7 are provided within the insulating layer 502, and are connected via the buffers 31, 32, . . . , 37 to the comparators 51, 52, . . . , 57, respectively (FIG. 4). The sensing electrodes 504-1, 504-2, . . . , 504-7 sense charges therebeneath via parasitic capacitances between the sensing electrodes and the substrate 501.
Also, reference numeral 505 designates a channel stopper for defining a charge transfer portion within the substrate 501.
In FIG. 5A, reference numeral 506 designates an N-type impurity region forming a diode with the substrate 501. The signal voltage V in is applied to the N-type impurity region 506. Therefore, when a voltage V G .spsb.1 is applied to form a potential well adjacent to the N type impurity region 506, a charge is transferred from the N-type impurity region 506 to the potential well, thus injecting the charge into the signal CCD pipeline 1.
Also, in FIG. 5A, reference numeral 507 designates an N-type impurity region forming a diode with the substrate 501. A reset voltage R is applied to the N-type impurity region 507. Therefore, when a voltage V G .spsb.2 is applied to form a potential well adjacent to the N-type impurity region 507, a charge is transferred from the N-type impurity region 507 to the potential well, thus resetting the terminal of the signal CCD pipeline 1.
In the charge input portion 10 of FIG. 5A, the injected charge is not linear to the signal voltage V in , and the injected charge is dependent upon the frequency of the voltage V G .spsb.1. In order to improve this, the charge input portion 10 can be constracted as shown in FIG. 6. In FIG. 6, an N-type impurity region 601, to which a bias voltage V B is applied, and a floating N-type impurity region 602 are provided within the substrate 501. That is, when the signal voltage V in is applied between the N-type impurity regions 601 and 602, a charge in proportion to the difference in potential between the signal voltage V in and the bias voltage V B is transferred from the N-type impurity region 601 to the N-type impurity region 602.
The reference CCD pipelines 21, 22, 23, . . . , 27 have similar configurations to the signal CCD pepeline 1.
For example, the reference CCD pipeline 23 is illustrated in FIG. 7. In FIG. 7, only one sensing electrode 504' is provided, which is different from the signal CCD pipeline 1 as illustrated in FIG. 5A.
In FIG. 8, which is a detailed circuit diagram of the comparator such as 51 of FIG. 4, the comparator 51 is composed of a differential amplifier 801 for amplifying the difference between the output signals of the buffers 31 and 41 which are formed by source followers, a latch circuit 802, and a comparator circuit 803 for generating a comparison output signal CMP1.
Switches SW1 and SW2 are turned ON to reset the sensing electrodes of the CCD stages 11 and 21, respectively. Also, the switches SW1 and SW2 are turned ON to charge offset voltages of the buffers 31 and 41 to capacitors C1 and C2, respectively, thus cancelling the offset voltages.
Switches SW3 and SW4 are turned ON to effect feedback upon the differential amplifier 801, so that offsets are charged to the capacitors C1, C2 and capacitor C3 and C4, thus cancelling the offsets.
Switches SW5 and SW6 are turned ON to reset the latch circuit 802.
During a reset period, all the switches SW1 to SW6 are turned ON, while, during a comparison period, all the switches SW1 to SW6 are turned OFF.
The boundary detecting circuit 6, the delay circuit 7 and the encoder circuit 8 are illustrated in FIG. 9.
The boundary detecting circuit 7 generates output signals H1, H2, . . . , H7 which have a relationship to the comparison output signals CMP1, CMP2, . . . , CMP7 as shown in FIG. 10. Also, the encoder circuit 8 generates a 3-bit digital signal (D2, D1, D0) which has a relationship to the output signals H1, H2, . . . , H7 as shown in FIG. 10.
In FIG. 9, reference D designates a D-flipflop which determines a delay time T which is the same as a delay time of each CCD stage of the CCD pipelines 1, 21, 22, 23, . . . , 27. Also, the inverter and AND circuit of the boundary detecting circuit 6 of FIG. 9 can be replaced by an exclusive OR circuit as illustrated in FIG. 11.
FIG. 12 is a modification of the boundary detecting circuit 6, the delay circuit 7 and the encoder circuit 8 of FIG. 9. That is, in a boundary detecting circuit 6' the signal H4 of FIG. 9 is not generated, and the output signal CMP4 of the comparator 54 is directly supplied via five D-flipflips to an encoder circuit 8', since, the logic of the output signal CMP4 is the same as the encoded data D2 as shown in FIG. 10.
Also, three OR circuits 71, 72 and 73 are introduced into a delay circuit 7', so that the output signals H1, H2 and H3 of the boundary detecting circuit 6' are combined with the output signals H5, H6 and H7 of the boundary detecting circuit 6'. That is, as shown in FIG. 10, the relationship between the signals H1, H2 and H3 and the encoded data D1 and D0 is the same as the relationship between the signals H5, H6 and H7 and the encoded data D1 and D0. In addition, when one of the signals H1, H2 and H3 is "1", all the signals H4, H5 and H6 are "0", and when one of the signals H4, H5 and H6 is "1", all the signals H1, H2 and H3 are "0".
Thus, in FIG. 12, the encoder circuit 8' can be reduced in size as compared with the encoder circuit 8 of FIG. 9.
In FIG. 13, which illustrates a second embodiment of the present invention, the signal CCD pipeline 1 of FIG. 4 is divided into two signal CCD pipelines 1A and 1B. In this case, the signal CCD pipeline 1A is formed by three CCD stages, and the signal CCD pipeline 1B is formed by four CCD stages. Also, the reference CCD pipelines 24, 25, 26 and 27 are modified into reference CCD pipelines 24', 25', 26' and 27', respectively, whose CCD stage numbers are 1, 2, 3 and 4, respectively. A boundary detecting circuit 6" is similar to the boundary detecting circuit 6 of FIG. 11. Also, the delay circuit 7 of FIG. 9 is modified into a delay circuit 7" which is reduced in size as compared with the delay circuit 7 of FIG. 9.
The A/D converter of FIG. 13 operates in the same way as the A/D converter of FIG. 4. In this case, since the number of stages of the signal CCD pipelines which can operate in parallel is smaller than that in FIG. 4, the operation speed becomes larger.
In FIG. 14, which is a modification of the A/D converter of FIG. 13, the principle of FIG. 12 is applied to the A/D converter of FIG. 13. That is, in the boundary detecting circuit 6", the signal H4 of FIG. 13 is not generated, and the output signal CMP4 of the comparator 54 is directly supplied via four D-flipflips to the encoder circuit 8'.
Also, three OR circuits 71, 72 and 73 are introduced into a delay circuit 7'", so that the output signals H1, H2 and H3 of the boundary detecting circuit 6" are combined with the output signals H5, H6 and H7 of the boundary detecting circuit 6".
Thus, in FIG. 14, the encoder circuit 8' can be reduced in size as compared with the encoder circuit 8 of FIG. 13.
In FIGS. 13 and 14, two 2-bit A/D converters are connected in parallel to each other to form a 3-bit A/D converter. Therefore, the second embodiment can be applied to an (M+N) - bit A/D converter where 2 M N-bit A/D converters are connected in parallel to each other.
The above-described embodiments decribe a three-bit A/D converter; however, the present invention can be applied to an N-bit A/D converter where N is four or more. Also, in the above-described embodiments, each stage of the pipelines is one CCD element, however, each stage can be formed by two or more CCD elements.
As explained hereinabove, according to the present invention, since a settling time for D/A converters is unnecessary, the throughput can be enhanced. Also, since reference voltages are also generated from CCD pipelines, errors in A/D conversions can be reduced. | A pipelined analog-to-digital (A/D) converter includes a signal charge-coupled device (CCD) pipeline formed by stages for passing analog signals therethrough, and a plurality of reference CCD pipelines each for passing reference signals therethrough. A plurality of comparators are provided for comparing output analog signals from the stages of the signal CCD pipelines with respective output signals of the reference CCD pipelines. An encoded digital signal is obtained in accordance with the output signals of the comparators. | 7 |
This application is division of U.S. patent application Ser. No. 11/632,084 filed on Jan. 8, 2007, now U.S. Pat. No. 7,726,814, the entire contents of which are hereby incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates generally to microscopes and, more particularly, to non-contact endothelium microscopes and the like.
BACKGROUND OF THE INVENTION
The endothelium is the innermost layer of tissues forming the cornea, consisting of a single layer of flat polygonal cells. One purpose of the endothelium is to control water content and, thus, permit suitable hydration of the cornea. Accordingly, the shape and number of cells in the endothelium influence the quality of one's vision. As the transparency of the cornea depends on a rather delicate balance of factors, there are a number of diseases that can readily disrupt this balance, cause a loss of transparency, and, thereby, hinder the quality of vision.
Endothelium cells in children and young people are typically hexagonal in shape. These cells, however, do not reproduce themselves. At birth, the density of endothelium cells is about 4000 per square millimeter but, as the years pass, the cells begin to change in shape, and the total number of cells decreases. In an adult, the average density is about 2700 cells per square millimeter, with a range of about 1600 to about 3200 cells per square millimeter. The loss of endothelium cells with age is accompanied by two main morphological changes: (i) the presence of cells with different surface areas, and (ii) an increase in the number of cells that are shaped differently from their original hexagonal shape.
Evaluation of the corneal endothelium has been found useful for providing a first clinical indication as to the potential risks of surgery, and for verifying a diagnosis or the effectiveness of a particular therapy. In these evaluations, it is considered particularly important to observe heterogeneous portions of the endothelium, such as intracellular and intercellular areas of no reflectance (dark spots), hyper reflective areas (bright spots), empty areas in the cells layer (guttae), bubbles, as well as Descemet's membrane rupture lines.
Such portions of the endothelium can be checked relative to the evolution of the various diseases of the endothelium which are of an inflammatory or dystrophic nature. Quantitative evaluation involves the assignment of a numeric parameter to a selected photographic field, which parameter is used to study variations in the endothelium over time, or for comparison between different patients.
The most readily accessible parameter is the average cellular density, obtained for comparison purposes by counting the number of cellular elements. A first evaluation method, in this regard, is accomplished by comparing the cellular dimensions with those of the hexagonal reticules that correspond to determined densities. According to a second method, counting of the number of cellular elements is, instead, performed by using fixed or variable reticules.
While beneficial, neither method provides information as to the evolution of the cellular dimensions. Such information can be obtained, however, by identifying, in addition to the dimension of the average cellular area and its variability, the perimeters of the cells as well. This information is obtained through observation using an endothelium reflection microscope, which was first introduced in ophthalmologic practice in 1960 by David Maurice who, by modifying a metallography microscope, obtained photographic images of a rabbit's corneal endothelium. Using the same principles, a microscope was developed subsequently that was able to photograph the endothelium without contacting the eye.
Generally speaking, reflection microscopes of the non-contact type are derived from high magnification microscopes with normal slit lamps. These microscopes are based on the principle of visualization of a selected structure in relation to its ability to reflect an incident ray of light used for illumination. In the most commonly used technique (i.e., triangulation), the observation angle is about 45° , the microscope being oriented such that the bisecting axis of the angle of view is perpendicular to the plane tangential to the corneal surface.
Non-contact endothelium microscopy is particularly suitable for applications where contact with the cornea can be dangerous, such as immediately after surgery or in cases where the structure of the cornea is extremely fragile. By integrating the microscope with techniques of image analysis, the apparatus also provides a quantitative description of endothelium tissue, in the form of average cellular density and specific morphometric parameters.
In one conventional arrangement, a non-contact endothelium microscope apparatus is provided, which includes an optical unit with an illuminating system, for obliquely illuminating through a slit a surface portion of a patient's eyeball, and frontal eye observation, optical system, wherein an alignment-use indicator light for positional adjustment of the imaging optical axis is projected toward the patient's eye and the resulting reflected light is received and imaged by a TV camera. An enlarged-imaging optical system is also provided for enlarged observation, or enlarged photographing, of the subject surface portion on the TV camera based on slit illuminating light from which the eyeball surface has been illuminated.
In addition, a photo-detector is arranged so as to detect a position at which the enlarged-imaging optical system has been focused on the subject surface portion, via a reflected optical path other than that through which the enlarged image has been formed by the enlarged-imaging optical system. The optical unit is automatically moved, in response to the location of the indicator light displayed on a video monitor, both in a transverse direction and toward the eye, so that the location “chases” a specified position on the screen. In this manner, when the photo-detector detects focusing, the enlarged visual image of the subject portion of the cornea is photographed via the TV camera.
While this system has been found workable, placement of a focus detection, photo-detector along a supplementary reflected optical path, renders the apparatus complicated, and thus costly for providing and maintaining reliable results.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide testing of the endothelium without the use of sensors, photosensors or placement of other devices in a reflected optical path.
Another object of the present invention is to provide an apparatus that achieves a higher quality endothelium image than that of conventional arrangements while reducing or eliminating the need for electronic components and, thereby, providing greater reliability, completeness and flexibility of use.
BRIEF DESCRIPTION OF THE DRAWINGS
A specific, illustrative apparatus for morphometric analysis of the corneal endothelium by direct image acquisition, according to the present invention, is described below with reference to the accompanying drawings, in which:
FIG. 1 shows schematically an optical pathway according to a first embodiment of the present invention;
FIG. 2 shows schematically an optical pathway according to a second embodiment of the present invention;
FIG. 3 illustrates schematically a hardware configuration of an apparatus according to one aspect of the present invention;
FIG. 4 shows a first image displayed on a monitor screen during image acquisition procedures, according to one aspect of the present invention;
FIG. 5 shows a second image displayed on a monitor screen during image acquisition procedures according to FIG. 4 ;
FIG. 6 represents schematically selected reflections obtained using an apparatus according to the present invention;
FIG. 7 is a flowchart showing a first procedure for image acquisition using an apparatus, according to one aspect of the present invention;
FIG. 8 is a flowchart showing a second procedure for image acquisition using an apparatus according to the present invention; and
FIG. 9 is a flowchart showing a third procedure for image acquisition using an apparatus according to the present invention.
The same numerals are used throughout the drawing figures to designate similar elements. Still other objects and advantages of the present invention will become apparent from the following description of the preferred embodiments.
According to one aspect of the present invention, there is provided an endothelium reflection microscope apparatus having an optical head comprising an illuminating system for obliquely illuminating, along a side projection axis through a slit, an eyeball surface of a patient's eye. The optical head also includes an eye-front observation optical system along a central channel in which alignment-use indicator light for positional adjustment of the imaging optical center is projected generally toward the eye and the resulting reflected light spot is received and imaged by a camera comprising a digital optical sensor. In addition, the optical head has an enlarged-imaging optical system arranged along a side reflection axis for enlarged observation or photographing of the subject part by the digital camera based on slit illuminating light with which the eyeball surface has been illuminated. The microscope further comprises a drive for moving the optical head along three Cartesian directions including an advancement direction (Z-) generally parallel to the central channel and transverse alignment directions (X-, Y-), and a CPU controller for automatically controlling the drive, the illuminating system, and the eye-front optical system. The CPU controller has a control unit operated by endothelium image acquisition procedure software.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, more particularly, to FIGS. 1-9 , there is shown generally a specific, illustrative apparatus for examination of the corneal endothelium and a method of operating the same, according to various aspects of the present invention. According to one embodiment, the apparatus comprises a movable optical head or microscope 1 having a CCD high speed camera 2 , e.g., a monochrome digital camera with shooting capacity of at least one hundred frames per second with FireWire high speed data output, such as an IEEE 1394 port or equivalent.
High speed camera 2 is connected directly to a central processing unit (CPU) 3 . The CPU includes a controller 4 , e.g., a 65XX type controller produced by National Instruments Corporation (Austin, Tex., U.S.A.) or equivalent. Controller 4 operates a power driver board 5 , such that the signal coming from the CPU is sufficient to power electric DC motors 6 , as described in more detail below.
One purpose of the motors is to position microscope 1 and the associated camera 2 , upon their automatic control by CPU 3 , so that center portion 7 of the eye to be examined may readily be found. This is accomplished by reflecting light from an infrared, light emitting diode (LED) 8 into the corneal surface, the LED being mounted to the mobile head of the apparatus, which comprises optical head or microscope 1 and camera 2 .
The aforementioned electronic components are preferably connected to one another according to a known arrangement. Alternatively, as shown in FIG. 1 , an optical scheme may be used wherein a second LED 9 with associated optics 10 is arranged in proximity to infrared LED 8 in order to provide a fixation point in association with a semireflecting mirror 11 and a semireflecting mirror 12 , as necessary, to center the patient's eye relative to the microscope and obtain the triangulation necessary to conduct the test. These components, like those forming the optical scheme, are triangulation elements for the endothelium test, as are known and already in use for such applications.
In accordance with one aspect of the present invention, the optical scheme comprises a side projection axis 13 , a side reflection axis 14 and a central channel 15 . In the embodiment of FIG. 1 , a halogen lamp 16 is arranged, transversely to side projection axis 13 , with a lamp condenser 17 and a slit 18 . Along the side projection axis, a semireflecting mirror 19 is also positioned for receiving the light beam generated by the halogen lamp, a beam that can be generated by a halogen lamp, and the beam of light that can be generated by a photoflash or photoflash lamp 20 located at the beginning of side projection axis 13 . On the same axis, following the photoflash lamp 20 is a photoflash condenser 21 , a slit 22 and, beyond semireflecting mirror 19 , an optical unit 23 that concentrates the beam at center portion 7 of the patient's eye. In the arrangement illustrated in FIG. 2 , lamp 16 , condenser 17 , slit 18 , semireflecting mirror 19 , and photoflash lamp 20 are replaced with a stroboscopic lamp 36 having the same function as, and activated analogously to, the previous optical scheme.
A side reflection optical unit 24 , arranged along side reflection axis 14 , concentrates the reflected beam and the endothelium image on a mirror 25 , from which the beam and image signal are reflected to central channel 15 passing through a filter 26 and a magnifying optical unit 27 . The beam, and the endothelium image conveyed thereby, joins the central channel at a point where a dichroic mirror 28 is located.
Starting from the eye to be examined, channel 15 accommodates, in addition, semireflecting mirror 12 and a central optical unit 29 that concentrates the image of the eye and of LED 8 on high speed camera 2 , passing through dichroic mirror 28 .
The system is preferably controlled by pulses 30 , 31 from controller 4 . First pulse 30 transmits an on/off signal to LEDs 8 and 9 , to the photoflash lamp, and to the halogen lamp, whereas second pulse 31 transmits a signal for operating motors 6 .
The optical head or microscope is driven by the motors along three Cartesian directions where a low-high direction corresponds with a Y-axis direction, motion in a direction horizontally approaching and moving away from the patient's eye corresponds to a Z-axis direction, and movement in a transverse sideways direction corresponds to an X-axis direction.
Turning now to FIGS. 4-9 , the microscope, according to another aspect of the present invention, operates as follows. Initially, after arranging the optical head at a desired position, the test commences with turning on LED 9 , the LED establishing a fixation point for the patient's eye. At the same time, infrared LED 8 is switched on, thereby projecting a spot of light onto the corneal surface via reflecting mirror 12 . This spot is detected by camera 2 along central channel 15 . Camera 2 then begins to acquire images, with a resolution of at least around 656× around 400 pixels, taken continuously at a frequency of about 100 Hz.
Desirably, data acquisition procedures are carried out with each acquired frame to identify points (pixels) where the grey level is inside a selected predetermined range, so as to eliminate the darker and clearer points of the predetermined range, to identify all the points that belong to the light spot reflected by the cornea, and thus to precisely outline the same spot.
Of all the pixels that form the image of the reflected spot, the X and Y coordinates are calculated, with reference to an upper left angle of the image that coincides with the same position on the camera sensor (See point ø in FIG. 4 ).
Subsequently, average, variance and standard deviation of the X, Y coordinates are computed so as to define the center of the reflected spot, and to identify the interference of possible remote luminous signals that could be associated mistakenly with the spot.
Driver board 5 is operated continuously so that, through action of electronic motors 6 , the luminous spot created by LED 8 follows and coincides with the center of the camera sensor. In practice, the apparatus, according to the present invention, causes the center position 7 of the eye to coincide with the center of the CCD camera sensor and of the video signal processed by the FireWire IEEE 1394 port and the controller, with a feedback control loop for automatic operation of the electric motors.
More specifically, as illustrated generally in FIGS. 4 and 5 , CPU 3 defines two concentric areas, namely, a bigger area 32 and a smaller area 33 . The bigger area, simply stated, is the area of the image that is deemed useful for testing purposes, the borders of the image being discarded because they are often affected by undesirable external reflections. When the center of the light spot is outside bigger area 32 , further testing is not permitted. Area 32 can be circular in shape, as in the example disclosed, or have a different shape (i.e., be oval, square, etc.)
The radius of area 32 may either be defined by the person operating the apparatus, or established as a design parameter, the center of the area coinciding with the center of the CCD camera sensor. Smaller area 33 , on the other hand, is the optimal area for centering, i.e., the target area to be reached by the center of the light spot such that the eye and the camera sensor are centered relative to one another.
In this manner, the center of the reflected spot is calculated, namely, the distance between the spot and the center of small area 33 (which can even be as small as a single pixel). The motors are then operated continuously to drive optical head or microscope 1 along the X and Y directions until such distance is minimized, i.e., until the center of the reflected spot is brought (and kept) within area 33 . In practice, the system automatically calculates the center location of the reflected spot relative to the center of area 33 so as to command the motors, accordingly. Through suitable arrangement of driver board 5 and motors 6 in two X-Y directions, movement of the optical head occurs at a frequency equal generally to that with which the frames are taken, i.e., approximately every ten milliseconds.
When the reflected spot (image) is deemed centered at the sensor (See step A in FIGS. 7 and 8 ), lamp 16 is switched on through a suitable TTL signal that activates the driver board. The lamp illuminates slit 18 through lamp condenser 17 , the resulting slit of light projecting on the eye along axis 13 through mirror 19 and lens 23 . The optical head is then moved along the Z-axis direction, until triangulation takes place, i.e., until the slit of light, through the geometric conditions that regulate the optical reflection, can be reflected by the corneal surface via reflection axis 14 . When reflection occurs, the image projected by the slit is superimposed on the image acquired by camera 2 coming from central channel 15 . The aforementioned geometric conditions are such that advancement of the optical head in the Z-axis direction corresponds to a shifting, from left to right (See camera sensor in FIGS. 4 and 5 ) of the image of the slit reflected by the corneal surface.
To achieve high quality images of the endothelium, it is considered important that the images be captured, and preferably that the cornea be illuminated by photoflash lamp 20 , for the duration of time that the incident beam coming from side projection axis 13 is in the optimal position to create the necessary reflection on the layer of endothelium cells. Accordingly, the apparatus, according to one aspect of the present invention, operates as follows.
First, as set forth in FIG. 5 , a check area or band 34 is established in a left hand side portion of the image taken by the CCD camera sensor. In the example shown, the check area is a band five pixels wide starting from the left hand border of the sensor, but may be displaced less relative to the center, and be smaller in width and length, depending on the circumstances. Absent triangulation, the image in check area or band 34 is generally comprised of a low intensity, grey background with a low intensity value.
Check area 34 is checked constantly, during advancement of the optical head in the direction of the Z-axis, against the maximum frequency permitted to be used with the camera (for instance, around 100 frames per second). As best seen in FIG. 6 , a beam 14 B is reflected by cornea C and, more particularly, by a surface thereof, i.e., the epithelium Cep. Reflected beam 14 B is captured by the camera as a luminous strip 35 (i.e., the aforementioned image produced upon illumination of the slit) moving from left to right.
When luminous strip 35 enters the check area, the grey level intensity detected increases to a value greater than a predetermined threshold value; and the corresponding time t o is fixed or set as a temporal reference. The grey level intensity detected in the check area is accomplished by calculating the average intensity over all the pixels forming the area.
From threshold or reference time t o , a suitable delay time Δt is set selected to control the acquisition of image data. Indeed, given the velocity of the optical head along the Z-axis and, moreover, the thickness of the cornea, it is only with the selected delay, after image 35 reflected by epithelium Cep has been detected in the check area, that an image reflected by the endothelium arrives at an optimal position for image capture by camera 2 . An arrangement of this general description is also shown in FIG. 6 , namely, where beam 14 A reflected by endothelium Cend produces a strip image 37 displaced rearwardly relative to image 35 , as reflected by epithelium Cep.
Generally, the length of time Δt between reference t o and the time when the image of the endothelium is captured is fundamental, and is evaluated based on the advancement speed and the average thickness of the cornea. The delay time ←t can, in any case, be adjusted either manually or automatically. Once Δt has been reached, photoflash lamp 20 is turned on, thereby illuminating the cornea, and the image of the endothelium is captured by camera 2 . A number of different images can be taken, in addition, so that the one of best quality can be chosen. The images are then stored in a database for further processing or treatment. After the data acquisition cycle has ended, the apparatus returns to its starting position and awaits the next test to be performed.
Optionally, both the time delay, Δt, and position of the check area 34 can be varied so as to give to the medical operator the ability to obtain better images, particularly in the case of corneas with specific morphologies. The photoflash lamp, with its supplementary luminous impulse, allows the user to lower the gain of the camera for less “noise” in the images. The photoflash lamp may be actuated upon a selected advance of the optical head relative to the time lapse Δt, taking into consideration the lag intrinsic to the device.
Overall, the apparatus, according to the present invention, advantageously provides testing of the endothelium without the use of sensors, photosensors or placement of other devices in a reflected optical path. It also achieves an endothelium image of much higher quality than those of conventional arrangements, while reducing or eliminating the need for electronic components, thereby providing greater reliability, completeness and flexibility of use. The absence of a photosensor or linear sensor along an optical reflection path, and the use of an acquisition procedure, controlled and realized through simple software-based instructions given to the apparatus, results in higher reliability, lower costs and greater flexibility. Furthermore, by allowing the user to capture a number of frames, and then choose the one of highest quality, increases the quality of endothelium images even more, as compared to known arrangements and conventional focusing techniques.
The patients, test data, and captured images are advantageously stored in a database, permitting the medical operator or user to use, review and/or otherwise work on the data collected, even after testing has concluded. In this manner, useful clinical parameters may be readily relied upon and, subsequently, processed so as to determine the number and density of the cells, their shape, their surface, i.e., minimum, maximum and average surface area, their deviation from standard parameters, a variance coefficient, the ratio of cells of various forms, as well as show graphically their distribution, the dimension of cell areas, and their perimeters' distribution. Moreover, because of the automatic control provided, testing can now be performed with significantly less assistance from the user.
Various modifications and alterations may be appreciated based on a review of this disclosure. These changes and additions are intended to be within the scope and spirit of the invention as defined by the following claims. | An apparatus for operating an endothelium reflection microscope. The apparatus includes an optical head, which comprises: (i) an illuminating system, (ii) a frontal eye observation optical system along a central channel in which an alignment-use light spot is received and imaged by a camera having a digital optical sensor, and (iii) an enlarged-imaging optical system for enlarged observation or photographing of the subject part by the digital camera. The apparatus further comprises a motor for operating the optical head, and a CPU controller for automatically controlling the motor, the illuminating system and the frontal eye observation optical system. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a semiconductor device having an intrinsic or weakly doped semiconductor layer containing a P doped zone and a N doped zone separated by an intrinsic or weakly doped base zone.
Bipolar transistors and field effect transistors are known semiconductor devices. In semiconductor thin-film technology, bipolar transistors can be constructed as so-called "lateral transistors". In this technology it is difficult to produce sufficiently short base zones.
SUMMARY OF THE INVENTION
An object of the invention is to provide a bipolar semiconductor device or component having transistor-like properties, which is suitable for construction in thin-film technology.
According to the invention, a semiconductor device is formed of an insulating or weakly conductive substrate with an intrinsic or weakly doped semiconductor layer arranged on the substrate. First and second P doped zones and first and second N doped zones are formed in this semiconductor layer. Each of the zones is separated from the others by a portion of the semiconductor layer which serves as an intrinsic or weakly doped base zone. A connecting line between the second P doped zone and the second N doped zone intersects a connecting line between the first P doped zone and the first N doped zone. The first P and N doped zones form a first sub-diode and the second P and N doped zones form a second sub-diode. The operation of one sub-diode affects the operation of the other sub-diode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates the construction of a semiconductor component corresponding to the invention;
FIGS. 2 and 3 are plan views of the arrangement of P type, intrinsic or weakly doped, and N type zones for various embodiments of the invention; and
FIG. 4 illustrates a component, provided with a field effect electrode, corresponding to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is based on the following considerations: bipolar semiconductor components consist of a sequence of semiconductor layers exhibiting differing doping. Layer sequences of this type can easily be achieved in semiconductor wafers by diffusing in dopant from both surfaces. In the Planar technique, only one surface side of a semiconductor wafer, e.g. a silicon wafer, is processed. Thus, for example, there are both laterally constructed transistors and PIN diodes in the Planar technique. Structures of this type are particularly suitable for the thin-film technique. A lateral structuring can be two-dimensional, e.g. in accordance with FIG. 1, where 1 designates a substrate, in particular an insulating substrate, 2 designates a layer of semiconductor material, 3 designates a first P doped zone; 4 designates a second P doped zone, 10 designates an intrinsic or weakly doped base zone, 6 designates a first N doped zone and 5 designates a second N doped zone. On the doped zones 3, 4, 5, 6 metal layers 13, 14, 15, 16 are applied as ohmic contacts and are provided with supply lines. The construction illustrated therein can be considered as a construction of two side-by-side diodes, or as has been done below, as a pair of intersecting diodes, depending upon the manner in which the terminals are applied and connected. The pairs of zones 3, 6 and 4,5 are considered as sub-diodes. The base path between the two doped zones can be shorter than, equal to, or exceed the diffusion length of the charge carriers. When the distance between the P zone and the N zone of a sub-diode is great in comparison to the diffusion length of the charge carriers in the base zone 10 lying therebetween, such a sub-diode will be referred to as a "long" diode, and otherwise as a "short" diode. The electrical current flow through the intrinsic or weakly doped base zone 10 takes place by diffusion of the charge carriers in the case of "short" diodes poled in the forward direction, and takes place by a drift movement of charge carriers injected to the P or N conducting zones in the case of "long" diodes. The system consisting of the two intersecting PIN diodes or PSN diodes can consist of two "short" and also of two "long" diodes or a combination of a "long" and a "short" sub-diode. The significance of the four-pole structure is that the characteristics of the sub-diodes mutually influence one another.
In a special embodiment of the invention, a "long" diode is combined with one (FIG. 2) or a plurality of e.g. two "short" diodes (FIG. 3). The asymmetrical form shown in FIG. 2 is used in particular when the intermediate area between the doped zones which represents the base zone 10 is not intrinsic but is weakly doped. With the described arrangement of the intersecting diodes, the currents flowing through the two diodes mutually influence one another. When one "long" diode is combined with a plurality of e.g. two "short" or also "long" diodes, a structure is obtained which has a plurality of inputs (4, 5 and 8,) (FIG. 3). A further generalization of the diode intersection leads to a star-like arrangement of diodes which mutually penetrate one another.
In the following the mode of functioning of the component corresponding to the invention will be explained in detail.
First, a special mode of functioning of the component corresponding to the invention comprising two sub-diodes will be explained. A sub-diode to which a voltage U 1 is connected and through which the current I 1 flows is referred to as an input diode. The other diode which is connected to the voltage U 2 and through which the current I 2 flows is considered as an output diode. The two currents I 1 and I 2 are dependent upon the two voltages U 1 , U 2 . We have:
I.sub.1 =G.sub.11 U.sub.1 +G.sub.12 U.sub.2,
I.sub.2 =G.sub.21 U.sub.1 +G.sub.22 U.sub.2
or in brief
I=G·U
where G 11 , G 12 , G 21 , G 22 are the elements of a matrix G; these are functions of the two voltages U 1 , U 2 resulting for U 1 →0 in G 11 U 1 →0 and G 21 U 1 →0 and with corresponding results when U 2 →0. Currents and voltages in the forward direction (forward currents and voltages) are marked with a positive sign, whereas backward (reverse) currents and voltages are marked with a negative sign. Now the situation
U.sub.1 >0, U.sub.2 <0 (Equation 1)
will be considered. The input will thus be considered to be poled in the forward direction, whereas the output will be considered to be poled in the backward direction. The input voltage U 1 >0 amplifies the output reverse current I 2 , which on account of U 2 <0, is I 2 <0. Likewise the output voltage U 2 <0 increases the input current I 1 which, on account of U 1 >0, is I 1 >0. Accordingly, G 12 <0 and G 21 <0. It is to be assumed that these two effects maintain a balance. Thus
G.sub.21 U.sub.1 +G.sub.12 U.sub.2 =0 (Equation 2)
Now, with a fixed input voltage U 1 , the currents I 1 and I 2 for U 2 ≠0 and U 2 =0 are compared with one another. Thus it is necessary to distinguish G(U 2 ) from G(0). Furthermore G 11 (0)≈G 11 (U 2 ) is set, and I 2 (U 2 =0)=G 21 (U 2 =0)·U 1 ≈0 and G 22 (U 2 )U 2 ≈0. Then from Equation 2 the equation
I.sub.1 (U.sub.2)-I.sub.1 (U.sub.2 =0)+I.sub.2 (U.sub.2)=0 (Equation 3)
can be approximately obtained, where I 1 (U 2 =0) is determined by U 1 .
The output reverse current I 2 is fundamentally transferred from the input current I 1 . In order to illustrate Equation 3, the current transfer coefficient ##EQU1## and the current amplification coefficent ##EQU2## are introduced.
A comparison of Equation 4 and Equation 5 indicates that ##EQU3##
Furthermore, since |I 2 (U 2 )|<I 1 (U 2 ), it follows that: 0≦α≦1 and 0≦β≦α.
With a full current transfer of α=1, the current amplification is β=α. With an absent current transfer α=0, the curent amplification also disappears, i.e., β=0. For α=1/2, β=1, i.e. α>1/2 supplies β>1. A current amplification results in a power amplification when |U 2 |>U 1 is chosen.
In order to underline the similarity of the component corresponding to the invention with a bipolar transistor, in the following the input diode will also be referred to as an emitter diode and the output diode will also be referred to as a collector diode. The interaction between input and output takes place in that the holes and electrons injected via the emitter diode of the input are partially sucked away by the collector diode of the output. To enable a reasonable current response to take place, the injection must be effected directly into the space charge zone of the collector diode. In the ideal situation of an intrinsic base, the space charge zone would extend from the anode of the collector diode to the cathode. With a doped base, the voltage applied to the collector diode must be sufficient for the space charge zone commencing from a contact to reach the connection line between anode and cathode of the emitter diode, the "emitter axis". An asymmetrical structure as illustrated in FIG. 2 meets this requirement.
As shown in FIG. 1, the input circuit may include the forward bias U 1 connected in series with a control voltage U s between terminals 13 and 16. The output circuit is a series connection of a reverse bias U 2 and load R 1 connected between terminals 14 and 15.
In order to estimate the degree of current amplification, it is provided that β=t 1 /t 2 , where t 1 signifies a minority carrier transit time between the emitter contacts (needed to cross the base region common with the collector diode) and t 2 signifies the corresponding time for the collector contacts. A more precise estimation can be given for an arrangement consisting of two "long" diodes in the form ##EQU4## Then the situation β>1 can easily be attained. Consequently, with an increasing reverse voltage, there is not only an increase in the current amplification but also a decrease in the switching time.
In pulsed operation, the switching speed essentially corresponds to the time required to transfer the injected charge carriers. The dimensions of the base zone 10 are related to the diffusion length of the charge carriers and thus, in particular, to the carrier lifetime. Thus when the charge carriers have a low lifetime, correspondingly small dimension have to be chosen for the base zone 10 which has a favorable effect upon the switching speed.
When the component corresponding to the invention is constructed in the SOS technology (silicon on sapphire), a distance of 10 μm is already "long" i.e., considerably longer than the diffusion length of the charge carriers. Therefore, by designing the component corresponding to the invention in the SOS technology, very short switching times can be achieved. In SOS technology, the production of good lateral transistors is difficult since the requisite short base length of approximately 1 μm cannot easily be preserved because of lateral diffusion. The component corresponding to the invention on the other hand has advantages because it is indeed capable of functioning in the case of comparatively larger base diameters.
In the device corresponding to the invention, an additional field effect control of the potential distribution and of the space charge distribution and the carrier concentration distribution can be carried out which affects the current distribution and the current transfer. For this purpose, as shown in FIG. 4, a field effect electrode 21 is applied over an insulating layer 20. The field effect voltage can be applied between the terminal 22 and a (not shown) substrate contact, or also between 22 and one of the base contacts 3, 4, 5 or 6.
Another additional control possibility consists in connecting a magnetic field in parallel to the surface, so that the Lorentz force is at right angles to the surface. In this way, for example, the current between the contacts of an emitter diode can be brought deeper into the base volume so that the current transfer into the collector circuit reduces.
The arrangement corresponding to the invention has here been represented as an input diode and an output diode which intersect with one another. In addition, simpler connection possibilities with conventional modes of functioning are possible. The interconnection of the two P contacts and the two N contacts produces a PSN diode. Naturally, one sub-diode will also be sufficient. In the case of a long base, a double injection diode is obtained. The application of a transversal magnetic field in parallel with the layer produces a magnetodiode. If, for example, a deeper semiconductor base exists, the injection current can be drawn downwards by the Lorentz force. The increase in the length of the current path then produces an increase of the resistance. In the case of a thin-film base, as occurs, for example, when the SOS technology is employed, a lifetime gradient extends into the semiconductor from the substrate surface towards the surface of the semiconductor layer. The Lorentz force can deflect the carriers either towards the substrate surface or towards the surface of the semiconductor layer. In the first situation the average lifetime is shorter than in the second situation. Therefore the double injection is impeded in the first situation but promoted in the second situation. In dependence upon the direction of the magnetic field, an extremely powerful positive or negative magnetoresistance is obtained.
If, in an arrangement corresponding to the invention comprising a "long" and "short" diode (e.g. as in FIG. 2), a terminal of the short transverse diode is left open, a structure is obtained for example, where π is a longitudinal base with injecting contacts at the opposite ends. A πN junction is arranged transversely thereto. This arrangement can be understood and operated as a double-base diode. In diodes of this type, the base can be provided with ohmic contacts in the longitudinal direction, but also, as here, with injecting contacts. The characteristics react sensitively to an external magnetic field which, however, must now be applied perpendicular to the layer. The component is then referred to as a double-base magnetiodiode.
An arrangement corresponding to the invention composed of two "short" sub-diodes can be understood and operated as a bipolar lateral transistor whose base terminal is divided in two.
An arrangement corresponding to the invention comprising a field effect electrode similar to the structure shown in FIG. 4 can be considered and operated as a pair of complementary field effect transistors having a common gate. If one transistor is opened by a field effect, the other becomes blocked and vice versa.
An arrangement corresponding to the invention with a field effect electrode, poled in the reverse direction as a diode, permits a field effect control of the reverse current.
The many operating possibilities of the structure corresponding to the invention render the latter suitable e.g. as a test structure, for example for a quality check on SOS wafers.
Although various minor modifications may be suggested by those versed in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon, all such embodiments as reasonably and properly come within the scope of my contribution to the art. | A semiconductor device is disclosed in which an intrinsic or weakly doped semiconductor layer is arranged on a substrate. The semiconductor layer contains a first P doped zone and a first N doped zone which are separated by a portion of the said intrinsic layer serving as base zone. The semiconductor layer further contains a second P doped zone and a second N doped zone which are also separated from one another by the base zone. The four doped zones are arranged such that a connecting line between the second P doped zone and second N doped zone intersects a connecting line between the first P doped zone and the first N doped zone preferably at right angles. A sub-diode formed of the first doped zones affects the operation of a sub-diode formed by the second doped zones. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to the field of digital electronic memory devices, and in particular to a built-in apparatus and method for enhancing reliability by monitoring repair solution consistency.
Since users generally depend upon the reliability of integrated circuit chips for their own systems to function properly, it is common practice for the chip manufacturers to test the functionality of chips at the manufacturing site before the chips are sold to users. As the line width within a integrated circuit chip continues to shrink, this reliability becomes more difficult to achieve. An ongoing challenge for the manufacturers is to increase circuit density without sacrificing reliability or suffering decreasing chip yields due to malfunctioning parts.
Thus, before memory chips are released for shipment they typically undergo testing to verify that the support circuitry for the memory array and the individual circuitry for each of the memory cells within the memory array is functioning properly. One standard way for testing chip memories involves using an external memory tester or Automatic Test Equipment (ATE) at the manufacturing site. An external memory tester supplies power and applies test patterns to the chip to detect faults. External memory testers can only test a limited number of chips at a time, and the test speed is limited by the external bus speed. Consequently, this method of testing is expensive in terms of time requirements and equipment costs.
Partly to address these issues, and partly to provide off-site testing, built-in self-test (BIST) units are now commonly incorporated into memory chips. Automated test equipment can now be simplified to the extent that the only necessary functions are to supply power (and sometimes a clock signal) to the memory chip, and to monitor a single output signal from the chip. The on-board BIST unit generates all the test patterns and asserts (or de-asserts) the output signal if the chip passes the functionality test. The BIST can be configured to run every time the chip is powered-on, or the BIST may be configured to run only when a test mode signal is asserted.
The BIST unit operates by writing and reading various patterns to/from the memory to determine various kinds of memory faults. In general, a BIST unit writes a data value to a memory cell and subsequently reads the memory cell. By comparing the data written and the data subsequently returned from the memory cell, the BIST unit is able to determine whether the memory cell is faulty. If too many errors are detected, then the fault may exist in the support circuitry.
It is not uncommon for a significant percentage of the memory cells within the chip to fail because of defects in the substrate or errors in the manufacturing process. To compensate for this, many memory chips are provided with a set of extra memory cells that can be used in place of the defective ones. Configuring the memory chip to replace the defective cells is termed “Repairing” the memory array. Some memory repair is performed at the manufacturing site. Conventional repairing techniques bypass the defective cells using fuseable links that cause address redirection. However, these techniques require significant capital investment for implementing the repairing process, and moreover fail to address the possibility of failure after shipment from the manufacturing facility.
To reduce repair costs and allow field repairs, some memory chips have been equipped with built-in self test (BIST) and built-in self repair (BISR) circuitry. The BIST circuit detects faults in the memory array and notifies the BISR circuit of the fault locations. The BISR circuitry generally reassigns the row or column containing the failing cell to a spare row or column in the memory array. BIST and BISR are typically performed each time power is applied to the system. This allows any latent failures that occur between subsequent system power-ups to be detected in the field.
Occasionally, the faults that occur in a memory chip are condition-sensitive. For example, some faulty cells may operate normally at power-up, but cease functioning under normal operating conditions. Other faults may be sensitive to the power supply voltage level. While BIST and BISR circuitry can compensate for these problems, changes in fault patterns of a chip are undesirable and may be symptomatic of underlying manufacturing problems. Consequently, it is desirable to provide a method of screening chips at the factory to detect fault pattern changes.
SUMMARY OF THE INVENTION
Accordingly, there is disclosed herein a memory device configured to detect changes in fault patterns. In one embodiment, the memory device includes a memory array, a built-in selftest (BIST) unit, and a built-in self-repair (BISR) unit. The BIST unit runs test patterns on the memory array to identify faulty locations in the array. A comparator within the BIST or external to the BIST compares the actual output of the memory array to the expected output, and asserts an error signal whenever a mismatch occurs. The BISR unit intercepts addresses directed to the memory array, and operates on the addresses in three distinct phases. During a training phase, the BISR unit stores the intercepted addresses when the error signal is asserted. During the normal operation phase, the BISR unit compares all intercepted addresses to stored addresses and redirects a corresponding memory access if any intercepted address matches a stored address. During a verification phase, the BISR unit compares intercepted addresses designated by assertions of the error signal to the addresses previously stored in the training phase. If the faulty intercepted address fails to match a stored address, the BISR unit asserts a “new error” signal. If at the end of the verification phase, a stored address has not matched any intercepted faulty address, the BISR asserts a “missed error” signal.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 depicts a functional block diagram of a memory equipped with BIST and BISR according to one embodiment;
FIG. 2 depicts a functional schematic diagram of a first BISR embodiment that detects changes in fault patterns;
FIG. 3 depicts a functional schematic diagram of a FLARE module; and
FIG. 4 depicts a functional block diagram of a BISR component for detecting changes in fault patterns.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
In the following description, the terms “assert” and “de-assert” are used when discussing logic signals. When a logic signal is said to be asserted, this indicates that an active-high signal is driven high, whereas an active-low signal is driven low. Conversely, de-assertion indicates that an active-high signal is driven low, and that an active-low signal is driven high. As used herein, the term “BIST” refers to the actual test, while “BIST unit” and “BIST circuitry” refer to the circuitry that performs BIST. Similarly, “BISR” refers to the process of built-in self repair, while “BISR unit” and “BISR circuitry” refer to the circuitry that performs BISR.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the figures, FIG. 1 shows a memory 100 having a set of signal lines that includes an address bus (ADDR), a read/write line (R/{overscore (W)}), a bi-directional data bus (DATA), a test mode bus (TMODE), and a fail line (FAIL). A set of multiplexers 104 , 106 , and 108 allows a BIST unit 110 to take control of the ADDR, R/{overscore (W)}, and DATA lines, respectively, when the TMODE bus includes an asserted test signal. The ADDR lines from multiplexer 104 connect to BISR circuit 112 , and from there to an address decoder in memory array 118 . When provided with an address, the address decoder asserts a word line to access cells in memory cell array 118 that correspond to the value on the address lines. If the R/{overscore (W)} line is asserted, the data from the accessed cells is driven onto the DATA lines. Otherwise, the binary values on the DATA lines are stored into the accessed cells.
BISR circuit 112 is provided to detect and block addresses of faulty cells, and to assert a replacement word line to access redundant cells to replace the faulty cells in the memory cell array. The BISR 112 circuit is preferably also configured to detect changes in fault patterns. The BISR circuit 112 may be considered as an undivided unit 112 or as a memory unit 116 and a remapping unit 114 . In one embodiment of the invention is shown in terms of an undivided BISR unit 112 , and a second embodiment is shown in terms of memory unit 116 . Both embodiments are discussed further below.
When a test signal is asserted, the BIST unit 110 takes control of the ADDR, R/{overscore (W)}, and DATA lines, and conducts a pattern of read and write operations designed to detect faults in the memory cell array. During write operations, the BIST unit 110 supplies test data to the memory cell array on the DATA lines. During read operations, the BIST unit 110 receives data from the memory cell array and compares it to the expected output data. When a mismatch is detected, BIST unit 110 asserts an error signal line (ERR).
Referring momentarily to FIG. 2, the BISR unit 112 includes a counter 202 which increments an error count every time the ERR line is asserted. Counter 202 also produces an overflow signal (OVFL) that is asserted when the number of detected errors exceeds the number of redundant memory words available. Upon detecting assertion of the OVFL signal, BIST unit 110 (FIG. 1) ceases testing and holds the FAIL line in an asserted state. If the testing completes without assertion of the OVFL signal, BIST unit 110 de-asserts the FAIL line.
In memory 100 , the repair unit 112 is configured to remap faulty rows as they are detected. Consequently, faulty rows are replaced by potentially un-initialized rows in the middle of testing. The BIST unit 110 prevents the potentially incorrect values stored in a replacement row from manifesting as an error in any subsequent accesses to the address where the error was detected. In one embodiment, the BIST unit 110 is configured to write a suitable value to the address after the replacement occurs and before proceeding with the testing. In another embodiment, the BIST unit 110 tracks the faulty addresses and disables the result comparisons during subsequent reads from the faulty addresses. In yet another embodiment, the BIST unit 110 re-starts the test after a row is replaced. In any case, the FAIL signal should not be de-asserted until the BIST unit 110 has performed a complete test without detecting any faults. Accordingly, if one or more faults is detected and repaired during a test, the BIST unit should repeat the test to verify the functionality of the repairs.
Memory 100 may alternatively be configured to allow BIST unit 110 to locate all the defects in memory cell array 118 before attempting any repairs. This configuration allows for determination of an optimal remapping solution when both columns and rows are being replaced, but requires a significantly more complex BIST unit implementation.
The phase of operation in which the BIST locates faults and configures the BISR to remap the faulty addresses to redundant memory locations is hereafter referred to as the training phase of the BISR unit. At some point subsequent to the training phase, the BIST unit will conduct a fault pattern verification test. In the fault pattern verification test, the BIST unit 110 will repeat its actions of the training phase. However, the BISR unit 112 retains some memory of the faults detected in the training phase, and compares them the faults detected by the BIST unit 110 in the fault pattern verification phase. Any difference between the sets of detected faults is identified by the BISR unit 112 .
Referring now to FIG. 2, BISR unit 112 receives address bus ADDR, test mode signal (MODE\), error signal ERR, and remap signal REMAP. The MODE\ signal is active low, and is asserted low during the verification phase to verify fault pattern consistency. The remainder of the time (during the training phase and during normal operation), the MODE\ signal is de-asserted (high) to allow training of the BISR circuit and remapping by the BISR circuit. During training, the BISR circuit stores the addresses of detected fault locations. The BIST unit asserts the ERR signal during detection of a faulty address, and REMAP signal is asserted to cause the repair circuit 112 to remap those faulty addresses it has stored. In response to these signals, the BISR circuit provides a filtered address bus FADDR, redundant word line signals RWLx, a new error detect signal (ERRNEW), and a missing error detect signal (ERRMISS). The BISR circuit either passes the ADDR bus value on to the FADDR bus, or the BISR circuit blocks the value if the value matches a stored faulty address and asserts one of the RWLx signals to replace the faulty location. The ERRNEW signal is asserted if a new, unlatched error is found, and the ERRMISS signal is asserted if one or more previously latched errors are not found by a subsequent BIST.
Repair circuit 112 includes counter 202 , decoder 204 , a series of stages (one for each redundant word in the memory), and logic gates 206 , 208 . Counter 202 provides an error count to decoder 204 . Decoder 204 asserts a signal line to the signal stage that corresponds to the error count value (an error value of zero causes the signal line to the first stage to be asserted).
Each of the stages can be understood in terms of four functional blocks: storage block 210 , comparison block 220 , filter block 230 , and tracking block 240 . Storage block 210 includes logical AND gate 211 , address latch 213 , and status latch 215 . Logical AND gate 211 receives the MODE\ signal, the ERR signal, and a signal from decoder 204 . If all three are high, i.e. the BISR is being trained, an error is detected, and the decoder 204 is asserting the signal line for the current stage, the logical AND gate 211 provides a clock transition to address latch 213 and status latch 215 . The address latch 213 stores the value on address bus ADDR, and the status latch 215 goes high to indicate that an address has been latched in the current stage.
Comparison block 220 includes logical AND gate 221 , inverter 223 , P-type transistor 225 , N-type transistor 227 , and inverted XOR gate 229 . Logical AND gate 221 receives the REMAP signal, the output of the status latch 215 , and an inverted blocking signal from a preceding stage. If all three are asserted, i.e. BISR remapping is enabled, an address is latched, and the preceding stage is not blocking the ADDR bus, then gate 221 asserts a switch signal.
Before the switch signal is asserted, transistor 225 couples an inverted address latch signal from inverter 223 to inverted XOR gate 229 . Since the other input of the inverted XOR gate 229 is the non-inverted address latch signal, this causes the inverted XOR gate 229 to register a mismatch and drive a match signal low. After the switch signal is asserted, transistor 225 isolates the inverter from inverted XOR gate 229 and transistor 227 couples the ADDR bus signal to inverted XOR gate 229 . This causes inverted XOR gate 229 to drive the match signal high only if the ADDR bus signal matches the latched address signal. If the MODE\ signal line is de-asserted (i.e. high) to indicate training or normal operation, the match signal is coupled to a redundant word line by a transistor 228 .
Filter block 230 includes bypass transistor 231 , stage input transistor 233 , delay chain 235 , and blocking transistor 237 . The ADDR bus is coupled to bypass transistor 231 , and when the switch signal from comparison block 220 is de-asserted, the signals on the ADDR bus are routed through to the FADDR output bus. When the switch signal is asserted, the bypass transistor 231 stops conducting and stage input transistor 233 couples the ADDR bus signals via delay chain 235 to blocking transistor 237 . Blocking transistor 237 receives the inverted blocking signal from logical NAND gate 239 , and when the blocking signal is asserted (low), the blocking transistor 237 isolates the ADDR bus signals from the FADDR output bus. The blocking signal is asserted only when the comparison block drives the match signal high and the MODE\ signal is not indicating a fault pattern verification phase.
Tracking block 240 includes a logical AND gate 241 , a tracking latch 243 , and a second AND gate 245 . Logical AND gate 241 receives the match signal from inverted XOR gate 219 , an inverted MODE signal, and the error signal. If all are high, i.e. if an error is detected at a location that matches the latched address while in the pattern verification phase, logical AND gate 241 clocks tracking latch 243 , causing it to latch a “hit” signal high. Second AND gate 245 normally provides an asserted “miss” signal if the status latch is high and the tracking latch is low, but when the tracking latch goes high, the miss signal is turned off.
Logic gate 206 is a NOR gate coupled to receive the MODE\ signal, an inverted ERR signal, and the match signals from each stage. Only if these are all simultaneously low, i.e. the ERR signal is asserted during the pattern verification stage and none of the match signals is asserted, is the ERRNEW signal asserted to indicate the detection of an error not found in the training phase. Logic gate 208 is a logical OR gate coupled to receive the miss signals from each stage. If any of the miss signals remains asserted after the end of the pattern verification phase, then an error detected in the first phase did now occur in the second phase, and the continued assertion of the ERRMISS signal indicates this.
Moving now the second embodiment, FIG. 3 shows a modular element of a BISR circuit memory module 116 . The element 302 is configured to store faulty address locations and compare the stored faulty addresses with newly-detected faulty addresses. Element 302 includes a multiplexer 304 , an address latch 306 , a reserve latch 308 , and a compare gate 310 . Multiplexer 304 receives a output signal from the reserve latch, an input signal (IN), and an input select signal (ISEL). The output of the multiplexer 304 is provided as an input (D) to address latch 306 . Address latch 306 also receives a shift input signal (TI), a shift enable signal (TE), a clock signal (CLK), and a reset signal (RESET). When the shift enable signal (TE) and the reset signal (RESET) are de-asserted, a clock pulse causes the address latch 306 to store the value of the input signal (D) and provide it as output signal (OUT). When the shift enable signal (TE) is asserted and the reset signal is de-asserted, a clock pulse causes the address latch to store the value of the shift input signal (TI). Assertion of the reset signal causes the output signal to be reset low.
Reserve latch 308 receives the output signal from the address latch and a reserve clock signal (RCLK). A pulse in the reserve clock signal causes the reserve latch 308 to store the output signal from the address latch. If the ISEL signal is subsequently de-asserted and the CLK signal pulsed, the contents of the reserve latch 308 may be moved back to the address latch 306 . Compare gate 310 performs an exclusive-OR comparison of the contents of the address and reserve latches, and drives a match signal (MATCH) low if they are the same.
FIG. 4 shows how the modular elements are coupled together. Each of the N bits (IN0 through INN-1) in an address are directed to a corresponding module 302 . During a training phase, the ISEL signal is asserted, the TE signal and the RESET signals are de-asserted. As a faulty address is detected, it is latched into address latch 306 (FIG. 3) by a pulse of the CLK signal. The configuration of FIG. 4 can only store a single faulty address, but multiple copies of this configuration may be provided to allow for storing multiple faulty addresses. At the end of the training phase, the faulty address bits are moved to the reserve latch 308 (FIG. 3) by a pulse of the RCLK signal, and the RESET signal is asserted to clear the address latches.
During the verification phase, the faulty address bits are again latched into the address latch 306 . If the faulty addresses stored in the training phase match the faulty addresses stored in the verification phase, all of the MATCH\ output signals will be asserted low, and all-zero detector 402 asserts a pass signal (PASS) to indicate this. Otherwise, one or more of the MATCH\ signals is de-asserted, causing the all-zero detector 402 to de-assert the PASS signal.
The OUT signal from each module 302 is coupled to the shift input signal of the subsequent module. This forms a shift chain that allows the latch contents to be scanned out for off-chip examination. To shift the address latch contents out via the SOUT output, the shift enable signal TE is asserted, and the CLK signal is repeatedly pulsed. Once the address latch contents have been completely shifted out, the contents of the reserve latches can be moved to the address latches (by de-assertion of the TE and ISEL signals and a pulsation of the CLK signal) and similarly scanned out for off-chip examination.
Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, while the description is directed to memory arrays, the BIST and BISR units are readily adaptable to other reconfigurable electronic systems having redundant portions. It is intended that the following claims be interpreted to embrace all such variations and modifications. | A memory device configured to detect changes in fault patterns is disclosed. In one embodiment, the memory device includes a memory array, a built-in self-test (BIST) unit, and a built-in self-repair (BISR) unit. The BIST unit runs test patterns on the memory array to identify faulty locations in the array. A comparator within the BIST or external to the BIST compares the actual output of the memory array to the expected output, and asserts an error signal whenever a mismatch occurs. The BISR unit intercepts addresses directed to the memory array, and operates on the addresses in three distinct phases. During a training phase, the BISR unit stores the intercepted addresses when the error signal is asserted. During the normal operation phase, the BISR unit compares all intercepted addresses to stored addresses and redirects a corresponding memory access if any intercepted address matches a stored address. During a verification phase, the BISR unit compares intercepted addresses designated by assertions of the error signal to the addresses previously stored in the training phase. If the faulty intercepted address fails to match a stored address, the BISR unit asserts a “new error” signal. If at the end of the verification phase, a stored address has not matched nay intercepted faulty address, the BISR asserts a “missed error” signal. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 07/298,534 filed Jan. 18, 1989, now abandoned.
FIELD OF THE INVENTION
This invention relates to compositions of polyglycols with hydrofluorocarbon and hydrochlorofluorocarbon refrigerants which are useful for lubricating heat pumps and air conditioning compressors.
Refrigerant R12 (dichlorodifluoromethane) is used in automotive air conditioners and many other types of refrigeration and air conditioning compressors. It is a chlorofluorocarbon that has been identified as depleting atmospheric ozone. The Montreal Accord restricts the production of R12 by 1990. Refrigerant R134a (1,1,1,2-tetrafluoroethane) has a vapor pressure that is very similar to R12 and it has the advantage that it does not deplete atmospheric ozone. R134a can replace R12 in most refrigeration systems without major redesign of present equipment. It could be used in automotive air conditioners without any or with minor re-tooling by the automotive companies.
The major problem of using R134a is that conventional lubricants such as naphthenic mineral oils are not soluble over the temperature range -20° to 80° C., the operating temperatures encountered in the different refrigeration applications. Some polyglycols are soluble in R134a at 25° C. and below but phase separate below 60° C. Phase separation of the lubricant from the refrigerant can cause poor lubrication of the compressor which results in increased wear and decreased compressor life. It is well known in the refrigeration industry that lubricant concentration in the refrigerant is limited to the preferred range of about 10 to 20 weight % due to thermodynamic considerations. However, a range of 1 to 25 weight % is considered to be useful in this invention.
The usefulness of this invention is that it will enable compressor manufacturers to substitute R134a and other hydrofluorocarbons or hydrochlorofluorocarbons for chlorofluorocarbons such as R12 in most compressors without mechanical modification to existing compressors and be able to operate over a broad temperature range.
DESCRIPTION OF THE PRIOR ART
The fundamentals of lubrication in air conditioners are set forth by H. H. Kruse et al. in "Fundamentals of Lubrication in Refrigeration Systems and Heat Pumps" pages 763-783: ASHRAE Transactions Vol 90 part 2B (1984). This reference is incorporated by reference herein.
Lubricants for various refrigeration compressors are U.S. Pat. No. 4,248,726. This patent shows polyether polyols or polyglycols with functionalitied of 1 to 6 are useful as refrigeration lubricants with various refrigerants such as R11, R12, R22 and the like. The polyglycols can have free OH groups or can be ether or ester capped and they contain an acid scavenging additive package. These fluids must have a viscosity of 50 to 200 cs at 98.8° C. and a viscosity index of at least 150. The focus of this patent is an additive package that prevents the degradation of the high viscosity polyglycols in a rotary type refrigerators. The high molecular weight polyglycols of this patent are insoluble in R134a at 25° C.
U.S. Pat. No. 4,267,064 shows essentially the same invention as the above U.S. Pat. No. 4,248,726 except that the '064 patent discloses and teaches the use of polyether polyols having viscosities of 25 to 50 cs at 98.8° C. The high molecular weight polyglycols of this patent are insoluble in R134a at 25° C.
U.S. Pat. No. 4,755,316 discloses compositions containing one or more polyether polyols for lubricating refrigeration compressors using R134a. However, it has been found (control D) that the polypropylene glycol based on trimethylolpropane mentioned in the patent is unexpectedly inferior to the polyglycols used herein.
Lubricants for various refrigeration compressors are also known from Japanese patent J57051795. This patent suggests that a high molecular weight polypropylene glycol based on glycerine might be useful as a refrigeration lubricant. However, the upper solution critical temperature of this glycol is not adequate as can be seen from Control E herein.
SUMMARY OF THE INVENTION
The invention comprises polyether polyol lubricant compositions with hydrofluorocarbon and hydrochlorofluorocarbon refrigerants which have upper solution critical temperatures equal to or greater than 60° C. In general, the compositions consist of
(A) a refrigerant selected from the group consisting of hydrofluorocarbons and hydrochlorofluorocarbons, and
(B) a polyether polyol which has a viscosity of greater than 80 centistokes at 38° C. and the formula
Z--[(CH.sub.2 --CH(R.sub.1)--O--).sub.n --(CH.sub.2 --CH(CH.sub.3)--O--).sub.m --H].sub.p
where
Z is the residue of an active hydrogen compound selected from the group consisting of glycerine, pentaerythritol, sorbitol, ethylene diamine, diethylene triamine, hydrazine. ethanolamine, diethanolamine, triethanolamine, isopropanolamine, diisopropanolamine and triisopropanolamine,
R 1 is hydrogen, ethyl, or mixtures thereof,
n is 0 or a positive number,
m is a positive number,
n+m is a number having a value which will give a polyether polyol with a number average molecular weight range from about 400 to about 2000,
p is an integer having a value equal to the the number of active hydrogens of Z.
The polyol lubricant compositions have a preferred upper solution critical temperatures in the range from about 65° C. to about 110° C.
The polyether polyols have a preferred viscosity in the range from about 90 to about 800 centistokes at 38° C.
DETAILED DESCRIPTION OF THE INVENTION
Examples of the polyether polyols or polyoxyalkylene polyols used in this invention are those derived from ethylene oxide, propylene oxide, 1-2, or 2-3 butylene oxide. The above oxides may be polymerized alone, i.e., homopolymerized or in combination. The combined oxides may also be combined in a random or block addition. While some of the above compounds may be of a hydrophilic nature, those of a hydrophobic nature are preferred, such as those derived from propylene oxide, butylene oxides or combinations thereof.
Examples of suitable polyoxyalkylene glycols are those derived from ethylene, propylene, and butylene oxides wherein the alkylene oxides are initiated from a compound having 3 to 6 active hydrogens in a known manner. These polyether polyols and their preparation are well known from the book "Polyurethanes" by Saunders and Frisch, lnterscience Publishers (1962), pages 33-39. This book is incorporated by reference herein.
Examples of suitable initiator compounds which are employed to prepare the above polyether polyols are compounds having 3-6 active hydrogens such as for example, glycerine, pentaerythritol, sorbitol, ethylene diamine. diethylene triamine, hydrazine, ethanolamine, diethanolamine, triethanolamine, isopropanolamine, diisopropanolamine and triisopropanolamine.
The foregoing polyether polyols should have a number average molecular weight range from about 400 to 2000 and preferably in the range 400 to 1500.
The final lubricant compositions of this invention may contain effective amounts of ashless additives, such as antioxidants, corrosion inhibitors, metal deactivators, lubricity additives, extreme pressure additives and viscosity index improvers as may be required.
Examples of useful ashless antioxidants which can be used herein are phenyl naphthylamines, i.e., both alpha and beta-naphthyl amines; diphenyl amine; iminodibenzyl; p,p-dibutyl-diphenylamine: p,p'-dioctyldiphenylamine; and mixtures thereof. Other suitable antioxidants are hindered phenolics such as 6-t-butylphenol, 2,6-di-tbutylphenol and 4-methyl-2,6-di-t-butylphenol and the like.
Examples of suitable ashless metal corrosion inhibitors are commercially available, such as Irgalube 349 from Ciba-Geigy. This inhibitor compound is an aliphatic amine salt of phosphoric acid monohexyl ester. Other useful metal corrosion inhibitors are NA-SUL DTA and NA-SUL EDS from the White Chemical Company (diethylenetriamine dinonylnapthalene sulfonate and ethylene diamine dinonylnaphthalene sulfonate) and N-methyl oleosarcosine, respectively.
Examples of suitable ashless cuprous metal deactivators are imidazole, benzimidazole, pyrazole, benzotriazole, tolutriazole, 2-methyl benzimidazole, 3,5-dimethyl pyrazole, and methylene bis-benzotriazole.
An effective amount of the foregoing additives for use in a air conditioning compressor is generally in the range from 0.1 to 5.0% by weight for the antioxidants, 0.1 to 5.0% by weight for the corrosion inhibitors, and 0.001 to 0.5 percent by weight for the metal deactivators. The foregoing weight percentages are based on the total weight of the polyether polyols. It is to be understood that more or less of the additives may be used depending upon the circumstance for which the final composition is to be used.
Examples of refrigerants useful in this invention are hydrochlorofluorocarbons such as chlorodifluoromethane, chlorofluoromethane, 2,2-dichloro-1,1,1-trifluoroethane, 1-chloro-1,2,2,2-tetrafluoroethane, 2-chloro-1,1,2,2-tetrafluoroethane, 1-chloro-2,2,2-trifluoroethane, 1,1-dichloro-1fluoroethane and 1-chloro-1,1-difluoroethane.
Other examples of refrigerants useful in this invention are hydrofluorocarbons such as 1,1,1,2-tetrafluoroethane, 1,1-difluoroethane, 1,1,1-trifluoroethane, 2,2-difluoroethane, trifluoromethane, methylene fluoride, methyl fluoride, difluoroethylene and pentafluoroethane.
The general procedure for the preparation of the controls and the examples of present invention with the refrigerant R134a is set forth below. The data is given in the following Table.
The selected polyol is vacuum stripped. Glass ampules are washed with acetone and vacuum dried at 110° C. The empty ampule or tube is weighed and the mixture to be evaluated is syringed into the tube. The tube is re-weighed to determine the weight of lubricant. The tube is evacuated to remove air and then immersed in a dry ice/methylene chloride slurry in a Dewar flask. The R134a is transferred at a pressure of 8 psig into the tube to give the desired lubricant concentration. The filled ampule was then disconnected and allowed to equilibrate at room temperature, 25° C. The ampules were placed in a controlled temperature bath and the temperature varied from -20° to 85° C. while observing for phase separation. The temperature of phase separation is called the upper solution critical temperature (USCT) and is reported in degrees C. Temperatures above 85° C. were not investigated because of pressure limitations of the glass ampule apparatus. Systems with USCT's above this temperature measurement limit are denoted as greater than 85° C.
TABLE______________________________________R134a Upper Solution Critical Temperature Data Lubricant-Neat Lubricant Viscosity- Wt % USCTRun Number (in cs @ 100° F. or 38° C.) in R134a °C.______________________________________Control A n-butanol + PO to 1170 16 60 Mol Wt-57 csControl B Propylene glycol + PO to 12 <25 2000 Mol Wt-160 csControl C Propylene glycol + PO to 25 70 1000 Mol Wt-73 csControl D Trimethylol propane + PO 16 52* to 720 Mol Wt-133 csControl E Glycerine + PO to 22 <25** 3000 Mol Wt-230 cs viscosity index 180Example 1 Glycerine + PO to 700 16 78-80 Mol Wt-108 csExample 2 Ethylene diamine + PO to 15 >85 511 Mol Wt-753 csExample 3 Ethylene diamine + PO to 15 70 951 Mol Wt-263 cs______________________________________ * This control which is similar to the TPF740 example of U.S. Pat. No. 4,755,316 (Magid et al.) shows that the lubricant has a USCT value that i too low. ** This control which is similar to the examples of U.S. Pat. No. 4,267,064 (Sasaki et al.) and U.S. Pat. No. 4,2448,726 (Uchinuma et al.) shows that high molecular weight lubricants have a USCT value that is muc too low. | A refrigeration fluid compositions for compression refrigeration which have an upper solution critical temperature equal to or greater than 60° C. are composed of (A) selected hydrochlorofluorocarbons and hydrofluorocarbons and (B) polyether polyols having viscosities of greater than 80 centistokes at 38° C. and having a number average molecular weight from about 400 to about 2000 wherein the polyols are the residue of an active hydrogen compound such as glycerine or ethylene diamine. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to pulp and paper making apparatus and in particular to pressurized disc-type refiners for reducing wood chips and like materials to pulp.
2. Brief Description of the Prior Art
One type of apparatus used in the production of wood pulp is the so called pressurized disc-type refiner. In this type of apparatus a pair of opposed parallel discs having attrition elements on their adjacent faces are adapted for relative rotation with respect to each other and are enclosed in a pressurized housing. The discs may each to be rotated in opposite directions, or one disc may be fixed while the other is rotated.
Wood chips or like material to be refined are usually introduced between the plates at their centers and are refined by being advanced across the closely spaced attrition elements by centrifugal force and generated steam. Free steam is generated by this refining process, and adjacent to the outer peripheral edge of the discs the refined material is discharged along with this steam through a port in the refiner.
This steam is typically at a pressure from about 15 to 200 pounds per square inch. Thus, it may be used for a number of heating purposes in the paper mill such as for heating the drying rolls on a paper machine. It is, of course, necessary that this high pressure steam be separated from the reduced fibrous material before it can be used in this manner, and several devices are presently in use for this purpose. Centrifugal devices such as a standard centrifugal cyclone are, for example, commonly employed to effect such separation. In an alternative kinetic energy device, a fan impellar enclosed in a pressurized housing throws the heavier fibrous material to the outer perimeter of the housing from where it is then discharged. The lighter steam recovered passes through the center of the housing from where it is recovered for use elsewhere in the paper will.
It will be appreciated that the above described means for separating steam from fibrous material require certain auxiliary equipment which may be costly both in terms of its initial procurement and the plant space which it then consumes. It is, therefore, the object of the present invention to provide a means for separating high pressure steam from fibrous material which avoids these disadvantages.
SUMMARY OF THE INVENTION
In the present invention, an integral steam separator is incorporated into a pulp refiner apparatus. In this apparatus, a conventional pressurized, disc-type refiner is equipped with a second fluid conveying means which diverges from the fluid conveying means containing the stream of steam and refined fibrous material which is discharged from the discs. Means fixed to a rotating disc for impeding the entrance of refined fibrous material into this second fluid conveying means are provided adjacent the mouth of this second fluid conveying means so that the steam removed in this second fluid conveying means is substantially free of refined fibrous material and is suitable for use as high pressure steam elsewhere in the paper mill. A preferred means for impeding the entrance of refined fibrous material into this second fluid conveying means is a plurality of fins positioned adjacent the mouth of this second fluid conveying means and on the outer periphery of a rotating disc. Considerable centrifugal force would be generated by the rotating disc. Thus it would be unlikely that significant amounts of the particulate fibrous material would enter the second fluid conveying means since any solids tending to follow the gas component in that direction would have to overcome that centrifugal force.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is further described with reference to the accompanying drawing which is a vertical cross sectional view of a pressurized disc-type refiner apparatus embodying the present invention.
DETAILED DESCRIPTION
Referring to the drawing, a pressurized refiner generally designated 10 as shown includes a base 12 supporting a pressurized housing 14. Within the refining chamber 16 defined by the housing 14 are disposed a first and second parallel spaced refiner discs 18 and 20.
Disc 18 rotates about its central horizontal axis while disc 20 is stationary. It will be understood, however, that the invention described herein can be readily adapted to refiners in which both discs are rotatable. Refining plates 22 and 24 are fixed, respectively, to the confronting faces of discs 18 and 20. As can be seen in the drawing, disc 18 is of solid, substantially unperforated construction.
The plates, which conventionally comprise precisely machined and balanced sets of plate segments, are characterized by attrition elements such as ribs or teeth on their working faces.
The disc 20 is secured by bolts 26 to the housing 14 and is thus fixed in position within the refining chamber 16. The disc 18 is mounted on one end of the drive shaft 28 for rotatin therewith. To vary the spacing between the plates 22 and 24 and hence the refining action of the plates, the shaft 28 is axially adjusted as will be presently described. Material to be refined is introduced axially between the refining plates through the axial inlet passage 30 and is discharged from the refining chamber through the radial discharge fluid conveying passageway 32.
The shaft 28 is journaled by roller bearing 34, ball bearing 36 and thrust bearing 38 within a quill 40 which is slidably disposed on quill support members 42 and 44 of the base. Rotation of the quill is prevented by keys 46 cooperating with keyways 48 in the quill, the keys being spring loaded by springs 50 disposed within the spring retainer assemblies 52 attached to the quill supported members.
The quill 40 and hence the shaft 28 and attached disc 20 and plate 24 are axially positioned by means of a positioning device 54 mounted on the base 12. In the present instance, the positioning device comprises a motor driven worm acting on the threaded positioning stud 56 secured to the arm 58 attached to the outer end of the quill 40. The keyways 48 are elongated to permit a predetermined range of axial movement of the quill and shaft. The shaft extends beyond the quill and the base and is connected with a suitable power source such as an electric motor (not shown).
It should be understood that the above described features of a pressurized, disc-type refiner apparatus are essentially conventional and do not in themselves describe the invention herein. Other equivalent arrangements to accomplish the above described functions are also possible.
Referring again to the drawings, it will be noted that a second fluid conveying passageway 60 diverges from the first fluid conveying passageway 32. This second fluid conveying passageway connects the first fluid conveying passageway 32 with an orifice 73 on the outside of the pressurized housing 14 which is, in turn, connected with a tube 64. It will also be noted that a plate 66 having a central orifice 68 is positioned across the first fluid conveying passageway 32. Circumferentially arranged around the outer peripheral edge of the rotating disc 18 there are a plurality of radial fins as at 70 and 72. It will be noted that these fins are positioned so that as disc 18 rotates past the opening of the second fluid conveying passageway so as to centrifugally impede the entrance of heavy refined fibrous material into the second fluid conveying passageway. The entrance of the lighter steam into the second fluid conveying passageway will not, however, be sufficiently impeded by these moving fins so that steam entering this passageway from the first fluid conveying passageway will be substantially free of fibrous refined material. This clean, high pressure steam will thus be suitable for use in other parts of the paper mill. The path of this stream from the first fluid conveying passageway 32 to the second fluid conveying passageway then into the tube 64 and through orifice 73 for transport to other parts of the paper mill is shown in the broken line in the figure. It will be appreciated that the relative amount of steam diverted from the first fluid conveying passageway 32 into the second fluid conveying passageway 60 will be controlled by selecting particular relative sizes for the orifices 73 and 68. Normally sufficient steam for transporting the discharged refined material would be maintained in the first fluid conveying passageway 32 while steam in excess of that required for transport of the refined fibrous material would be diverted to the second fluid conveying passageway 60.
Although the invention has been described herein with a certain degree of particularity, it is to be understood that the present disclosure has been made only as an example and that the scope of the invention is defined by what is hereinafter claimed. | A pressurized disc type refiner having parallel discs housed inside a pressurized chamber and a fluid conveying passageway for removing refined fibrous material entrained in steam is equipped with a second fluid conveying passageway. Fins on the one of the rotating discs impede the entrance of refined fibrous material into the second passageway by centrifugal force so that the steam conveyed in that passageway will be substantially free of entrained fibrous material. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of sealing joints, in particular those that ensure sealing at the level of and around a movable element, such as a shaft, an axle or the like, driven by a rotational movement and extending in or through a passage, a housing, an opening or the like of a stationary body, element, casing or the like.
2. Description of the Related Art
More particularly, the invention relates to a sealing joint comprising, on the one hand, a support ring or frame (generally made of steel plate) with an external axial flange and an internal radial flange, and, on the other hand, a washer made of a TEFLON®-based sealing material, which is mounted or arranged on said ring, by at least partially covering the external surface of the axial flange and extending beyond the inner end of the radial flange in such a way as to form a flexible sealing lip. This lip is designed to be applied circumferentially against or on an element that is to be sealed, in particular a rotational cylindrical element such as a shaft or the like, with said sealing lip then having a first annular portion that for the most part rests on the element that is to be sealed and a second annular curved connecting portion (connecting the first end portion of the lip to the part of the washer made integral with the radial flange of the ring).
Such a joint is known in particular by the documents WO 2008/009317 and US 2003/0031828 (FIG. 5 a ).
These joints ensure, with the same washer, a double-seal, namely both an internal dynamic seal relative to the movable element (by means of the flexible sealing lip that is not supported by the ring) and an external static seal relative to the wall of the housing or the mounting opening, through which the element that is to be sealed generally passes (by means of the washer part present on the external surface of the axial flange).
However, the sealing joints disclosed by these two documents have at least the following two drawbacks:
1) A lifting of the free end of the sealing lip whose effect is negative in terms of maintaining tightness and sealing behavior is noted, in particular when this lip rests on the element that is to be sealed over a great length (significant axial distance);
2) These joints are not suitable for withstanding pressure (problem of sealing behavior at the level of the element that is to be sealed when the medium that is to be isolated contains pressurized liquid, typically between approximately 1 and 10 bar), because of a low resistance to deformation, and even a possible turning of the sealing lip when the latter is subjected to pressure (for example, in applications such as sealing pump shafts).
To attempt to remedy these two drawbacks, the document US 2002/0117810 proposes a sealing joint whose sealing lip has a significant thickness and is subdivided radially into a primary sealing lip, coming to rest on the element that is to be sealed, and a secondary elastic support lip.
This secondary lip comes (in the absence of significant pressure) into contact with the free end (tip) by exerting a support force stressing this end against the element that is to be sealed and thus combating its separation and its lifting.
In addition, when the medium that is to be isolated is subjected to pressure, the primary and secondary lips are superposed tightly and together form a single lip of great thickness that can withstand pressure without turning.
However, although providing satisfaction when the lip/element contact area has a short distance, this solution is complex structurally and its achievement is difficult (requiring a precise cutaway of the lip, double-machining of the primary and secondary lips).
In addition, the material cost is high, taking into account the large thickness of the bottom lip, and the friction forces between the lip and the movable element are increased.
Finally, in the document US 2002/0117810, the external static seal (between joint and housing) is obtained by using a second sealing material.
BRIEF SUMMARY OF THE INVENTION
This invention has as its object to remedy at least the above-mentioned major drawbacks by proposing a simple solution, easy to implement and economical.
For this purpose, the invention proposes a sealing joint of the above-mentioned type, improved and in particular suitable for withstanding pressure, whereby this joint is characterized in that the sealing lip has a small thickness, typically less than 0.8 mm, and forms, in the absence of stress, essentially a sleeve or tapered ring with a peak angle of 90°−α, with a being between 10° and 50°.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood using the description below, which relates to preferred embodiments, provided by way of nonlimiting examples and explained with reference to the accompanying diagrammatic drawings, in which:
FIG. 1 is a cutaway view of a sealing joint according to a first embodiment, in the absence of any stress;
FIG. 2 is a cutaway view similar to the sealing joint of FIG. 1 after its mounting in a housing and around the element that is to be sealed (shaft);
FIG. 3 is a partial cutaway view of a sealing system of a fuel pump comprising a sealing joint as shown in FIGS. 1 and 2 ;
FIGS. 4 and 5 are partial cutaway views of a sealing joint in the mounted state, according to two other design variants of the first embodiment of the invention;
FIGS. 6 to 8 are partial cutaway views of a sealing joint in the mounted state, according to three design variants of a second embodiment of the invention, and
FIG. 9 is a partial cutaway view of the joint of FIG. 8 , in the absence of stress (before mounting).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1, 2 and 4 to 8 show a sealing joint 1 , in particular for pressurized liquid. This joint 1 comprises, on the one hand, a support ring or frame 2 with an external axial flange 3 and an internal radial flange 4 , and, on the other hand, a washer 5 made of a TEFLON®-based sealing material, which is mounted or arranged on said ring 2 , by at least partially covering the external surface 3 ′ of the axial flange 3 and by extending beyond the inner end 4 ′ of the radial flange 4 in such a way as to form a flexible sealing lip 6 . The latter is designed to be applied circumferentially against or on an element 7 that is to be sealed, in particular a rotational cylindrical element such as a shaft or the like, with said sealing lip 6 then having a first annular portion 6 ′ that for the most part rests on the element that is to be sealed and a second annular curved connecting portion 6 ″.
In accordance with the invention and as FIG. 1 shows more specifically, the sealing lip 6 has a small thickness EL, typically less than 0.8 mm, and forms, in the absence of stress, essentially a sleeve or tapered ring with a peak angle of 90°−α, with a being between 10° and 50° ( FIGS. 1 and 9 ).
In other words, and as FIG. 1 shows, the peak angle AS=90°−α is between 40° and 80° (with α being the angle relative to the plane perpendicular to the central axis of symmetry of the joint 1 ).
The inventors noted that in an unexpected and surprising way, a sealing joint 1 of the type indicated above, whose lip 5 had the two above-mentioned technical arrangements, did not experience the phenomenon of lifting of the end of the lip 6 , even when the contact area 9 has a significant axial dimension.
In addition, the specific initial inclination (inherent to the washer 4 ) of the sealing lip 6 , before its being applied against the element 7 that is to be sealed, relative to the central axis of symmetry of the joint 1 (generally combined with the axis X of rotation/symmetry of the element 7 ), on the one hand, and relative to the part 5 ′ of the washer 5 tightly applied on the inner end 4 ′ of the radial flange 4 (angle α), on the other hand, simultaneously ends in a preconditioning of the lip 6 increasing its resistance to a turning in the case of pressure application from the side toward which the lip 6 is originally inclined.
Of course, the connection between the lip 6 and the part 5 ′ of the washer 5 does not have a clean folding line, but rather a curved transition area 8 .
More specifically, and according to an advantageous arrangement of the invention, the sealing lip 6 , preferably in the form of a tapered sleeve with an essentially flat wall in the absence of stress, is connected to the part 5 ′ of the washer 5 that rests on and/or is made integral with the radial flange 4 , by a precurved or inflected annular region 8 of the washer 5 , advantageously located immediately after the inner end 4 ′ of said radial flange 4 , oriented in the direction of the medium MLS that is to be sealed and being part of the annular connecting portion 6 ″.
The region 8 is thus formed in the washer 5 (in the form of permanent local deformation of the wall of the latter) during the production of the sealing joint 1 (preferably by deformation during the engagement of the washer 5 with the ring 2 ) and constitutes a start of the curving of the connecting portion 6 ″ during the mounting of the joint 1 on the element 7 .
Consistent with a preferred practical embodiment of the invention, making it possible according to the inventors to respond in an optimized manner to the above-mentioned drawbacks, while limiting the costs and avoiding complicating the design and the process of production of the joint 1 (in particular relative to the production process described in the above-mentioned document WO 2008/009317), it is advantageously provided that the thickness of the sealing lip 6 is between 0.4 and 0.7 mm, preferably between 0.45 and 0.65 mm, and that the angle α is between 15° and 45°, preferably between 20° and 40°. In addition, the precurved region 8 is advantageously shaped by local deformation of the wall of the washer 5 , before or after mounting on the carrying ring 2 .
So as to ensure a seal of sufficient quality for meeting final application requirements, in particular under pressure, the relative dimensions and arrangements of the support ring 2 , of the washer 5 that is made of a TEFLON®-based material, and the element 7 that is to be sealed can be determined for defining an area 9 for tight contact and support of the portion 6 ′ of the sealing lip 6 on said element 7 with an axial distance P (in the direction X) of between 1.5 and 5.0 mm, preferably between 2.5 and 3.5 mm, from the free edge 6 ′″ of said lip 6 .
Despite this significant distance, the inventors noted that the respect for the above-mentioned geometric arrangements could make it possible to prevent the phenomenon of lifting of the end 6 ″ and to provide an increased resistance to turning (folding of the lip 6 and passage under the radial flange 4 ).
The portion 6 ′ of the lip 6 can comprise a smooth support surface (contact area 9 ) and generally has a thickness that is essentially constant (although a variation of the thickness based on conditions of use can be considered).
Nevertheless, according to an additional characteristic of the invention, not shown in detail in the accompanying figures (only diagrammatically in FIG. 2 ), the sealing lip 6 can comprise, at the level of the contact surface of the portion 6 ′ of this lip 6 designed to come to rest on the element 7 that is to be sealed, a delivery structure 10 that is helical or in the form of threading, advantageously in the form of a groove with opposite sides of inclinations or different slopes, preferably with a cross-section or profile that is asymmetrically triangular in shape.
Such a structure 10 can, for example, be of the type of the one that is described in the PCT patent application No. PCT/FR2012/050239 and in the French patent application No. 12 51011 of Feb. 3, 2012, in the name of the applicant.
In addition, as shown in FIGS. 1 to 4 and 6 to 8 , it can also be provided that the sealing washer 5 extends beyond the free edge 3 ″ of the axial flange 3 and forms a projecting part 11 , inclined or curved toward the interior and covering at least the outside ridge of said free edge 11 .
The projecting part 11 thus forms a bevel connected to the frontal ridge for the introduction of the joint 1 into its housing 14 , facilitating its centering and preventing any separation of the washer 5 relative to the axial flange 3 during the tightened or adjusted mounting of the joint 1 .
So as to ensure preservation of the dynamic seal in the event of high pressure, to prevent damage to the sealing lip 6 in the case of pressure peaks (in particular repeated), and to rule out any turning of said lip 6 , the joint 1 can also comprise or include a specific annular structure 12 for support and reinforcement for the sealing lip 6 located on the side opposite to the medium MLS that is to be sealed and extending at the level of the curved annular portion 6 ″ of said lip 6 by partially assuming the shape of this portion 6 ″ and by being separated from the latter.
As emerges from the accompanying FIGS, the lip 6 is not made integral with this structure 12 , nor rests against it in the absence of sufficient pressure on said lip 6 (presence of a wedge-shaped gap 12 ″ between 12 and 6 except in FIG. 3 because of the presence of sufficient pressure). This absence of engagement makes it possible to ensure that the lip 6 has great flexibility and an appropriate ability to adapt to possible radial movements or dissymmetry of the mobile element 7 that is to be sealed.
It is further noted, by comparing, for example, FIGS. 1 and 2 , that the size of this gap 12 ″ increases when the lip 6 comes to rest on the element 7 , this because of the forced bending of the portion 6 ″ resulting in a more accentuated curving and therefore in a more significant separation between 6 ″ and 12 (in the absence of pressure on the lip 6 by the medium that is to be sealed).
The result is a good adaptability of the lip 6 (to the relative movements between ring 2 and element 7 ) despite the presence of the rigid structure 12 .
Consistent with an advantageous embodiment of the invention, the annular structure 12 for support and reinforcement consists of a curved circumferential flange, with the curving radius of said flange 12 being greater than the curving radius, in the absence of pressure, of the annular connecting portion 6 ″ of the sealing lip 6 after installation of the sealing joint 1 around the element 7 that is to be sealed, preferably greater than the curving radius of the precurved annular region 8 of the washer 5 , in the absence of stress on the sealing lip 6 .
Preferably, the annular structure 12 for support and reinforcement, in the form of a circumferential flange, extends up to a short distance D from the element 7 that is to be sealed, with the free edge 12 ′ of the flange 12 being located at a distance from said element 7 that is less than the thickness EL of the sealing lip 6 , preferably less than at least half of said thickness EL, and even on the order of one-quarter or one-third of this thickness (function also of the uniformity of the surface and the movement of the element 7 ).
The flange 12 can then also act as a dust-barrier screen, etc., in combination with the component 2 or 13 of which it is part.
In accordance with a first embodiment of the invention, of which different variants are illustrated in FIGS. 1 to 5 of the drawings, the structure 12 for support and reinforcement is part of a second ring 13 that comprises at least one radial flange 13 ′ extended from the inner side by a curved annular flange portion 12 forming said structure.
The second ring 13 can be assembled in different ways (mechanically, adhesively, materially, or by a combination of several engagement methods) with the ring 2 and/or the washer 5 , and then forms with the latter a composite sealing joint 1 with three constituent components.
The second ring 13 preferably also comprises an axial flange 13 ″ for its mounting with retention in the housing 14 simultaneously with the ring 2 (the rings 13 and 2 are preferably produced from the same material).
Although not shown, a sealing material can optionally be installed on this flange 13 ″ (on its surface in contact with the housing 14 ).
In an advantageous manner, at least the part 5 ′ of the washer 5 arranged on the radial flange 4 of the support ring 2 is sandwiched between the latter and the radial flange 13 ′ of the second ring 13 , optionally ensuring mechanical clamping of said washer part 5 ′.
The second ring 13 can even interlock elastically tightened on the support ring 2 with sandwiching of the washer 5 ( FIG. 4 ).
As FIGS. 1 to 5 show, the flange 12 accompanies the lip 6 beyond the end 4 ′ of the radial flange 4 and can even participate in or support the precurving of the region 8 at the level of its transition with the part 5 ′ of the washer 5 , without, however, being made integral with this lip 6 .
In accordance with a second embodiment of the invention, of which several variants are illustrated in FIGS. 6 to 8 , the structure 12 for support and reinforcement is an integral part of the support ring 2 and consists of a portion of curved flange extending the radial flange 4 on the inside.
The result is thus a simple joint construction 1 , not requiring an additional component, while providing the above-mentioned advantages.
The support ring 2 can have different shapes. In particular, the same basic shape can be broken down into several variants according to the dimensions of the housing 14 , the desired rigidity, the available space requirement, or the local configuration ( FIGS. 6 to 8 ).
According to a practical variant embodiment, suitable in particular for applications in relation to chemically aggressive liquids, the shape of the ring 2 and the relative arrangement of the washer on this ring can be provided in such a way that said washer 5 covers all of the surfaces of the support ring 2 that are directed, on the one hand, toward the pressurized medium MLS, and, on the other hand, toward the wall 14 ′ of the mounting housing 14 of the sealing joint 1 , against which the axial flange 3 of the support ring 2 comes to rest in an airtight manner.
Finally, for the purpose of ensuring the behavior of the mounting of the joint 1 in the housing 14 , even in the case of significant thermal variations, the invention can provide that the support ring 2 and, if necessary, the second ring 13 , is (are) made of an HLE-type plate, as specified in the PCT and French patent applications of the applicant.
Of course, the invention is not limited to the embodiments described and shown in the accompanying drawings. Modifications are possible, in particular from the standpoint of the composition of the various elements or by substitution of equivalent techniques, without thereby exceeding the scope of protection of the invention. | A gasket, in particular for a pressurized liquid, includes: a support ring ( 2 ) having an axial flange ( 3 ) and a radial flange ( 4 ); and a PTFE washer ( 5 ) arranged on the ring ( 2 ), the washer at least partially covering the outer face ( 3′ ) of the axial flange ( 3 ) and forming a flexible inner sealing lip ( 6 ) intended to be applied against an element to be sealed, such as a shaft. The sealing lip ( 6 ) includes an annular portion bearing mostly on the element to be sealed and a curved annular connecting portion. The sealing lip ( 6 ) has a small thickness (EL), typically less than 0.8 mm, and, in the absence of stress, substantially forms a frustoconical ring or sleeve having a vertex angle of between 40° and 80°. | 5 |
BACKGROUND OF THE INVENTION
Reuse or recycling of old asphalt pavement is much in vogue these days. The old pavement is first removed and sized to produce an aged mix or "RAP", as it is often called. To produce a recycled mix the RAP is then combined with fresh or virgin aggregate, "VAM" as it too is often called, and new liquid asphalt, all typically in apparatus of the drum mixer nature. One of the problems inherent in this type of apparatus is to prevent the hot flame of the burner from firing or coking the old asphalt in the RAP before the latter joins the VAM and the fresh asphalt. Not only does coking of the old asphalt damage it but also produces excessive clouds of odious smoke forbidden by environmental regulations. Consequently, the almost universal practice nowadays is to introduce the RAP at a point well downstream of the burner in order to shield the RAP as much as possible.
One technique of performing this is described in U.S. Pat. No. 4,165,184 to Schlarmann in which a cylindrical inner drum extends part way down the main drum through its upstream end, the flame of the burner and the VAM entering the inner drum while the RAP enters the annular space between the two drums. The RAP is thus shielded from direct contact with the flame until it joins the VAM well downstream of the burner. Added advantages are that the RAP is heated by the hot exterior surface of the inner drum before it joins the VAM and the lesser diameter of the inner drum increases the "veil" of VAM across the flame in order further to protect the RAP. The Schlarmann arrangement performs well enough in many instances, but it was later discovered that if the plant is operated at high production rates it is difficult to get sufficient VAM through the inner drum owing to its lesser diameter. At the same time the consequent increased air velocity through the inner drum tends to entrain too many fines from the VAM. Furthermore, it turned out that if the plant is operated with RAP quantities in excess of fifty percent or so of the total, the proportionately lesser quantity of VAM reduced its screening effect or "veil" across the inner drum enough so that the RAP, even though not exposed to direct flame until well downstream of the burner, was nevertheless inadequately protected from coking.
Subsequent to Schlarmann there appeared the earlier of two versions of a recycle drum mixer combining in effect the Schlarmann principle and that, for example, of U.S. Pat. No. 3,999,743 to Mendenhall. In the latter patent the RAP is introduced midway or so down the drum through circumferentially spaced feed ports through the drum wall, the ports being enveloped by a shroud within which scoops attached to the drum revolve. That earlier version of a recycle drum mixer just referred to likewise features similar feed ports and an enveloping shroud intermediate the ends of the drum but also includes a short conical inner drum disposed with its smaller end directed downstream. The RAP entering the feed ports falls upon the larger upstream end of the inner drum which abuts the inner wall of the outer drum. As in Schlarmann the RAP is thereupon heated and falls off the downstream end of the inner drum to join the heated VAM, the RAP being thereby shielded from the burner by the inner drum until that occurs. No flighting is used on either the interior or exterior of the inner drum. Also, as in Schlarmann, the smaller downstream end of the inner drum increases the density of the "veil" of the VAM across the burner flame just upstream of the junction of the VAM and the RAP. However, only one side wall of the shroud concerned is stationary, its remaining side and circumferential walls being fixed to and revolving with the drum. Not only is sealing between the stationary and revolving parts of the shroud consequently more difficult, but the RAP must enter the shroud through its stationary side wall. This is accomplished by a feed chute that opens into the shroud tangentially. Thereupon, a series of angled flights carried by the outer drum and the two revolving walls of the shroud direct the RAP into the feed ports from which it falls onto the inner drum. However, since those flights are fixed to the revolving portions of the shroud there is no cleaning action by them upon the two walls involved which thereby can become caked with RAP. Furthermore, the RAP entering the shroud must make two right angle turns, first from the feed chute through the stationary side wall of the shroud and then from the interior of the latter into the feed ports.
In the later version of the same apparatus, flighting is provided on the interior, but not on the exterior, of the inner drum, the feed chute is moved to atop the stationary shroud side wall, and the angled flights are omitted. Instead, a series of angle blades attached to the revolving circumferential wall of the shroud and aligned with the edges of the feed ports are relied upon to direct the RAP into the ports. While this arrangement eliminates the second right angle turn the RAP must take in the earlier version yet caking of the interior of the shroud and the lack of self-cleaning action are still present. Furthermore, in both versions any RAP which does not immediately fall into the feed ports when it enters the shroud must then be carried around within the shroud during one or more revolutions of the drum which also adds to wear and caking of the shroud. And, since no flighting is used on the exterior of the inner drum, in either version, considerable RAP, instead of moving downstream of the inner drum, slides circumferentially of the latter directly into the bottom of the outer drum, impairing its heating and mixing with the VAM.
Returning now to the Mendenhall patent mentioned above and others of his, see for example, U.S. Pat. No. 4,215,941, the shroud about the feed ports is stationary. The scoops revolve within the shroud, pick up the RAP introduced into the shroud, carry it around the latter, and finally dump it into the feed ports, causing considerable wear as well as caking on the interior of the shroud since the RAP travels nearly the entire circumference of the shroud before entering the ports. A later modification of that approach is shown in U.S. Pat. No. 4,147,436 to Garbelman et al. in which the scoops are replaced with paddle-like devices called "funnels" and the feed ports equipped with hinged covers which prevent material in the bottom of the drum from falling back into the shroud through the ports. This avoids some of the previous wear and caking of the shroud but the covers often stick, are themselves subject to wear from the VAM passing over them as it joins the RAP and besides are relatively cumbersome and expensive. Another variation of the Mendenhall approach also uses a stationary shroud but fits chutes to the ports which angle back along the inner wall of the drum in a trailing direction relative to its rotation. But these chutes too are subject to high wear by the passing VAM which in addition can fall back through the chutes into the shroud. Moreover, in all the arrangements just mentioned the shroud must seal against the hot surface of the drum since the area of the latter concerned is not shielded from the burner flame. Nor is there any heating or shielding of the RAP before it joins the VAM.
SUMMARY OF THE INVENTION
The present invention constitutes a different approach to feeding the RAP medially into a drum mixer. A conical inner drum and a stationary shroud are employed, but the RAP enters the shroud tangentially through its circumferential wall where it falls directly into one or more of a series of "hoppers" formed about circumferentially spaced feed ports through the outer drum. These "hoppers" are formed by a pair of annular side walls within the shroud bounding the upstream and downstream edges of the feed ports and by a series of skewed deflectors, the side walls and deflectors revolving with the drum. The deflectors extend between the annular side walls and between the circumferential wall of the shroud and the trailing edge (with respect to the direction of drum rotation) of the feed ports. Consequently, little if any RAP can fall into the bottom of the shroud, and the little that does so is prevented from caking the interior of the shroud by appropriate "scrapers" secured to the annular side walls and one or more of the deflectors. In addition, the shroud if formed in three parts bolted together so that it can be easily removed for interior cleaning if necessary. Finally, the exterior as well as the interior of the inner drum is provided with flighting to direct the RAP in a downstream direction over the exterior surface of the inner drum and so prevent it from sliding circumferentially of the latter into the bottom of the outer drum. The interior flighting of the inner drum closely adjoins that on the interior of the main or outer drum so that there is no interruption of flighting and hence heat transfer through the area in which the RAP is introduced. The flighting on the exterior of the inner drum in turn increases heat transfer to the RAP from the inner drum and improves its mixing with the VAM emerging from the interior of the latter drum.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a drum mixer fitted with the recycle apparatus of the present invention.
FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1, certain parts being further broken away to illustrate the relationship of the feed ports to the deflectors.
FIG. 3 is a perspective view of the medial portion of the drum mixer of FIG. 1, certain parts being broken away and others omitted for better clarity and understanding of the invention.
FIG. 4 is a detail perspective view illustrating the manner in which the interior of the shroud is kept clean.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drum mixer 10 depicted in FIG. 1 consists essentially of an outer cylindrical drum 11 rotated about its axis by a motor 12. Virgin aggregate ("VAM") is introduced at 13 at the upstream end 14 of the drum 11 adjacent the burner 15 which injects its flame axially in a downstream direction. Fresh asphalt is added at 16 and the recycled mix exits the drum 11 through a chute 17 at its downstream end 18. The entire interior of the drum 11 is fitted with successive sets of flighting 19 and 20, some of which are shown in FIG. 3, which when the drum 11 is inclined by elevating the forward end of the base frame 21, serves to move material through the drum 11 in a downstream direction. All of this and other details of the construction and operation of the mixer 10, apart from those pertaining particularly to the invention itself, are conventional and well-known so need not be further described.
The mid-point or so of the drum 11 is apertured to provide a series of circumferentially spaced feed ports 25 (see FIGS. 2 and 3), a total of 8 being used in the embodiment concerned. Each feed port 25 includes a leading edge 26 parallel to the drum axis and a trailing edge 27, preferably skewed as shown with respect to the drum axis, the terms "leading" and "trailing" being used here and later with regard to the direction of drum rotation indicated by the arrow R. The remaining edges of the ports 25 are bounded by a pair of annular side walls 28, secured to the drum wall 11, between which are fixed a series of deflectors 29. The latter are equal in number to the feed ports 25 and are of plate form, having leading and trailing ends 30 and 31. Each deflector 29 is also skewed, as shown in FIGS. 2 and 3, and its trailing end 31 adjoins the trailing edge 27 of its respective port 25. The side walls 28 and deflectors 29, which thereby form a kind of "hopper" around each feed port 25, revolve with the drum 11 in a channel formed by a stationary annular shroud 32 carried by the base frame 21, the deflector leading ends 30 closely abutting the inner circumferential wall of the shroud 32 and the latter being sealed to the drum wall 11 by appropriate annular lip seals 33 (see FIG. 3). Aged mix ("RAP") enters the shroud 32 tangentially, as shown in FIG. 2, on that side of the drum where the deflectors 20 are ascending during drum rotation. A hopper 34 is provided for this purpose and leads down into the shroud 32 through a chute 35 and an appropriate opening 32a in the circumferential wall of the shroud 32. The lower end of the chute 35 is provided with a pair of inclined baffles 35a (only one being shown in FIG. 2) to direct the RAP between the annular side walls 28. The outboard face of the chute 35 is fitted with a RAP bypass chute 36 and a gate 37 hinged at 38 to swing as indicated by the arrow in FIG. 3 so as to close off entry into the shroud 32 and divert the RAP down the bypass chute 36. The chute 36 is used in connection with calibrating the conveyor feeding the RAP into the hopper 34. In order to provide for cleaning of the interior of the shroud 32 should that be necessary, the latter is preferably fashioned in three arcuate sections bolted together at 39 as shown in FIGS. 1 and 2.
Within the outer drum 11 is disposed a conical inner drum 40 in axial alignment with the former and closely abutting the adjacent drum flighting 19 and 20. The larger or upstream end 41 of the drum 40 abuts and is welded to the inner face of the drum 11 such that the feed ports 25 open onto the upstream portion of the drum 40, the downstream end 42 of the drum 40 thus being well inboard of the inner face of the drum 11. In the annular space thus formed a series of renewable triangular flights 43 are bolted to the outer face of the drum 40 and closely abut the inner face of the drum 11, the flights 43 being skewed as shown in FIG. 3 in the same manner as the feed port trailing edges 27, whence the leading and trailing ends 44 and 45 of the flights 43 correspond to the upstream and downstream ends 41 and 42 of the drum 40. There are preferably twice as many flights 43 as feed ports 25 and the former are arranged so that each port 25 straddles one flight 43, as shown in FIG. 3. Finally, the inner face of the drum 40 is equipped with short flighting 46, similar to the flighting 19. In order to cleanse the interior of the shroud 32 (see now FIG. 4) to the small extent that may be necessary, the leading end 30 of one deflector 29 (or more if necessary) is shortened and equipped with an appropriate scraper blade 47 bolted to its trailing face which engages the interior of the circumferential wall of the shroud 32. Adjacent the blade 47 the annular side walls 28 are oppositely notched at 48 and fitted with outboardly splayed brackets 49 to whose outer ends are secured scrapers 50 which engage the interiors of the side walls of the shroud 32.
Accordingly, RAP entering the hopper 34 and chute 35 passes into the shroud 32 through its opening 32a and is immediately directed into the feed ports 25 by the baffles 35a, the annular sidewalls 28 and the deflectors 29 as the latter pass the lower end of the chute 35, whence little if any RAP works its way into the bottom of the shroud 32 or needs be carried around a further time or times by the deflectors 29 before finally entering the ports 25. Once through the latter the RAP then falls onto the outer face of the inner drum 40 in the spaces between its flights 43, the latter preventing the RAP from sliding circumferentially around the drum 40 and into the bottom of the drum 11 directly below the drum 40. Instead, the RAP slides downstream along the flights 43, being thereby partially heated by the hot surface of the drum 40, and off its downstream end 42 to join the VAM exiting the interior of the drum 40 in a protective "veil" formed by the flighting 46. The fresh asphalt emitted at 16 is introduced into the combined RAP and VAM at the upstream end of the flighting 20 and after thorough mixing the recycled mix is discharged from the drum 11 through the chute 17.
Relative dimensions are not critical. As an example, for an outer drum of, say, 30 feet in length and 8 feet in diameter, the smaller diameter of the inner drum may be 51/2 feet and its slant height 31/2 feet. The number of feed ports and flights on the exterior of the inner drum may also be varied without departing from the invention. Hence, though the latter has been described in terms of a particular embodiment, being the best mode known of carrying out the invention, it is not limited to that embodiment alone. Instead the following claims are to be read as encompassing all adaptations and modifications of the invention falling within its spirit and scope. | A drum mixer for recycling old asphalt pavement features a stationary shroud enveloping a series of circumferentially spaced feed ports medially of the drum. The old pavement is introduced tangentially into the shroud and then into a series of "hoppers" within the shroud formed about the feed ports and revolving with the drum. The old pavement falls through the feed ports onto the exterior of a conical inner drum and is directed to the downstream end of the latter by flighting thereon where it joins virgin aggregate emerging from the interior of the inner drum. | 4 |
This is a continuation of application Ser. No. 354,387, filed May 19, 1989, abandoned.
This invention relates to apparatus for providing a controlled drainage of waste material from a toilet in an airplane. More particularly, this invention relates to apparatus which is operable under all weather conditions including freezing for providing a controlled drainage of waste material from a toilet in an airplane.
While an airplane is flying through the atmosphere at elevated temperatures such as approximately forty thousand feet (40,000'), the temperature inside the airplane is quite pleasant for the convenience of the passengers. Therefore, the passengers are able to relieve themselves of waste material in a toilet whose visible parts are at the ambient temperature inside the airplane. These visible parts include the toilet and the toilet bowl and the valve for flushing the material in the toilet bowl. When the toilet bowl is flushed by the operation of the valve, the waste material in the bowl passes to a waste storage tank. The waste storage tank may be exposed to the atmosphere outside of the airplane. At elevations such as approximately forty thousand feet (40,000'), the temperature of the atmosphere may be considerably below freezing.
When the airplane lands, the waste storage tank is drained during ground service by the operation of accessible drain couplings attached on the aircraft to the waste storage tank. Such drain couplings generally have a protective end cap over an outer opening. The end cap is removable so that a drain hose from a ground service cart can be coupled to the outer opening in the end cap. In addition to the end cap, the drain couplings include a drain valve or plug which is opened after the drain hose is attached. Since the airplane has often been subjected to freezing temperatures in the air and may even be subject to freezing temperatures on the ground, it has not been easy to open the valves so that the waste material in the storage tank can be drained.
After the storage tank has been drained of waste material, the maintenance or service personnel decouples the drain hose, closes or replaces the drain valve or plug and replaces and repositions the end cap over the outer opening in the drain coupling. In practice, sometimes the ground servicing personnel make errors, such as forgetting or incompletely closing or replacing the drain valve or plug or improperly repositioning the end cap. Such incomplete closure or replacement of the drain valve or plug or improper repositioning of the end cap may result from ice on these parts, either from the recent flight of the airplane in the atmosphere or the parking of the airplane on the ground.
Under the conditions discussed in the previous paragraph, the incomplete closure or replacement of the drain valve or plug and the improper repositioning of the end cap may occur even if the service personnel is conscientious. If the airplane is thereafter flown under such circumstances, there can be an unsanitary and even dangerous leakage or loss of the waste material from the storage tank and malfunction of the toilet system in the airplane.
The problems discussed in the previous paragraphs have existed for some time. Knowledge of these problems has also existed for some time and these problems have been considered to be serious in the aircraft industry. Because of this, a considerable amount of energy, and a significant expenditure of money, have been devoted to resolving these problems. In spite of this effort and money expenditure, the problems still persist.
This invention provides apparatus which overcomes the problems discussed above. The invention includes a valve assembly which is operable to close a storage tank for waste materials under all weather conditions including freezing. The valve assembly is also operable under all weather conditions including freezing to provide for an easy opening of the coupling to the waste storage tank so that the waste material in the tank can be quickly and efficiently cleaned from the tank.
In one embodiment of the invention, a valve assembly provides for a controlled flow of waste material from a toilet in an aircraft under all weather conditions including freezing. The valve assembly includes a first valve disposed within a hollow tube and manually movable between a first position sealing the tube against the passage of waste material and a second position providing for such passage.
The first valve includes first and second members and a plate manually rotatable within the tube between the first and second positions, the second member and the plate receiving a multiplied force from a further rotation of the first member to pivot to a position sealing the valve to the tube. An energy member associated with the second member facilitates the pivotable movement of the second member. Detents in the tube and at the end of the second member retain the plate in sealing relationship with the tube.
The valve assembly also includes a second valve mounted externally on the tube downstream from the first valve and manually rotatable between a first position sealing the tube and a second position opening the tube. The second valve includes a member for rotating, and then pivoting, the second member and the plate in the first valve from the second position to the sealed relationship with the tube when the second valve is rotated from the second position to the first position. The second valve includes a retainer in the tube and a mechanism on the valve for latching the second valve to the tube in the first position of the second valve.
As will be seen, the first and second valves operate on a redundant basis to assure the proper opening or closing of the coupling to the waste storage tank. -Furthermore, an additional safety factor is provided by disposing the first valve inside the drainage coupling and the second valve externally of the drainage coupling and by closing the second valve after the closing of the first valve. This safety factor is enhanced by providing for the closure of the first (or internal) valve by the closure of the external valve in case the first (or internal) valve has not been previously closed. This is effective in insuring the closure of the waste storage tank even if the service personnel has unintentionally failed to close the first valve or is unable to close the first valve because of ice. However, each of the first and second valves is constructed to provide for effective closure or opening even if such closure or opening is hampered by icy conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary simplified elevational view showing an attachment to a waste storage tank in an aircraft of a drain coupling assembly constituting one embodiment of this invention;
FIG. 2 is a perspective view from a position below the waste storage tank, as may be seen by aircraft service personnel, of the drain coupling assembly when installed in an aircraft toilet system and an access panel in the plane body is open but a drain endcap and a drain valve in the assembly are still closed;
FIG. 3 is an enlarged cross sectional view in elevation, taken substantially on the line 3--3 of FIG. 2, of the capped and closed drain coupling assembly of FIG. 2, but with the access panel in the closed position;
FIG. 4 is a cross sectional elevational view similar to that shown in FIG. 3 but shows the drain coupling assembly of FIGS. 2 and 3 with (a) the access panel in the open position and the drain endcap opened and hanging down and (b) a valve lock lever pushed down partially to release a valve lock without a valve plate being opened;
FIG. 5 is a cross sectional elevational view similar to that shown in FIGS. 3 and 4 and shows the drain coupling assembly of FIGS. 2-4 with (a) the access panel opened and drain endcap opened and hanging down and a drain hose attached and (b) the valve lock released and valve plate fully opened to enable waste fluid to flow downwardly through the hose from the waste storage tank;
FIG. 6 is a cross sectional elevational view similar to that shown in FIGS. 2-5 and shows the coupling assembly of FIGS. 2-5 during the simultaneous closure, by means of a handle lever, of the valve plate and the drain endcap associated with the drain endcap when blocking matter, such as ice, has made closure of the valve plate by the valve lock lever ineffective; and
FIG. 7 is a simplified schematic elevational diagram, as seen from a position similar to that shown in FIGS. 2-6, illustrating how the valve plate and the end plate are closed by the operation of the handle lever associated with the drain endcap when blocking matter, such as ice, has made closure of the valve plate by the valve lock lever ineffective.
DETAILED DESCRIPTION
FIG. 1 shows a drain coupling assembly generally indicated at 10, the parts of the assembly being generally made of a suitable durable metal such as stainless steel. The assembly 10 has a flange 12 attaching it to a portion of an aircraft structure 13. An upper cylindrical pipe or tube portion 14 of the assembly 10 is coupled to a drainpipe 15 of an aircraft toilet storage tank 16 constructed to retain waste 18. For example, a typical dimension for the tube portion 14 would be about four inches (4") in diameter, though the invention can be adapted for any suitable diameter. FIGS. 2 and 3 show how the drain coupling assembly appears when first viewed by ground service people after an access panel 24 in an outer plane body or faring 22 has been opened about a hinge 23 by releasing an access lock 26 (FIG. 2).
The upper cylindrical tube portion 14 has an annular raised portion or nipple 17 (FIG. 3) to facilitate coupling to the tank's drainpipe 15. The drain coupling assembly 10 also has a lower cylindrical pipe or tube 32 formed to facilitate a hose coupling, such as by having an annular raised portion or nipple 33.
The flange 12 has flange holes 30 (FIG. 2) to enable the flange to be bolted to the aircraft structure 13. To enable rotatable closure of the tube 32 by an endcap generally indicated at 34, a large, downward-projecting U-shaped bracket 36 (FIG. 3) is formed on the right side of the flange 12. The large bracket 36 has two hinge holes 37 at each lower end of the U-shaped portion through which is mounted an endcap hinge pin 38 retained in place by endnuts or the like. To enable attachment of an endcap latch, a smaller downward-projecting U-shaped bracket 40 (FIG. 3) is formed on the left side of the flange 12. The small bracket 40 has two hinge holes 41 at each lower end of a U-shaped portion through which is mounted an endcap latch pin 42.
The endcap 34 has a circular central cap portion 46 (FIGS. 3 and 6) formed with an upwardly-extending projection or cone 47 used for valve closing in a manner to be described below. At the rim of the central cap portion 46 is a U-shaped annular flange 48 adapted to accommodate a resilient O-ring or annular gasket 50. The annular gasket 50 is adapted to seal the endcap 34 to the bottom opening of the tube 32 when the gasket is pressed against the tube.
Extending from the right end of central cap portion 46 are two parallel arm portions 52, (FIGS. 2 and 3), each formed with an upward-extending tab 54 (FIG. 3) that has a hinge hole 56 in it to accommodate the endcap hinge pin 38. Thus, the central cap portion 46 is rotatably attached on the right about the hinge pin 38 in the large bracket 36 of the flange 12. Extending from the left end of the the central cap portion 46 are two parallel arm portions 58 (FIGS. 2 and 3), each formed with an upward-extending tab 60 has a hinge hole 62 in it to accommodate a handle hinge pin 63 retained in place by endnuts or the like.
During ground servicing, the endcap 34 is opened and closed by a handle lever 64 (FIGS. 2 and 3). The handle lever 64 is provided with a flat circular grip 66 at its free (right) end and is hingedly connected about the handle hinge pin 63 of the endcap 34 by an upward-projecting U-shaped bracket portion 68 at its other end, via hinge holes 70.
On the upward ends of the U-shaped portion of the bracket 68, above the hinge holes 70, are a parallel pair of latch recesses generally indicated at 72. The latch recesses 72 used to engage and disengage the right end of the endcap 34 from the latch pin 42 on the bracket 40. Each latch recess 72 has a latch cam surface defined by a cam ramp 74, a ramp peak 76, and a hinge-retaining hook 78. As shown in FIG. 3, when the endcap 34 is closed, it is secured against the bottom edge of the lower tube 32 by the hooking action of the hinge-retaining hook 78 around the endcap latch pin 42.
However, if the service person simply pulls down on the grip 66 of the handle lever 64, the left end of the endcap 34 will be smoothly released. This is because the handle lever 64 will rotate about the handle hinge pin 63, causing the ramp peak 76 of the latch cam surface 73 to ride up slightly over the latch pin 42 until the cam ramp 74 begins to engage and slide by the pin 42. This will "unhook" each latch recess 72 from the pin 42, releasing the left end of the endcap 34 so that it rotates downwardly about the endcap hinge pin 38 as a fulcrum. The partially released position of the endcap 34 is shown in FIG. 6 and the released position of the endcap 34 is shown in FIG. 5.
As shown in FIG. 5, it is a feature of the invention that the downwardly hanging open endcap 34 is conspicuous. Furthermore, the downwardly-hanging open endcap 34 blocks closure of the access panel 22. This makes it unlikely that the endcap 34 will be overlooked when open or ignored by ground service personnel when such personnel complete the draining of the toilet system and thereafter decouple a drain hose 79. Furthermore, since the endcap 34 is attached by the hinge pin 38, it cannot become lost, and it cannot be discarded by negligent or disgruntled ground personnel.
Removing the endcap 34 allows the drain hose 79 to be connected, after which the next step is to open an inner valve generally indicated at 80, which is closed in FIG. 3. To form the seal of the inner valve 80, an annular projection 82 protrudes inwardly from the inner wall of the upper tube portion 14 to engage a resilient sealing grommet 84 that has a sealing face 86 and a wall-contacting extension 88. The sealing face 86 engages a rotatably mounted valve disk plate or flap 90.
To be rotatable, the valve plate 90 has attached to it at the right two parallel orthogonal projections 92 pierced by concentric hinge holes 94. The wall of the lower cylindrical pipe or tube 32 is also traversed at its right by two concentric hinge holes 100 (FIG. 2), and these holes are extended on the front and back sides of the tube 32 by cylindrical hinge tube portions 102. The hinge holes 94 on the-projections 92 are aligned with the hinge holes 100 and the tube portions 102 (FIG. 2) in the tube 32 and the holes 94 and 100 and the tube portions 102 are of similar radius. A shaft 96 (FIGS. 2 and 4) of a hexagonal cross section passes through the holes 94 and 100 and the tube portions 102. The hexagonal shaft 96 is retained in place by endnuts or the like at each end. At the front end of the shaft 96, a valve handle 106 (FIGS. 2 and 4) with a grip tab 108 is attached so that turning the valve handle 106 rotates the hexagonal shaft 96.
At the left end, the valve plate 90 has attached to it a single orthogonal projection 104 (FIGS. 3 and 4) with a leftward-facing hole 107 through which passes a valve lock bolt 109 having a spring-biased bolt head 110. The bolt head 110 engages a lock catch 112 formed by upper and lower cylindrical rods 114 and 116, the latter being notched with a flat catch surface 116a. A bias spring 122 surrounds the bolt 109 and is trapped in compression between the left projection 104 and a spring stop pin 124 passing transversely through the bolt 109 at an intermediate position along its length. The effect of the spring 122 is to bias the bolt 109 towards the right.
At its right end, the valve lock bolt 109 has a yoke which is rotatably linked by a pin 121 to a driving arm 118. The arm 118 has a hexagonal hole that nonrotatably engages the hexagonal shaft 96. To open the inner valve 80, the service person pulls the valve handle 106 downwardly (counterclockwise in FIGS. 2 and 3). This turns the hexagonal shaft 96 counterclockwise and pivots the driving arm 118 until it retracts the valve lock bolt 109 to about the position shown in FIG. 4. The bolt head 110 is then no longer in the lock catch 112. Further pivotal movement of the valve handle 106 in the counterclockwise direction beyond this point causes the valve lock bolt 109 to jam in the hole 107 (there is a small hole tolerance) so that the rotation of the handle 106 rotates the valve plate 90 downwardly, opening the inner valve. This permits the waste fluid 18 to drain through the toilet drain coupling 10 and the hose 79.
Before explaining how the valve can be closed, the structure of the spring-biased bolt will be described. The left end of the valve lock bolt 109 (FIG. 6) is formed with a tubular hole to slidably accommodate a cylindrical shaft 128, at the left free end of which is a latch head 130. The latch head 130 has a cylindrical upper cam surface and a flat catch lower surface. A bias spring 136 surrounds the shaft 128 and is trapped in compression between the latch head 130 and the left end of the bolt 109. The effect of the spring 136 is to bias the shaft 128 towards the left to move the latch head 130 into engagement with the catch 112 defined by the rods 114 and 116. The travel of the shaft 128, and hence the latch head 130, is limited by a stop pin 142 passing transversely through the shaft 128 near its left end and a longitudinally extending travel slot 143 formed in the lock bolt 109.
When the aircraft storage tank 16 has been drained, the service person removes the hose 79 (FIG. 5) and pushes valve handle 106 upwardly (clockwise motion in FIGS. 3 and 4). This turns the hexagonal shaft 96 clockwise and rotates the driving arm 118, the lock bolt 109, and the valve plate 90 until the valve plate meets some resistance, such as by contact with the seal grommet 84. Further rotation of the valve handle 106 (FIG. 3 and 4) beyond this point causes the valve lock bolt 109 to be pushed leftward in the hole 107 as the driving arm 118 turns relative to the valve plate 90. If the angle of the lock bolt 109 is right, the flat catch surface 134 enters the lock catch 112, sliding against the flat catch surface 116a as shown in FIG. 3.
It may sometimes happen that the angle of the lock bolt 109 is not sufficient for the flat catch surface 134 to slide against the flat catch surface 116a, in which case the spring bolt head 110 does not enter the catch 112. This may result from an ice formation 135 on the resilient grommet 84 as shown in FIG. 6. When ice blocks closure of the inner valve defined by the plate 90, the grommet 84 and the tube 14, the cylindrical upper cam surface 132 (FIG. 6) of the spring biased bolt head 110 simply rides on the lower cylindrical surface of the lower cylindrical rod 116. The valve handle 106 is in the "closed" position, but the inner valve 80 is not closed.
As shown in FIG. 6, it is still possible for service personnel to close the endcap 34 even when ice blocks such closure. Using the handle lever 64 (FIG. 6), the endcap 34 is pushed upwardly to engage cam ramp 74 on the endcap hinge pin 42. When the lever 64 is pushed further upwardly, the hinge pin 42 rides the cam ramp 74 over the ramp peak 76 and becomes "hooked" in the hinge-retaining hook 78. The upward-extending projection or cone 47 on the endcap 34 is dimensioned so that, when the endcap 34 is closed by pushing on the lever 64, the top of the cone 47 pushes against the valve lock bolt 109, causing the spring biased bolt head 110 to retract sufficiently to pop into the lock catch 112.
FIG. 7 shows that a lever action is instrumental in causing the force f applied by the center of the cone 47 to be many times greater than that applied at the end of the handle lever 64. This can be estimated by equating the work performed on the lever 64 to the work performed by the cone 47. For example, suppose a force F is applied to the lever 64 which has a lever arm R to rotate it through a relatively large angle φ1. Then the work performed by the service person is approximately W =F×R×φ1. Now suppose that this causes the cone 47 to apply a force f over a shorter lever arm r, rotating through a relatively small angle φ2. Since the work performed in each case is the same, the ratio of forces will be:
f/F=(R×φ1)/(r×φ2)
For example, taking conservative ratios of R/r=2 and φ1/φ2=10, the ratio f/F=20. While the actual amounts will, of course, vary according to the dimensions selected and the exact shape of the latch cam 73, it is clear that there is a multiplier effect that facilitates crushing of any blocking ice, etc. so that the inner valve defined by the tube 14, the grommet 84 and the plate 90 can be closed.
The apparatus described above has certain important advantages. It provides a first valve internally disposed within the tube portion 32 and defined in part by the valve plate 90, the lock bolt 109 and the grommet 84. This valve is disposed at the upstream side of the tube portion 32. The seal between the valve plate 90 and the grommet 84 is produced by initially rotating the driving arm 118 manually in a clockwise direction to produce a corresponding rotation of the valve lock bolt 109 and thereafter rotating the driving arm manually in the clockwise direction to produce a pivotal movement of the lock bolt 109 relative to the driving arm 118.
As the lock bolt 109 pivots relative to the driving arm 118, it advances to the left in FIGS. 3 and 4 to become locked in the catch 112 between the rods 114 and 116. The advance of the lock bolt 109 into the catch 112 between the rods 114 and 116 is facilitated by the constraint produced in the bias spring 122 as the lock bolt is pivoted from one side of a straight line defined by the lock bolt and the driving arm 118 to a position on the other side of the straight line.
The initial rotation of the lock bolt 109 and the plate 90 in the clockwise direction causes the plate 90 to become rotated to a position close to the sealing relationship with the grommet 84. The subsequent pivotal movement of the lock bolt 109 in the clockwise direction, and accordingly the advance of the lock bolt 109 to the left in FIGS. 3 and 4, causes an increased force to be imparted to the lock bolt to produce a movement of the left end of the lock bolt into the catch 112 between the rods 114 and 116. This increased force facilitates the sealing of the valve defined by the plate 90 and the grommet 84 even when this sealing is impeded by ice on various parts of the valve including the lock bolt and the detent arrangement defined by the catch 112, the rods 114 and 116 and the left end of the lock bolt. The movement of the lock bolt 109 into sealing relationship with the catch 112 is facilitated by the constraint produced in the bias spring 122 during such pivotal movement of the lock bolt. It is also facilitated by the constraint produced in the spring 136 disposed on the shaft 128.
The valve defined by the tube 32, the gasket 50 and the end cap 34 is disposed externally of the tube downstream in the tube from the valve defined by the tube 32, the end plate 90 and the grommet 84. This provides a safety arrangement for assuring that the tube 32 will be closed against the flow of waste material from the waste storage tank 16. The valve defined by the tube 32, the end cap 34 and the gasket 50 is constructed to provide a positive opening and closure of the tube 32 even when there is ice on various parts of such valve including the tube, the end cap and the gasket.
The positive operation in opening and closing the valve is provided by including the handle lever 64, the latch pin 42 externally of the tube 32 and the latch defined by the can ramp 74, the ramp peak 76 and the hinge-retaining hook 78 at the end of the handle lever 64 opposite the end which is manually rotated. This positive operation is also facilitated by attaching the handle lever 64 to the endcap 34 at one end for pivotal movement relative to the hinge pin 63 on the endcap 34. The positive operation is also facilitated by attaching the end cap 34 to the hinge pin, the hinge pin being attached to the bracket 36 extending from the tube 32.
By pivoting the handle, lever 64 and latching the handle lever to the tube 32 at one end and pivoting the end cap at the other end in accordance with the pivotal and latching movements of the handle lever, a positive action is produced for sealing the end cap and the grommet 50 relative to the outer surface of the tube 32 even when this sealing is impeded by ice on various parts. This arrangement also facilitates the opening of the valve even when ice is formed on various parts in the valve.
As previously described, if the valve defined by the valve plate 90, the lock bolt 109 and the grommet 84 is inadvertently open at the time that it is desired for the valve to be closed, this valve may become closed simultaneously with the closing of the valve defined by the tube 32, the end cap 34 and the gasket 50. This results from the inclusion of the projection or cone 47 on the end cap 34 at the surface of the end cap facing the upstream direction of the tube 32. This projection or cone 47 engages the lock bolt 109, during the rotation of the end cap 34 in the direction to provide a seal with the gasket 50, to rotate and then pivot the lock bolt, and rotate the end plate 90, into a sealing relationship between the end plate and the gasket 50. This sealing relationship is facilitated by the mechanical advantage imparted to the projection or cone 47 to move the lock bolt 109 and the plate 90 in accordance with the rotational movement produced in the end cap 34.
Although this invention has been disclosed and illustrated with reference to particular embodiments, the principles involved are susceptible for use in numerous other embodiments which will be apparent to persons skilled in the art. The invention is, therefore, to be limited only as indicated by the scope of the appended claims. | A valve assembly provides for a controlled flow of waste material from a toilet in an aircraft under all weather conditions including freezing. The valve assembly includes a first valve disposed within a hollow tube and manually movable between a first position sealing the tube against the passage of waste material and a second position providing for such passage. The valve includes first and second members and a plate manually rotatable within the tube between the first and second positions, the second member and the plate receiving a multiplied force from a further rotation of the first member to pivot to a position sealing the valve to the tube. An energy storage member associated with the second member facilitates the pivotable movement of the second member. Detents in the tube and at the end of the second member retain the plate in sealing relationship with the tube. The valve assembly also includes a second valve mounted externally on the tube downstream from the first valve and manually rotatable between a first position sealing the tube and a second position opening the tube. The second valve includes a member for rotating, and then pivoting, the second member and the plate in the first valve from the second position to the sealed relationship with the tube when the second valve is rotated from the second position to the first position. The second valve includes a retainer in the tube and a mechanism on the valve for latching the second valve to the tube in the first position of the second valve. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a map display system suited for setting a route from an arbitrary starting point (or present point) to a goal (destination) and for easily designing the route to the goal.
2. Related Art
Navigation systems with map displays function to search the optimum route to the to thereby provide guidance to the destination along the searched route. For this function, there have been proposed a variety of systems for displaying the searched route on a map screen.
The navigation system of the prior art designs the route in accordance with the input, but its starting point is always determined by the information coming from the global positioning system (GPS), i.e., the present location.
To assist setting the destination, one navigation system allows manually scrolling of the map, by referring to lists of different genres or by calling up a point registered in advance. At the reception of the GPS signal at the vehicle, the direction and straight distance from the present location to the destination are then calculated and displayed. With reference to this display, the user selects the road and direction to be followed to the destination. In the VNS system having a searching function, on the other hand, if the destination is registered as above, an optimum route from the present location is automatically determined by a search to provide guidance to the destination by voice and picture. A navigation system of this type is disclosed in Japanese Patent Laid-Open No. 66131/1993, for example.
However, the system of the prior art cannot design a route while imagining an arbitrary starting point, i.e., a virtual starting point. In other words, the conventional system cannot design a route to the destination in advance by utilizing, as a starting point, a point apart from the present location. Thus, the route cannot be planned on the basis of an input arbitrary starting point and destination, i.e., two arbitrary points freely input.
In the prior art, moreover, an optimum route can be displayed, but the screen has to be manually scrolled along a road to be observed, when it is desired to confirm the route before the start of driving. The manual scroll sequentially moves the ahead screen in the selected direction while the button or joy stick of a controller or any of (generally) eight direction touch switches of the display is operated. However, manipulation of the controller or the like while watching the movement of the map displayed on the screen is troublesome.
In either case, the information is the straight distance, direction or recommended route from the present position, as detected from the GPS received information or the sensor information received at the vehicle, so that such systems are inconvenient for use when the route is to be planned from one arbitrary point to another arbitrary point.
Calculation of the required travel time may utilize intrinsic average speed data for various types of roads such as expressways or typical national roads with determination of the distances on the individual types of roads on the set route or route determined by search of the map data. Since, however, the aforementioned method is provided with only the average vehicle speed data intrinsic to the individual kinds of roads, the average speed may differ with the various conditions such as the number of intersections per unit distance, the number of lanes, the days of the week, the time of day, the degree of business activity and the number of curves, even for the same road such as an expressway or a trunk national road. This is a disadvantage in that the estimated travel time may significantly differ from the actual travel time.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a map display system which can easily design a route from an arbitrary starting point to a destination.
In order to achieve the object, according to a first aspect of the present invention, there is provided a map display system which comprises: point setting means for setting at least two arbitrary points; route setting means for setting a route between the two set points; display means for displaying the set route; scroll instructing means for scrolling the display screen displayed on said display means along the set route; and scroll control means for scrolling the display screen along the set route in response to the instruction of said scroll instructing means.
According to the present invention, the map display system described above may also have any of the following features:
(1) vehicle position display means for displaying the position of a vehicle on the route, to effect the scrolling with the vehicle position being fixed on the map display screen;
(2) calculation means for calculating the time period required for travel between the two points input by said point setting means, wherein said display means displays the calculated time period required for travel between the two points;
(3) input means for inputting a starting time; and
(4) calculation means for calculating elapsed time from the starting point input by said point setting means to the vehicle position on the route, wherein said display means displays the elapsed time period to the vehicle position on the route on the basis of the starting time.
According to an aspect of the present invention, there is provided a map display system which comprises: point setting means for setting at least two arbitrary points; route setting means for setting a route between the two set points; display means for displaying the set route; scroll instructing means for scrolling the display screen displayed on said display means along the set route; and scroll control means for scrolling the display screen along the set route in response to the instruction of said scroll instructing means, wherein said map display system has a navigation mode, in which information necessary for the navigation of a vehicle is detected to guide the vehicle along the set route, and a virtual run mode in which a virtual run is made for the set route by scrolling the map with the vehicle position being fixed.
According to the first aspect, the route setting means sets the route between at least the two arbitrary points set by the point setting means, e.g., between the virtual present point and the destination, and displays the set route on the map screen. In the case of a virtual run along the set route, if the instruction is made by the scroll instructing means, the display screen scrolls along the set route to simulate the vehicle running the route.
Since, the scrolling is accomplished with the vehicle position being fixed on the route on the map display screen, the map scrolling reference point is cleared to make the display screen more easily read.
In the display of the route information on the screen in the virtual runmode, on the other hand, the required travel time and the covered distance of the actual run can be accurately estimated to aid in selecting whether to take a route having toll roads or a route having general roads.
According to yet another aspect of the present invention, the system can be transported between the home and the vehicle. The designed course information is stored in the recording medium, and this medium can be read in advance, so that the drive plan may be made in advance while enjoying a simulated journey at home and can be easily used in the vehicle during actual driving.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a map display system according to the present invention;
FIG. 2 is a block diagram of hardware of the map display system according to the present invention;
FIG. 3 is a flow chart of an operating procedure and screen transition of the map display system according to the present invention;
FIGS. 4a, 4b, 4c and 4d show startup screens;
FIG. 5 illustrates one example of an entire route display screen;
FIG. 6 shows one example of a basic screen of the virtual run mode;
FIG. 7 shows one example of a route information screen;
FIG. 8 shows one example of a main menu display screen;
FIG. 9 shows one example of a point setting menu display screen;
FIG. 10 shows a search condition menu display screen;
FIG. 11 shows one example of a present position display screen for the entire route;
FIG. 12 shows one example of a speed setting screen;
FIG. 13 is a flow chart of the entire operating routine for the system;
FIG. 14 is a flow chart following the entire processing flow of the system shown in FIG. 13;
FIG. 15a is a flow chart of a destination setting routine;
FIG. 15b is a routine for calling a file by key strokes;
FIG. 16 shows a startup screen in the navigation mode;
FIGS. 17a and 17b shows a main menu display screens in the virtual running mode;
FIG. 18 shows a file calling display screen for selecting a file from the main menu;
FIG. 19 is a flow chart of the operating routine from the startup of the system to the display of the search results;
FIG. 20 is a flow chart of the operating routine from a map screen display to map scrolling in the virtual run mode;
FIG. 21 is a flow chart of the operating routine from decision of map scale to a selection of an entire route screen;
FIG. 22 is a flow chart showing a routine from selection of a routine information screen to storage of a route in memory;
FIG. 23 is a flow chart showing the entire routine of the system including scrolling control;
FIG. 24 is a flow chart of a single-action automatic scroll control;
FIG. 25 is a flow chart of a manual scrolling control subroutine;
FIG. 26 is an explanatory diagram illustrating display of map data;
FIG. 27 is a flow chart of a display subroutine for display of present position in the virtual run mode at Step S304 of FIG. 22;
FIG. 28 shows a speed control display screen with a speed control key;
FIG. 29 is a table of map scales correlated with speed magnifications (multiplication factors);
FIG. 30 is a diagram illustrating route design pursuant to a search;
FIG. 31 is a table of one example of set values for vehicle speed correlated with road type between the nodes of a designed route;
FIG. 32 is a table of set vehicle speed values correlated with road type stored independently of the map data for a designed route;
FIG. 33 is a flow chart of a subroutine for scroll control;
FIG. 34 is a flow chart of a subroutine for step-scrolling, started by operating a step-scrolling key or the like arranged on a controller;
FIG. 35 shows a progression of display screens utilized in setting step scrolling;
FIG. 36 shows one example of a menu display screen for selecting step scrolling and for speed control;
FIG. 37 is a flow chart of the step-scrolling subroutine started by selection from the menu shown in FIG. 35;
FIG. 38 is a continuation of the flow chart of FIG. 37;
FIG. 39 is a flow chart for display of distance, speed and a required travel time;
FIG. 40 is a flow chart of a speed setting subroutine;
FIGS. 41a and 41b are exemplary graphs showing the relationship between average speeds according to functions (A) and (B) and the number of signal intersections per unit distance;
FIG. 42 is a table of average speed data correlated with individual road types;
FIG. 43 is a flow chart of a subroutine for display of elapsed time;
FIG. 44 is a flow chart of a subroutine for display of time elapsed in reaching a present position in a virtual run;
FIG. 45 is a flow chart of a subroutine for display of running distance and remaining distance;
FIG. 46 is a block diagram of one embodiment of a navigation system to which is applied the map display system of the present invention;
FIG. 47 is a diagram showing one example of organization of the route data stored with the information relating to an intersection array for a designed route;
FIG. 48 is a diagram showing an example of a search area for setting a detour in the designed route;
FIG. 49 is a block diagram showing one example of a navigation system having a detour searching function;
FIG. 50 is a flow chart of an operating routine of a route guidance navigation system;
FIG. 51 is a flow chart of a detour searching routine;
FIG. 52a is a diagram illustrating a search area defined by designated points and closest intersections thereto on the route;
FIG. 52b is a flow chart of a subroutine for executing a search as illustrated in FIG. 52a;
FIG. 53a is a diagram illustrating a search area defined by designation of an arbitrary area;
FIG. 53b is a flow chart of a subroutine for execution of a search as illustrated in FIG. 53a;
FIG. 54a is a diagram explaining the automatic setting of the search area;
FIG. 54b is a flow chart of a subroutine for automatic setting of the search area shown in FIG. 54a;
FIG. 55 is a flow chart of a subroutine for searching for a detour point;
FIG. 56 is a flow chart of one example of a subroutine for selecting designing a route;
FIG. 57 is a flow chart of a routine for display of a virtual run including a detour search;
FIG. 58 is a block diagram showing one embodiment of a navigation system to which the map display system of the present invention may be applied;
FIGS. 59a and 59b are diagrams showing organization of road data in storage;
FIG. 60 is a diagram showing an example of a layer display area which is determined in accordance with the distance between the starting point and the destination;
FIGS. 61a, 61b, 61c and 61d illustrate a progression of screen displays in transit between the starting point and the destination;
FIG. 62 is a flow chart of a destination input routine;
FIG. 63 is a flow chart of a routine for processing map data during running; and
FIG. 64 is a diagram showing an example of the layered display area which is determined by the distances between the starting point, a transit point and the destination.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an embodiment of the map display system of the present invention and FIG. 2 shows that embodiment incorporated into an EPU system. The elements represented by dotted lines in FIG. 1 are necessary when the system is used as a navigation system, but are optional in the home use mode.
The embodiment of FIG. 1 is a home type map display system for aiding in confirming a route to a destination in advance or in designing the route in a place, such as the home, other than in the vehicle, but can also be used as a navigation system mounted on the vehicle to guide travel along a designed (searched) route. Thus, the map display system of this embodiment has a simulated or virtual running function (hereinafter called the "virtual run mode") for virtually running on the display screen along the route determined by search (designed) and a navigation function (hereinafter called the "navigation mode") for guiding travel on the basis of navigation information such as the present location, speed and forward direction of the vehicle.
As shown in FIG. 1, the map display system includes: an input/output section 1 for inputting/outputting the information necessary for operation in the virtual run mode and in the navigation mode; a data medium or media (storage section) 2 stored with map data necessary for determining the route and data necessary for confirming the route; and a central control section 3 for executing the route search for searching for a route between at least two points and the operations in the two modes to thereby control the entire system.
The input/output section 1 is composed of: point setting means 10 for inputting at least two points, e.g., a starting point and a destination, the transit point and the destination; scroll instructing means 11 for instructing the scrolling of the display screen along the designed route; route information display instructing means 12 for instructing the display of route information; virtual run instructing means 13 for instructing the virtual run on the basis of the searched route; navigation instructing means 14 for instructing the navigation on the basis of the searched route; display means 15 for displaying the designed route and the route information on the screen; printing output means 16 for outputting the data necessary for guiding, confirming and designing the route, the route information and the map screen to a printer; and voice output means 17 made of a speaker for voice guidance along the route.
In order that the above-described system may output the route information by voice or screen display, when desired by the user, may instruct scrolling of the screen displayed along the designed route or may display a peripheral map of a certain point on the screen, the central control section 3 can be instructed to display the map in accordance with the will of the user, and the processed data or the like can be output to the printer, spoken from the speaker or output to the display by the printing output means 16.
The point setting means 10 is composed of control switches for inputting the starting point (or present location) and the destination in terms of their addresses, telephone Nos. or coordinates and for requesting the route confirmation. The display means 15 is composed of a color CRT or a color liquid crystal display for displaying in color all the screens that are necessary for both navigation and virtual running, such as the point setting screen, a route guiding screen, the section screen or the intersection screen, on the basis of the map data and guide data processed by the central control section 3. The route guiding screen is equipped to display at least the entire route map, the route information and the vicinity map.
The point setting or screen controlling means is composed of a display having a touch switch (or soft switch) for emitting, when a function button displayed on the screen, a signal corresponding to the function, a controller having a push button switch (or hard switch) arranged on the panel for emitting signal corresponding to the function when operated, or a remote control.
On the other hand, the output means is composed of: a display for displaying a screen pursuant to a request by the user or automatic route guidance; a printer for printing the data processed by the central control section and the data stored in the storage medium; and a speaker for outputting the route guidance in the navigation mode, the route confirmation in the virtual run mode, background music in the virtual run mode, sound effects and voice output of major guidance information. The sound effects are exemplified by a running sound having its tone changed with the vehicle speed, or a blinker sound indicating a turn to the left or right. Moreover, the major guidance information might include the name of an interchange (IC) to be passed, a toll road or the route number.
The global positioning system (GPS) receiver enables acquisition of the present location by mounting the system as a navigation system on the vehicle and a virtual run by registering the home position, for example, to use the home as the starting point.
The storage medium may be a CD-ROM, IC card or magneto-optic disc and is stored with all the data necessary for route guidance and route design such as the maps, intersections, nodes, roads, photographs, destination points, guide points, detailed destinations, road names, branches, display guides, voice guides and speed limits for the roads. Moreover, the auxiliary information may include destination information and the tariffs of the toll roads.
The central control section 3 includes: point recognizing means 31 for judging whether or not the present system can recognize at least two points which are inputted; route setting means 32 for setting the route on the basis of the recognized points; drawing/display control means 33 for drawing a map to display the set route on the display and for displaying the map concerning the route information designated by the user or the processed data on the screen; scroll control means 34 for controlling the screen in a virtual run designated by the user at the time of executing the virtual run mode; and storage means 35 stored with all the data necessary for the navigation mode and the virtual run mode.
The aforementioned central control section 3 is exemplified by the EPU system, as shown in FIG. 2. Specifically, the EPU system includes: a main CPU 40 for executing arithmetic procedures; a program ROM 41 stored with the program for searching the route, the program for controlling the display necessary for the route guidance and the voice output control necessary for the voice guidance, and the data necessary for executing the programs; a SRAM 42 for storing the information for guidance along the set route and the data being arithmetically processed; a DRAM 43 stored with the display information data necessary for route guidance and map display; a VRAM 44 for storing the image data to be used for the display; an image control section 45 for writing the image data in the VRAM in response to the command from the CPU and for sending the display data from the VRAM to an image signal converting part 46; an image signal converting section 46 for converting the RGB digital signal to be output from the image control section into an RGB analog signal or video signal in conformity to the specifications of the display; a GPS receiver communication section 49 for converting the electric signals of communication data such as the positional information sent from the GPS receiver so that the data can be read out by the main CPU; a controller input/output signal converting section 48 for converting the signal to be transferred to an external controller; a memory driver 50 constituting a reader for the stored data; a clock 51 for providing the date and time in the internal diagnostic information; and a ROM 52 stored with marks and kanji patterns to be used for displaying the route information.
The controller 60 is equipped with a variety of function button switches necessary for controlling the point setting and the screen controls from a remote location so that the functions of setting the point, selecting the reduced map scale, displaying the map and displaying the menu can be accomplishing by key input.
The present system is so constructed that the driver can select the screen display and/or the voice output for the route guidance.
FIG. 3 shows a routine for the virtual run mode of the map display system according to an embodiment of the present invention. When the power of the present system is turned ON, the start screen is first displayed showing a menu for selecting how the route of the virtual run mode is to be set. In the case of a prepared file, the entire route display screen is displayed by designating the corresponding file while omitting the route search. In the absence of corresponding file, on the other hand, the point setting screen is displayed, showing a window for a sub-menu for setting a point such as the destination or starting point, and the route search is executed by designating and (initially) setting the point in the sub-menu. When this route search is ended, the entire route is displayed on the screen.
When the execution key (or start button) is operated from the entire route display screen, the virtual run screen is opened to display the vehicle on the route, generally at the center. With the vehicle being shown at the center of the screen, the map display is scrolled past the vehicle to simulate the vehicle running along the route. For scrolling the map screen in the virtual running mode, the map is scrolled with the vehicle pointed upward on the screen or, so to speak, headed up, or the map is scrolled by turning the vehicle 360 degrees with the azimuth such as north N being fixed upward of the screen.
While the virtual run mode is being executed on the virtual run screen, the course can be designed in advance with a detour to a point off the route, a change in the route and/or a rest at some place. Especially in case where the route is to be changed, the search is again executed ("re-searched"), and the virtual run mode is again executed along the re-searched (redesigned) route. When the virtual run is to be interrupted to acquire the route information, on the other hand, the route information screen can be opened to view the route information such as major points on the route, the express highway, the name of the interchange (IC), the national route No. the inter-point distance, the time or the toll of the express highway. This route information makes it possible to confirm the details of the designed route other than by resort to the map. After this, the mode can be returned to the virtual run mode to design the route and confirm the route. When the present system is mounted as a navigation system on the vehicle, the navigation mode can be started on the basis of the route confirmation or route designed in the virtual run mode.
Here will be described display screens utilized in the virtual run mode. FIGS. 4a-4d show one example of the layout of startup screens (i.e., screen A of FIG. 3). The initial startup screen, FIG. 4a, displays the entire area map contained in the data bus, and the second and later screens display the screen at the previous ending time. Next, the main menu is displayed, FIG. 4b, and the key "FROM THE BEGINNING" is selected. Then, the stored information relating to the virtual run is initialized, and a point on the map is set from the beginning to search the route so that the virtual run is executed along the searched route. If instead the key "FILE" is operated and then "CALL" is selected in the submenu of FIG. 4c, it is possible to use a set route which has been prepared in advance filed in storage.
In case the key "FROM THE BEGINNING" is selected, the cursor is positioned at an arbitrary point selected from the wide area map containing all the regions of the data base displayed as the initial screen, and the point setting menu is displayed by operating the set key so that the starting point (or present location), the transit point, the destination and so on are designated and set from that menu. Next, by the search condition setting menu, search conditions, such as whether or not a toll road is preferred and whether or not the transit point is to be used, are set.
If the keys "FILE" and "CALL" are selected, the file calling display screen, FIG. 4d, is displayed listing files in order of their Nos. along with the individual routes, their dates of registration and the contents of routes. If a file No. is designated from this list, the entire route display screen (i.e., screen B) based upon that route is displayed.
In FIG. 5 showing one example of the layout of the entire route display screen, the vehicle marker is displayed at the starting point together with the route information for confirming the overall designed route, the toll road information, the distance information, the required travel time information and/or the tariff information. In the illustrated example, the displayed route has been designed by a search executed under the condition preferring toll roads by setting "FUJII-CHO" as the present location or position and "WAKAYAMA CITY" as the destination. The "entrance" IC and the "exit" IC of the toll road on this route are set as "OODAKA" and "WAKAYAMA INTERCHANGE", respectively. Moreover, this route has a distance (KM) of 350 Km, a required travel time (TIME) of 5 hours and thirty minutes, and a toll (¥) of 3,500 yen. If the virtual run mode is selected after the route has been confirmed on this entire route display screen, the virtual run screen (of FIG. 6) is displayed.
FIG. 6 shows one example of a layout of the virtual run screen. The map on which the vehicle is to run in the upward N direction, is displayed, and the controller is operated to start the vehicle. Specifically, the vehicle appears to advance as if it is running along the route, by fixing the vehicle marker in that position and by scrolling the map on the screen past the vehicle marker. In the present example, the situation of the periphery of the virtual present location is easily found because the vehicle is displayed as fixed at the center of the display screen.
The route information to be displayed while the vehicle is running on the route includes the distance remaining to the destination, the distance travelled from the starting point and the speed of the vehicle. In the illustrated example: the remaining distance to the destination (to GOAL) is 250 Km; the covered distance is 100 Km; and the present speed is 200 Km/hr. In this virtual run mode, the vehicle speed can be selected to have a speed magnification or increase according to the reduced scale of the map by the controller. If the detail of the route is acquired at the virtual running time, a route information screen (of FIG. 7) is opened.
In FIG. 7 showing one example of a layout of the route information screen, the route is drawn straight in the horizontal direction on the screen. On this route, there is displayed route information such as the road name, the major point names, the distance between the major points, and/or the scheduled times of arrival at the major points. This display screen can be horizontally scrolled. Here, the portion enclosed by a frame at the lefthand side of the drawing is displayed in the route information screen. In the shown example, the vehicle runs 25 Km on National Road 23 from "FUJII-CHO" to "OODAKA IC" of Nagoya Expressway and 19 Km on Nagoya Expressway from "OODAKA IC" and enters Higashimeihan Toll Road at "KUSUNOKI IC". The virtual present location in the virtual run is displayed as located at Kusunoki IC.
The upper portion of the screen displays the scheduled times of arrival at the individual points. Specifically, the starting time is displayed for Fujii-cho, and the times of transition are displayed at Oodaka IC and Kusunoki IC. Moreover, the tariffs displayed are those to be consumed between the interchanges having toll gates. For example, the toll of "600 yen" is displayed at Oodaka IC between Oodaka IC and Kusunoki IC. If the virtual run is further executed, the screen is scrolled from the right to the left so that similar route information is displayed.
In addition, since the information as to detours or rest spots is displayed on the route information screen, the detailed route information on what point and how long a rest is to be taken and where and how long the detour is can be confirmed on the screen and reflected in the route design. After the designed route has been confirmed on the route information screen, the search condition can be changed again to execute the route search thereby to effect the virtual run suitably according to the route.
Next, additional screens used in the virtual running mode will be described.
FIG. 8 shows an example of the main menu display screen used in the virtual run mode. This main menu display screen can be opened from any of the other screens, to select a map search, point registration, the setting of starting time, a change in the search conditions, the file procedure and the setting of the date and to display their setting screen to thereby set the conditions for a new route design. In the main menu, the "SEARCH MAP" provides display of an arbitrary point on the map in accordance with a telephone No. or a point name reference. The "REGISTER POINT" key registers an arbitrary point as the home or the memory point. The "STARTING TIME" key sets the time at the starting point so as to calculate the arrival time on the basis of the required travel time. The "CHANGE SEARCH CONDITION" key changes only a search condition (e.g. whether or not the "toll road is preferred" or "the transit point is used") but not the starting point or the destination. The "FILE" key calls the virtual run route from the memory, registers (saves) the route or deletes the route file. The "FROM THE BEGINNING" key initializes all the set items and starts a new virtual run from the setting. The "SET DATE/TIME" key sets the date and the time. The "CHANGE MODE" key can switch, when the GPS receiver is connected, the mode from the virtual run mode to the navigation mode or vice versa.
FIG. 9 shows an example of the point setting menu display screen. This point setting menu display screen is automatically displayed, when a point is set, with the destination, the present location and the transit point as the selected points. According to this function, it is easy to designate selected points as the set points.
FIG. 10 shows an example of the search condition menu display screen. This search condition menu display screen is automatically displayed, when a necessary point is set, and provides for selection of "PRIORITY" or "NOT" for a toll road priority search condition and "PASS" or "NOT" for a transit point each time a transit point is set. This function provides easy selection of the search conditions.
FIG. 11 shows an example of the screen displayed by operation of the present point key on the controller during the virtual run mode. From this display screen, the time the vehicle has run and/or the distance remaining to be travelled can be determined at a glance by locating the present position on the route. In the present example, the entire route is displayed as a straight bar, on which is displayed the virtual present position marker. Since, according to this function, the position of the virtual present location relative to the entire route is linearly displayed, it is possible to easily confirm where the vehicle is running.
FIG. 12 shows an example of the speed setting screen. This speed setting screen is displayed, when the set key on the controller is operated during a virtual run, so that the virtual running speed can be arbitrarily set by manipulating the joy stick. According to the present function, the set present speed can be found at a glance, when desired, by operating the set key.
In addition to the display screens described above, there are a peripheral list display screen and a re-search display screen, although not shown. The peripheral list is a display of features in the vicinity of the destination such as roads or buildings in the sub-menu, when their details are desired. A guide of registered points provides detailed information for various destinations such as date spots, camping sites or recreation grounds. When the designed route is to be wholly or partially changed after the virtual run of the route, it can be set again if a new point is set and re-searched, to again confirm the portion which has been changed by the virtual run.
Here will be described the entire procedure of the present system. FIGS. 13 and 14 are flow charts of the routine for operation of the above-described embodiment. First of all, when the power of the present system is turned ON to start the system, the connection of the GPS is decided (at S100). In the connected state, the routine comes into the navigation mode to display the startup screen of the navigation mode (at S101), as shown in FIG. 16. FIG. 16 shows the map display screen with the present location. If the GPS is not connected and the system is used as the so-called "home type", the routine provides the virtual run mode which commences with display of the startup screen shown in FIG. 14 (at S112).
When the navigation mode is initiated, it is decided (at S102) whether or not the mode is switched in the screen of FIG. 16. If the answer is NO, it is decided (at S103) whether or not a file has been called. If a file has been called, the routine enters the "FILE CALL BY KEYSTROKE" (at S108), as shown in FIG. 15. Then, the route of the called file is displayed (at S109) on the map screen. Without a file call, on the other hand, it is decided (at S104) whether or not the destination has been set by key operation. If this answer is YES, the routine goes to "GOAL SETTING BY KEYSTROKE" (at S105), as shown in FIG. 15. Then, the route is designed by search (at S106), and the designed route is displayed (at S107) on the map screen. Through Step S107 or S109, the guidance is started (at S110). The routine is returned to Step S101 if it is decided that the operation of Step S104 has not been executed or if the guidance is ended (at S111).
In case it is decided at Step S100 that the GPS is not connected or it is decided at Step S102 that the mode is switched, the routine enters the virtual run mode to display the startup screen of the virtual run mode (at S112, FIG. 14). From this point on, the procedures similar to those of Steps S102 to S109 are executed (at S113 to S120). In case, however, it is decided at Step S113 that the mode is switched, the routine is returned to Step S100. The route design is entered (at S121) through Step S118 or S120. It is decided (at S122) whether or not the designed route is to be stored in the memory. If this answer is YES, the storing operation is executed (at S123). After the end of the storing operation or in case no storage is decided at Step S122, the routine is returned to Step S113.
Here, the "FILE CALLING BY KEYSTROKE", as shown in FIG. 15b, is started by operation of the main menu key. First of all, the main menu shown in FIG. 4b or 17a is displayed (at S135) by operating the main menu key to select the "FILE" key (at S136). When the file menu is displayed (as shown in FIGS. 4c or 17b), the "CALL" key is selected (at S137) to display the file calling list (at S138), as shown in FIGS. 4d or 18. The file to be executed is selected (at S139) from the list and is read (at S140) from the memory by the set key. Thus, the operations of Step S108 or S119 are ended to go to the next routine.
On the other hand, the "SETTING OF GOAL OR POINT BY KEYSTROKE", FIG. 15a, is started by operation of the joy stick or the main menu key. By operation of the joy stick, the routine starts screen scrolling (at S124). After the cursor has been moved to an arbitrary point at Step S124, the point is set by the set key (at S125). Subsequently, the point set menu (of FIG. 9) is displayed (at S126), and the the point is designated a starting point, the destination or a transit point by operating the joy stick and the set key (at S127).
It is decided (at S128) whether or not the point setting necessary for the search has been wholly ended. The minimum necessary for the search are the starting point and the destination in the virtual run mode and the destination in the navigation mode. Unless ended, the operation of Step S105 of FIG. 13 is repeated. If ended, the search condition setting menu (of FIG. 10) is displayed, and the condition is selected by the joy stick and determined by the set key (at S129). After the end of the search condition setting, Step S105 or S116 is ended to allow entry into the subsequent routine.
The map screen including an arbitrary point is displayed by making use of the map searching function in the main menu. For this purpose, the main menu key is manipulated to display the main menu (at S130), and the "MAP SEARCH" is selected (at S131). Subsequently, the search condition is set, or the point name is selected (at S132). Here, the search condition is exemplified by the telephone No. and the memory point. Moreover, the point name indicates the method to be executed by displaying the list which is in the data base and classified by genre such as addresses, hotels and stations. If the search condition is decided by the set key (at S133), the map screen around the center is displayed to go into the scroll screen (at S134) by manipulation of the joy stick.
The routine for the virtual run mode is illustrated in FIG. 19 which shows processing from the system startup to the display of the search results. After the system has been started up, the starting time is set (at S200) on the route setting screen, and the starting point and the destination are set (at S201) to execute the route search (at S202). In this route searching routine, the distance data (at S203) and the speed data (at S204) for each named road are read to calculate the required travel time (at S205). Then, the toll data for a toll road such as an expressway is read (at S206) to calculate the toll of the toll road on the designed route, and the search results including the route information such as the distance, the required travel time and the required toll is displayed (at S207) on the entire route display screen (as shown in FIG. 6). It is decided (at S208) whether or not any key has been operated on the entire route display screen. If this answer is YES, the routine goes into the virtual run mode.
When the virtual run mode is entered, as shown in FIG. 20, the map screen displays a map of the area around the starting point or the first present location (at S209). The virtual present location marker (or the vehicle marker) is displayed on this map (at S210). The virtual run screen shown in FIG. 16 is displayed by the procedures of Steps S209 and S210. After recognition (at S211) on which road the virtual present location is located, the speed data searched is read (at S212). Next, the speed factor in the present reduced scale is read (at S213), and the virtual present location is fixed on the screen so that the map is scrolled (at S214) along the designed route according to the speed indicated by the speed data. During the virtual run, the elapsed time, the covered distance and the remaining distance are individually calculated and displayed on the screen. It is decided (at S215) whether or not the type and name of the road being followed has changed. If this answer is YES, the routine returns to Step S211 to determine the type and name of the road. Otherwise, it is decided (at S216) whether or not the scale of the map shown in FIG. 16 has been changed.
If a change in the map scale is indicated in FIG. 21, it is displayed (at S217), and the routine is returned to Step S213 to determine the present speed factor. The speed can be decelerated to allow making a detailed course design for a certain area or accelerated where the course is merely to be travelled as is without any detailed design or where the vehicle is running through an area requiring no change by the drive such as an expressway between interchanges. It is decided (at S218) whether or not such speed control has been carried out. If this answer is YES, the routine is returned to Step S214 to scroll the map according to the controlled speed. Otherwise, the step-scrolling is decided (at S220). Without any step-scrolling, it is decided (at S221) whether or not the "ENTIRE ROUTE SCREEN" has been selected from the menu. With step-scrolling selected, the step-scrolling is executed (at S222), and the routine returns to Step S220.
Here, the step-scrolling implies that the area around the starting point, which is well known to the driver, is stepwise scrolled at each intersection or service area or at a constant time interval so that the virtual run can be slowly examined and confirmed in detail after reaching point such as an interchange near the destination.
If the entire route screen is not selected at Step S221, the routine shifts to that shown in FIG. 22. Specifically, it is decided (at S223) whether or not the "ROUTE INFORMATION SCREEN" has been selected from the menu. If NOT, it is decided (at S224) whether or not the route is to be stored in the memory. This route, if necessary, is stored in the memory. If the route is unnecessary, the routine is returned to Step S214 to continuously advance the virtual run. If the route information screen is selected at the decision of Step S223, the route information such as the section distance, the elapsed time period and the section toll, in addition to the distance, the required travel time and the required toll are displayed on the route information screen, as shown in FIG. 8. The details of the route information are confirmed on this route information screen.
It is decided at S226 from the route information screen whether or not the "ENTIRE ROUTE SCREEN" has been selected from the menu. If this answer is YES, the entire route display screen is displayed at Step S207. If the entire route screen is not selected, it is decided at (S227) whether or not the "VIRTUAL RUN SCREEN" has been selected. If this answer is YES, the virtual run screen is displayed at Step S214. If this virtual run screen is not selected, it is decided (at S228) whether or not the route is to be stored in the memory. This route, if necessary, is stored in the memory, but otherwise the routine is returned to Step S225.
FIGS. 23 to 25 show a processing routine for the virtual run with scrolling of the screen showing the designed route. In the present example, the route is searched by setting at least two arbitrary points (i.e., the starting point and the destination, "goal") and is displayed, and the display screen is scrolled along the searched route by input of a request for scrolling.
In FIG. 23, the system is started up, and the starting point and the destination are set (at S300) on the route setting screen to execute the route search (at S301). In this route search, the data necessary for the virtual run is processed, and the search result is displayed in the entire route display screen (at S302). It is decided (at S303) whether or not a key has been operated. If this answer is YES, the map is displayed (at S304) with predetermined coordinates A on the screen coinciding with the coordinates of node 0 (i.e., the starting point). Next, the scrolling is executed by a scroll starting key. If neither the scroll starting key nor the backward scroll starting key is operated, arbitrary coordinates on the route are held at the predetermined coordinates A on the screen (at S305).
FIG. 24 shows a single-action automatic scrolling routine. First of all, it is decided (at S306) whether or not the scroll starting key has been operated. If this answer is YES, a search is made at S307 to identify the node on the search route passed at a predetermined distance toward the destination and coordinates obtained by interpolating the nodes, from the map coordinates coinciding at present with the coordinates A on the screen. The map is displayed (at S308) with the coordinates identified by the search coinciding with the coordinates A on the screen. By the operation of Steps S307 and S308, the screen is scrolled as if the vehicle were running along the designed route. During this simulated running, it is decided (at S309) whether or not the backward scroll starting key has been operated. The operation of the stop key is decided (at S310) if the answer is NO, and the strolling is stopped if the answer is YES. If the backward scroll starting key is operated, on the other hand, the backward scrolling at and after Step S312 is executed. If neither the backward scrolling key nor the stop key has been operated, the routine is returned to Step S307 to execute the scrolling continuously.
If the scroll starting key has not been operated at Step S306, it is decided (at S311) whether or not the backward scroll starting key has been operated. If this answer is YES, operations similar to those of Steps S307 and S308 are executed to scroll the screen backward (at S312 and S313). If the scroll starting key is operated (at S314) during the backward scrolling, the routine is returned to Step S307, at which the scrolling is executed. If the stop key is operated (at S315), the scrolling is stopped. By thus switching the scrolling directions between forward and backward, an arbitrary point in the virtual run can be restored many times, and the virtual run can be repeated for detailed examination.
If neither the scroll starting key nor the backward scroll starting key is operated in the single-action automatic scrolling, the manual scrolling is executed. This manual scrolling routine is shown in FIG. 25. First of all, it is decided (at S316) whether or not the joy stick is manipulated toward the destination. If this answer is YES, the node on the search route past a predetermined distance toward the destination and the coordinates obtained by interpolating the nodes are searched (at S317) from the map coordinates coinciding at present with the coordinates A on the screen, as shown in FIG. 26. The map is so displayed (at S318) as to provide a coincidence between the searched coordinates and the coordinates A on the screen. As a result of the operations of these Steps S317 and S318, the screen is scrolled toward the destination as if the vehicle were running along the designed route. In this running situation, the manipulation of the joy stick is decided (at S319), and the scrolling is stopped if the manipulation is interrupted.
If it is decided at Step S316 that the joy stick is not manipulated toward the destination, it is decided (at S320) whether or not the joy stick is manipulated toward the starting point. If this answer is YES, operations similar to those of Steps S317 and S318 are executed to scroll the screen backward (at S321 and S322). This scrolling toward the starting point can involve the operations similar to those of the backward scrolling in the aforementioned automatic scrolling. If an arbitrary point toward the starting point is restored and the manipulation of the joy stick is stopped (at S323), the scrolling is stopped.
In map scrolling according to the present embodiment, at least two arbitrary points (i.e., the starting point and the destination) are set to search the route so that the virtual present location is displayed on the route determined by the search, i.e., the "designed route", the virtual present position is fixed on the display screen by input of a request for scrolling along the designed route. In the example shown in FIG. 16, a line drawing of the vehicle is displayed as the virtual present position marker, which is fixed at the center of the display screen. Especially in the display having the vehicle position fixed at the center of the display screen, the nature of the vicinity of the virtual present location is easy to understand.
The means for displaying the virtual present location marker is exemplified, in the processing routine shown in FIG. 23, by interposing the vehicle position displaying means between Steps S305 and S306. Specifically, after the virtual run mode has been entered to display the map according to the designed route (at S304), the virtual present position marker indicating the virtually running vehicle is displayed (at S304A) at the coordinates A on the screen, as shown in FIG. 27. The display position of coordinates A on the screen are specifically set to the optimum position for widening the displayed vicinity of the virtual present location and the screen of the forward direction of the virtual run. Preferably, the coordinates are set at the center of the screen so that the nature of the vicinity of the virtual present location may be easily observed, and is set with a backward shift from the center of the screen so that the map area forward of the vehicle may be more widely displayed on the screen. The subsequent routine is similar to that of FIG. 23.
Here will be described the scroll controlling operation with reference to FIG. 28 which shows the relationship between the speed control selecting screen displayed responsive to operation of the set key during the virtual run and the speed control key disposed in the controller. This scroll setting screen functions to switch the virtual running speed between three stages and the virtual run between the forward and backward directions.
The setting means in the present example allows control of "forward" run, "stop", "backward" run by using the joy stick. Moving the joy stick to the "+" side steps the run control from "backward" to "stop" or from "stop" to "forward", and moving the joy stick to the "-" side steps the run control form "forward" to "stop" or from "stop" to "backward". Moreover, the forward run and the backward run are individually divided into three speed stages (LOW, MID and HIGH). In the case of the forward run, the speed is accelerated in the order of "STOP"→"LOW"→"MID"→"HIGH" by moving the joy stick to the "+" side and is decelerated in the order of "HIGH"→"MID"→"LOW"→"STOP" by moving the joy stick to the "-" side. The acceleration and deceleration are reversed in the case of a backward run.
The foregoing embodiment has been described as using a joy stick as the speed changing means but, alternatively, can use forward/backward keys and speed changing push keys to switch the running directions and the speeds.
Thanks to the aforementioned scrolling speed control function, the speed can be easily dropped for an area requiring a detailed course design and a course confirmation or raised for another area to improve the operability. Especially, thanks to the forward and backward switching function when the vicinity of a point having already been passed is to be examined again, the virtual run need neither be stopped midway nor repeated from the start, but can be switched backward to restore that point, so that the route can be examined again from that point.
Here will be described the calculation of the running vehicle speed on the route. The route designed by the search is divided at nodes n from the starting point to the destination, as shown in FIG. 30, and has a data structure in which a change of the road No. type are made to correspond to a node. In case the running vehicle speed value is to be calculated, the node No., the road No., the road type and the set vehicle speed value, as shown in FIG. 31, are tabulated and stored in the storage means, and the set vehicle speed value corresponding to the road No. being virtually run is read. According to another method, as shown in FIG. 32, the designed route information may be utilized to store the road type and the vehicle speed value in the storage means, to read the vehicle speed value corresponding to the road type during the virtual run.
FIG. 33 shows a processing routine for the scroll control means. When the route search is ended (at S400), a reference speed for each road type is calculated at (S401), and a virtual run screen corresponding to the speed is displayed (at S402). The type of the road on which the virtual present position is located is decided (at S403), and the speed value x corresponding to the road type is detected from the decision result (at S404). A speed multiplication factor (magnification value) r is detected from the reduced scale of the map (at S405). Here, the "DETECTION" at Steps S404 and S405 reads the speed data obtained by the aforementioned calculation, as to the vehicle speed, and reads the stored data sin correlation with the reduced scale of the map selected and the speed range set by the speed control, as to the multiplication factor of the speed.
The map is scrolled at the product (x×r) of the detected speed value and the speed multiplication factor r. It is then decided (at S407) whether or not the type (or name) of the road being followed has changed. If this answer is YES, the routine is returned to Step S403, at which the type of the road having the virtual present position is decided. If the road type has not changed, it is decided (at S408) whether or the scroll speed control has been executed, that is, whether or not the speed mode has been operated to the "+" side. If this answer is NO, it is decided (at S409) whether or not the speed mode has been operated to the "-" side. If the speed mode has not been changed, the routine is returned to Step S406, at which the scrolling is continued at the speed value (x×r). If the speed mode is operated at Step S408 or S409, the scroll speed control is executed. Specifically, if the speed mode is operated to the "+" side, it is changed by one step to the "+" side, e.g., from LOW to MID (at S410). After this, it is decided (at S409) whether or not the speed mode is operated to the "-" side. If the speed mode is operated to the "-" side, moreover, it is changed by one step to the "-" side (at Step S411), and the routine is returned to Step S405, at which the speed multiplication factor 4 is detected.
Here will be described the speed magnifications for the individual reduced scales of the map. The present example will be described for three steps of speed magnification which can be set for each of reduced scales of the map. FIG. 29 presents an example of the speed multiplication factors in the scale reduction of the map. Here, the controller is equipped with a speed control key for changing the speed magnification. This speed control key is provided with a "+" button for changing the magnification to the "+" side and a "-" button for changing the magnification to the "-" side to shift the speed range by one step each time the "+" button or "-" button is operated, so that the speed range thus set is displayed on the scroll selecting screen.
For setting a speed magnification, the "+" button of the speed control key, as shown in FIG. 28, is manipulated to switch the speed range, and the joy stick is brought down to the "+" side for forward running. In this case, in a map of the scale 1/10,000, the speed multiplication factor is set to a scale of 1 time in the Low range so that the distance of 100 Km is taken for an actual run of 1 hour at 100 Km/h. If the range is switched to the Mid range, the speed multiplication factor is increased to 1.5 so that the same distance as that of the Low range can be covered for 40 minutes by the virtual run. In the High range, moreover, the speed multiplication factor is increase to two so that the virtual run is executed at a speed twice as high as that of the Low range. As a result, the same distance can be covered within one half hour by the virtual run.
By thus setting the speed multiplication factors by the scale reductions of the map, the running time period can be shortened for the virtual run in accordance with the map scale reductions. In short, for constant scrolling of the map, the speed of the virtual run can be changed according to the map reduction ratio by changing the map scale. When the route information for each necessary point is to be roughly confirmed, the wide map screen is displayed for the virtual run. If the wide map has a scale reduction of 1/640,000, the virtual run can be achieved at eight times in the Low range, at sixteen times in the Mid range and thirty two times in the High range, as compared to the low range (of one time) for a map of 1/10,000.
The present invention can improve the operability of course design and confirmation by lowering the speed magnification, for the detailed course design and confirmation, to effect the virtual run at a relatively low speed and by raising the speed magnification, for the area requiring no course confirmation or the area such as a detour requiring no course design change, to accelerate the speed. In short, when the detailed map is selected, it is expected that the user intends to observe the vicinity of the virtual present location in detail. Thus, the speed multiplication factor for the detailed map is set to a low value so that a virtual run at a low magnification may be started simultaneously with the change in the scale reduction. In case the wide map is selected, on the other hand, it is expected that the user intends a cursory observation of the route (or to pass without any observation). Thus, the speed multiplication factor for the wide area is set to a high value so that a virtual run with a high magnification may be started simultaneously with the change in the scale reduction.
Here will be described step-scroll control in which the route is divided for the virtual run so that given units may be skipped. FIG. 34 shows a step-scrolling routine for a controller equipped with a step-scrolling key or the like for starting the step-scrolling. Here will be described the case of stepping at a predetermined distance.
When the step-scrolling is started, it is decided (at S420) whether or not the step-scrolling has been executed forward. If this answer is NO, it is decided (at S421) whether or not the step-controlling has been executed backward. If neither forward nor reverse scrolling has been executed, the step-scrolling is ended. If it is decided at Step S420 that the forward step-scrolling has been executed, a search is executed (at S422) to locate a point on the route representing advance of a predetermined distance from the virtual present location. The map of the searched point is displayed (at S423). If backward step-scrolling has been executed, on the other hand, operations similar to the aforementioned are executed (at S424 and S425).
According to the present invention, the route design and confirmation can be improved by step-scrolling through an area between the points which is geographically well known, such as the vicinity of the starting point or an area requiring no detailed route examination, at intersections or at intervals of a predetermined distance.
FIG. 35 shows on example of the step-scrolling setting operation by the menu and the joy stick. In the virtual run screen, displays the sub-menu, from which the "SET STEP" key is selected. Then, the step setting window is displayed to select a step-scrolling reference. In the present example, the selected step can be (1) an intersection, (2) an interchange (IC), a service area (SA) or a parking area (PA), (3) a predetermined time period or (4) a predetermined distance. In case of step-scroll at each predetermined point such as an intersection, interchange, service area or parking area being selected, the nodes ahead of the specified point are searched to display the map of the searched point. If the predetermined time period or the predetermined distance is selected, a window is displayed for inputting those values. FIG. 36 shows one example of the step-scrolling, in which the speed control to be displayed on the screen in the speed control has "STEP" keys for selecting the step-scroll. When this "STEP" key is selected, STEP-SCROLLING" is started in which the virtual present location is moved at the end of each predetermined time period in accordance with the reference set in the menu.
FIGS. 37 and 38 show a routine for step-scrolling utilizing the menu and the joy stick. During the virtual run at a speed magnification x, it is decided (at S450) whether or not a selection has been made from the sub-menu. If this answer is YES, a sub-menu, as shown in FIG. 35, is displayed (at S450). The "SET STEP" key is selected (at S452) from that sub-menu, and the step-scrolling reference is set (at S453). Simultaneously as the selected reference is set up, the sub-menu is deleted (at S454). Then, (at S455) the scrolling reference set by the "SET STEP" key is determined. In the route obtained by the search, the set reference point such as the first node or intersection is searched on the side toward the destination from the virtual present location and is designated "node a" (at S456). The map is displayed for a predetermined time to make the node a coincide with the coordinates A on the screen (at S457).
It is decided (at S458) whether or not the speed change key has been operated, and it is otherwise decided (at S459) whether or not the sub-menu key has been operated. If neither key has been operated, the routine is returned to Step S456, at which the next reference is prepared. If the sub-menu key is operated, the routine is returned to Step S451, at which the selection is made from the sub-menu.
If it is decided at Step S450 of FIG. 37 that the operation of the sub-menu key has not been executed, the routine advances to the routine of FIG. 38. Specifically, if the sub-menu key is not operated, it is decided (at S460) whether or not the speed change key has been operated. If neither key has been operated, the run is continued at the speed magnification set at present. If the speed change key has been operated, the step selection and its direction are decided (at S461). If the forward step has been selected, the scroll reference is determined at Step S455 of FIG. 37 so that the step processing is executed from the result of decision. If the backward step has been selected, on the other hand, operations similar to those of Steps S455 to S457 are executed (at S463 to 467).
When the speed change key is depressed, the routine is returned to Step S461. If no scroll in either direction is selected, it is decided whether or not the speed magnification has been changed. Without any change, the run is continued at the speed magnification x set at present. If the speed magnification is changed to "y", on the other hand, a relationship of x=y is set (at S469) to execute the virtual run with the speed magnification y.
Here will be described the operations for processing the distance, the speed and the required travel time period with reference to FIG. 39 which shows a routine processing the distance, the speed and the required travel time. The present invention can provide a virtual run by scrolling the display screen along the designed route and calculates and displays the desired time period for two points inputted.
In FIG. 39, when the virtual run is started, the road type data of node 0 is read (at S500), and the road type data of next node is read (at S501). It is then decided (at S502) from the road type data of the individual nodes whether or not the road type has been changed. If these answers are NO, the distance between the nodes on that road is calculated (at S503), and the calculated values are accumulated (at S504). By repeating these Steps S501 to S504, the sum of the distances over the same road type is calculated. If the road type has changed at a certain node, the speed deciding routine shown in FIG. 40 is started to calculate the speed of the road type at that section. When the speed decision is completed, the time period (distance/speed) for travel of that section is calculated (at S505) on the basis of the calculated speed. After the total distance, the required travel time period and the speed data have been stored for each road type (at S506), the total distance value between the nodes is cleared (at S507). It is then decided (at S508) whether or not a series of those operations have completed. If this answer is NO, the routine is returned to Step S501, at which the data of the subsequent node is processed. When all the operations between the individual nodes on the route are completed, the total distance value (at S509) and the arrival time (at S510) of all the routes are individually calculated the result displayed (at S512).
Here will be described a specific example for deciding the speeds to be assigned to the aforementioned classifications. In this specific example, an average vehicle speed is set for each expressway. For national roads (having different route Nos.), on the other hand, the speed is calculated from a formula (A) wherein a variable Xa represents the number of signal intersections within a predetermined distance. For other general roads, on the other hand, the speed is calculated from a formula (B) wherein a variable Xb represents the number of signal intersections within a predetermined distance:
f(Xa)=AXa+B; Speed Calculating Formula (A)
and
f(Xb)=CXb+D Speed Calculating Formula (B).
Incidentally, these formulas have their constants set according to various conditions such as the number of lanes or the day of the week. FIGS. 41a and 41b presents relationships, based on the formulas (A) and (B), between the average speed and the number of the signal intersections per unit distance.
FIG. 40 shows one example of the speed deciding method. The road type, if changed, is decided (at S520), and, if changed, this routine is ended by determining the name of an expressway (at S521) and by reading the individual speed data for the expressway (at S522). If the road is not an expressway, it is decided (at S523) whether or not the road is a national road. If this answer is YES, the number of signal intersections in the section is read (at S524), and the number Xa of signal intersections per unit distance within that section is calculated (at S525) and is substituted into the speed calculating formula (A) to calculate the speed (at S526).
In the case of a road other than an expressway or a national road, the road is subjected to operations similar to those for the national road. Specifically, the number of signal intersections within the section is read (at S527), and the number Xb of signal intersections per unit distance within that section is calculated (at S528) and is substituted into the speed calculating formula (B) to calculate the speed (at S529).
According to the method described above, the travel time required for the actual run can be accurately estimated to provide a reference for selecting whether a route giving priority toll roads or a route giving priority to general roads is to be used. Moreover, the desired travel time can be more accurately calculated by changing the vehicle speed data of each for the aforementioned expressways and the individual coefficients A, B, C and D in the formulas (A) and (B) on the basis of the various conditions such as the number of lanes, the day of the week, the time zone and the amount of business traffic.
The average vehicle speed data for each of the aforementioned road types may be set in advance as a table, as shown in FIG. 42. Moreover, the table shown in FIG. 43 may include conditions such as the number of lanes and the day of the week. In addition, the aforementioned two means can be suitably combined to calculate the average speed.
FIG. 43 shows an elapsed time displaying routine. The function is to determine and display the elapsed time from the time of transit from the starting point to the present location in a virtual run executed by scrolling the map with the vehicle position being fixed on the map display screen.
Before the start of the virtual run, the total required time period tr (i.e., the time period required for travel of the entire route) estimated by the routine of FIG. 39 and the speed Vn per hour for the road type of each node section are set (at S600 and S601), and the accumulated required time period is set as t=0 (at S602). The location of the virtual present location is defined as L and is set as L=node n, and the starting point (of node 0) is set as n=0 (at S604). The elapsed time t from the starting point and the remaining time period tr-t required to reach the destination are individually displayed (at S605 and S606), to start the virtual run (at S607).
It is decided (at S608) whether or not the virtual present location has reached the node n+1. If this answer is NO, the same elapsed travel time and remaining time are continuously displayed. In short, the display is not changed until reaching the next node. When this next node is reached, the elapsed time period t is calculated by the following Equation (at S609):
t=t+(distance between nodes n and n+1)/Vn.
Then, the increment of n=n+1 is set (at S610). The routine is returned to Step S605 to display the new elapsed travel time t and the remaining travel time tr-t. In this virtual run, the nodes will change at Step S610 as node 0→node 1→node 2→. . . →node n so that the values of t and tr-t are accordingly changed on the display.
The routine of FIG. 43 advances to Step S609 only when the virtual present location crosses over a node. However, because the route on the map is composed of those individual nodes and the lines joining the nodes, the virtual present location may appear, not at a node, but on a line between nodes. In this case, too, a more current time can be displayed by calculating the required time period by an interpolation of L between the node n and n+1 at Step S608.
FIG. 44 shows a routine for displaying time at a virtual present location. The function is to display the elapsed time for travel calculated on the basis of the starting time by determining the required time period from the starting point to the vehicle location on the route when a virtual run is executed by scrolling the map with the vehicle position being fixed on the map display screen.
First, at Steps S700 and S701, the total required time period tr estimated by the routine of FIG. 39 and the speed Vn per hour of each road corresponding to a node section are set, and a scheduled starting time tsr at the starting point is input (at S702). Then, the accumulated required time period t=0 and the location L of the virtual present location are set (at S703 and S704) to determine the distance (L=node n, n=0) to the virtual present location and the virtual time (t=tsr+t) at that point (at S705 and S706). The content of the virtual time t determined is displayed (at S707) to continue the virtual run (at S708). It is then decided (at S709) whether or not the virtual present location has reached the node n+1. If the virtual present location is midway between the node n and the node n+1, the routine is returned to Step S707, at which the previous time is displayed. If the node n+1 is reached, the time is updated (at S710) by the following Equation:
t=t+(distance between nodes n and n+1)/Vn.
Then, the node is updated to the next node (i.e., n=n+1), and the routine is returned to Step S707, at which the time t determined at Step S710 is displayed.
When the present system is installed for use on the vehicle after a schedule has been made at home, the route of the past actual run, and the day and time of the run, and the required time period are stored in the memory means on the basis of the scheduled route planed in advance, so that the file can be called up and displayed for each destination. As a result, the comparison between the required time period calculated by the system and the time period actually required in the past can be made to help plan the next trip over that route. Moreover, the day and time and the required time period of the past run are stored as data so that the past average value can be calculated to deduce the required time period.
FIG. 45 shows a routine for display of covered distance and remaining distance. The present function is to display the covered distance from the starting point to the virtual vehicle position on the route and the remaining distance from the virtual vehicle position to the destination when the virtual run is executed by scrolling the map with the vehicle position being fixed on the map display screen.
In FIG. 45, the total distance Kr from the starting point to the destination, the accumulated distance K=0 and the location L of the virtual present position are set (at S800, S801 and S802). Then, the inter-node accumulated distance obtained by the operations of FIG. 38, that is, the distance K covered from the starting point is displayed (at S804), and the remaining distance (Kr-K), i.e., the difference between the total distance and the covered distance, is determined and displayed (at S805) to continue the virtual run (at S806). It is then decided (at S807) whether or not the virtual present location has reached the node n+1. If this answer is NO, the routine is returned to Step S804, so that information including the covered distance and the remaining distance is continuously displayed.
When the virtual present location reaches the node n+1, the covered distance K is determined by the following Equation (at S808):
K=K+(distance between the nodes n and n+1).
Then, the node is updated (n=n+1) (at S809), and the routine is returned to Step S804, at which the covered distance and the remaining distance are updated.
The present invention also allows for the following modifications:
(1) In the foregoing embodiment, the means for setting the route between two set points allows the route between the two points to be searched by the system so that the virtual running function may be realized along the designed route. However, the setting of the route between the two points could be determined by designating the points or roads in advance by the user. Moreover, the route can be determined by following the road as displayed on the displayed map screen.
(2) The foregoing embodiment has been described as scrolling the virtual run screen downward from the top, but can be modified to scroll the same upward from the bottom. Moreover, an inverting function can be added to switch the scrolling direction from the downward direction to the upward direction so that the scrolling directions may be switched at the option of the user.
(3) The foregoing embodiment has been described as a map display device which can be utilized as a navigation system, but the present invention can also be embodied as a system operable only in the virtual run mode by separating out the navigation function. In this modification, the route information designed by the map display means is stored in a memory medium such as an IC card or a floppy disk which may be read by a navigation system installed on a vehicle and thereby used for route guidance.
(4) The present invention can also be used to allow the user to take a simulated journey on the home TV set, by combining it with picture data for generating a computer graphic screen or a photograph.
Here will be described an embodiment of the navigation system in which a detour point is set for a set route to thereby determine a route passing the detour point on the set route and returning to the set original route from the detour point.
In FIG. 46, an input/output section 1010 is equipped with a display, a speaker, a touch panel and a button switch for inputting/outputting route guidance information. A present position detecting section 1020 detects the present position of the user's vehicle by using various sensors and the GPS receiver. An information storage section 1030 stores navigation data 1006 including the map data necessary for calculating the route, calculated route data 1007 and display guide data 1008 necessary for the guidance. An operation section 1050 includes route setting means 1001, route guiding means 1002, search area setting means 1003, detour searching means 1004 and route selecting means 1005, and executes a route setting operation, a display guiding operation for route guidance and controls the entire system. By inputting the present location or the staring point and the destination from the touch panel or the button switch of the input/output section 1010, moreover, the route is set by the route setting means 1001 of the operation section 1050 to produce the route data 1007, and the route guidance is given by the display or speaker of the input/output section 1010 with display of the route by the route guide means 1002. The route data 1007 obtained by setting the route is stored and includes data for the number of intersections between the starting point and the destination, the identifying Nos. of the individual intersections, and an intersection array for the route, for example, as shown in FIG. 47. The navigation system of the present embodiment allows changing of the first-set route by designating a detour point P, as shown in FIG. 48, for the first-set route. For this operation, there are provided the search area setting means, the detour searching means 1004 and the route selecting means 1005. The search area setting means 1003 sets the search area from the detour point P, as shown in FIG. 48, when the detour point P is designated by the input/output section 1010; the detour searching means 1004 executes the route search to the detour point for each of intersections Ci to Cj in the search area set by the search area setting means 1003; and the route selecting means 1005 selects that route which passes through the detour point P and which has the shortest distance (Loi+li+Ij+Ldj) in the search area. Moreover, the route selecting means 1005 allows selection of that route which has only the intersections ahead of the present location, in case when present location is in the area.
Next, specific construction of the individual portions of the navigation system having the detour searching function according to the present embodiment will be described with reverence to FIGS. 49-51.
In FIG. 49, the input/output section 1010 functions to receive input of the destination and to instruct the operation section (central control section) 1050 of the navigation in accordance with input from the user and to output the processed data or the data received by data communication to the printer so that the guide information may be spoken and/or displayed in the screen as the drivers require. In order to realize these functions, the input section is equipped with: a touch switch 1011 for inputting the destination in terms of a telephone No. or coordinates and for requesting route guidance; a voice recognizer 1012; and a card reader 1013 for reading out the data recorded in an IC card or magnetic card. Moreover, the output section is equipped with a display 1014 for displaying the input data on a screen and for displaying the route guidance automatically on the screen upon request of the driver, a printer 1015 for outputting and printing the data processed by the operation section (central control section) 1050, the data stored in the information storage section 1030 and the communication data transmitted from the information center, and a speaker 1016 for outputting the route guidance in voice form.
The display 1014 is a color CRT or a color liquid crystal display for displaying in color all the screens necessary for navigation such as the route setting screen, the section map screen and the intersection map screen, based upon the map data and the guide data processed by the operation section 1050, and for displaying buttons for setting the route guidance on the screen, and for guiding the route and switching the screens. Especially, information for an intersection to be passed, such as the name of the intersection to be passed, is temporarily popped up in color on the section map screen.
This display is disposed in the instrument panel in the vicinity of the driver's seat so that the driver is allowed to confirm the present location of his vehicle and to learn the route ahead by observing the section map. Moreover, the display 1014 is equipped with the touch switch 1011 corresponding to the display of the function buttons so that the aforementioned operations may be operated on the basis of input signals generated by touching the buttons. The input signal generating means thus constructed of the touch panel and the push button switches constitute the input section.
The voice recognizer 1012 constitutes the input signal generating means for producing the signals to be processed by the operation section (central control section) 1050 after it has recognized the coordinate information input by voice through a microphone 1012a by the user.
The present position detecting section 1020 is equipped with: a GPS receiver 1021 making use of the global navigation system (GPS); a beacon receiver 1022; a data transmitter/receiver 1023 for receiving correcting GPS signals, making use of a cellular phone or a FM multiplex signal; an absolute direction sensor 1024 in the form of a geomagnetic sensor, for example; a relative direction sensor 1025 in the form of a wheel sensor or a steering sensor, for example; a distance sensor 1026 for detecting the covered distance from the r.p.m. of the wheels; and an accelerator sensor 1027.
The information storage section 1030 is a data base containing stored data necessary for route guidance, such as map data, intersection data, node data, road data, photographic data, destination data, the guide point data, the detailed destination data, road name data, branch point data, address data, display guide data, voice guide data and route data.
The data communication section 1040 is equipped with: a data transmitter/receiver 1041 for transmitting/receiving data with an external information center stored with massive route guiding information, to provide the information upon request of the user, and for transmitting/receiving the data to input the point coordinates by using the destination information which is stored in advance in the information storage media (i.e., the digital data storage means) such as an electronic notebook or IC card by the user; and a telephone transmitter 1042 for automatic communication by telephone transmission to acquire information regarding the vicinity of a point by designating the point and to communicate with the destination after the destination has been set.
The operation section (central control section) 1050 is equipped with: a CPU 1051 for executing the arithmetic operations; a first ROM 1052-1 stored with the programs for the route search, the programs for the display control necessary for route guidance and the voice output control necessary for voice guidance, and the data necessary for operating the programs; a RAM 1053 for temporarily storing the guidance information for the designed route and the data being processed; a second ROM 1052-2 stored with the display information data necessary for route guidance and the map display; a picture memory 1054 stored with the picture data to be used for the screen display; a picture processor 1055 for retrieving the picture data from the picture memory on the basis of the display control signal coming from the CPU 1051, for processing the picture data graphically and for outputting the processed data to the display; a voice processor 1056 for synthesizing the voice, phrase, sentence and sound, which is read out of the information storage section 1030 on the basis of the voice output control signal coming from the CPU, to convert it into analog signals and to output the analog signals to the speaker; a communication interface 1057 for transferring the input/output data through communications; a sensor input interface 1058 for retrieving the sensor signals of the present position detecting section; and a clock 1059 for supplying the date and time as internal diagnostic information. The driver can select either the screen display or the voice output for route guidance.
The routine for operation of the navigation system which is provided with the detour searching function according to the present embodiment, as shown in FIG. 49, will now be described with reference to FIG. 50.
When the program of the route guidance system is started by the CPU 1051, the map of and around the present position is displayed by recognition of the present position by the present position detecting section 1020, as shown in FIG. 50, and the name and so on of the present position are displayed at steps S1001 to S1003. Next, the vicinity map is extracted from the place name index and the national map to set the destination (goal), and the route from the present position to the destination is searched (at steps S1004 and S1005). At Step S1005, the route from the present position to the destination may be designated on the displayed map or set by another method.
When the route is determined, the route guidance is repeated until the destination is reached, while tracing the present position by the present position detecting section 1020 (at Steps S1006 to S1009). In case an input is made for setting a detour before the destination is reached, the search area is set for re-search so that the route guidance is likewise repeated until the destination is reached (at Steps S1006 to S1010).
The route data obtained by the aforementioned route searching operation (of Step S1005) is composed of a list of n number of intersections, the individual intersection Nos. and the distances to the next intersection. On the basis of this route data, the intersections are indicated by circles, and the roads joining the intersections are indicated by lines to thereby illustrate the detour point P and the search area, as shown in FIG. 48. Loi designates a distance between an intersection, which precedes entry of the route into the search area from the side of the starting point, and Ci designates the next intersection (i.e., an entrance intersection) which is located in the search area, and LDj designates the distance between an intersection (i.e., an exit intersection), which is located before the route leaves the search area, and the next intersection which is located at the side of the destination and outside of the search area. Moreover, the distance of the route, which is searched from the entrance intersection Ci in the search area to the detour point P, is designated as li, and the distance of the route, which is searched from the detour point P to the exit intersection Cj, is designated as Ij.
The detour search (of Step S1010) of this case, in which the detour point is set, is executed by the routine shown in FIG. 51.
Specifically, the detour point P is first set, and the search area is then set (at Steps S1011 and S1012) by designating the intersections and an arbitrary area on the route and by calculating the distances between the detour point and the intersections on the route. Next, the intersections on the route in the search area are searched, and a search is made up to the detour point P for each of the intersections so that the routes and their distances li and Ij are stored (at Steps S1013 and S1014). Moreover, the distances Loi and Ldj on the routes from the intersection outside of the search area to the intersection inside of the area are calculated (at Step S1015), and their sum of Loi+li+Ij+Ldj is calculated (at Step S1016) to determine such a combination of i and j (i≦j) as to give the shortest total distance (at Step S1017). Thus, the route C1→Ci→P→Cj→Cn is set as the new route (at Step S1018).
A method of setting the search area will now be described with reference to FIGS. 52-54.
When intersections on the route are to be utilized in setting the search area in the operation of Step S1012, two points a and b in the vicinity of the route are set, as shown in FIGS. 52a and 52b, intersections Ca and Cb on the route nearest from the two points a and b are located by the search to set the intermediate route as the search area. When an arbitrary area is to be designated, on the other hand, arbitrary two points a and b are set to include the detour point P, as shown in FIGS. 53a and 53b, within a rectangle having as apexes of a diagonal, those two points a and b, with the area inside of the rectangle set as the search area. In automatic setting without designation of either intersections or the areas, as in the aforementioned cases, the intersection Cp on the route which is the nearest by a straight distance r to the detour point P is located by a search, as shown in FIGS. 54a and 54b. Then, imagining a circle having a radius expressed by a function f(r), using the distance r between the point P and the point Cp as a variable, the intersections Ca and Cb on the route which are nearest to the circuit around the detour point P are located by search to set the intermediate route as the search area.
FIG. 55 is a flowchart of the subroutine for searching to modify a route to include a detour point. In the search for the detour point to be executed at Step S1014, the route to go out of the area need not be set in the case where the search area is two-dimensionally set, as has been described with reference to FIG. 53. As shown in FIG. 55, however, a search to the detour point P is performed for each intersection in the area while examining whether or not the search route is within the area, as shown in FIG. 55, and the route and its distance I are stored. In the selection of the search route to be executed at Step S1017, whether or not the present location is within the search area is examined, as shown in FIG. 56, in case the vehicle is running with route guidance. If the present location is not in the search area, the combination of i and j for the shortest total distance, as has been described with reference to FIG. 51, is determined as is. If the present location is in the search area, on the other hand, the combination of i and j for the shortest total distance may be determined by selecting only the intersections ahead for li and by selecting all the intersections in the search area for Ij.
FIG. 57 is a flow chart for a routine including the detour search in the virtual running mode. When the virtual running is started, the starting point and the destination are first set from the initial screen display to search the route between them. When the route is set, the entire route is displayed, and the virtual run is then started along the route. If the detour setting comes midway, the detour search is executed like before, and the virtual run is continued along the corrected new route.
The navigation system having the detour searching function according to the embodiment thus far described comprises: stored route data including the information concerning the intersection array of a set route; search area setting means for setting the search area from a detour point by designating said detour point; detour searching means for executing the route search passing through said detour point for returning to an intersection in a search area set by said search area setting means, for each of the intersections in said search area; and route selecting means for selecting the route passing through the detour point on the basis of said search results, whereby the route search in the case of a detour can be accomplished within a short time period. In case, moreover, the present position is present in the search area, what is selected is the route to be joined to the intersection, in which the route toward the detour point is present ahead of said present position, so that the route can be easily changed even while running along the first set route or even in case a place to be called comes to mind.
In case, moreover, the first set route fails to match the desire of the user, as in case a route to be followed is present in the district but is not desired, the route can be changed to the desired one by designating a point on the road as the detour. Even in case the user makes an ambiguous desire "to pass around here", the route can be changed to a desired one by designating the central portion of that area. As the method of confirming the set route, there is the virtual run mode, and the route can also be automatically changed in this case by setting the detour so that the information such as the covered distance, the elapsed time period and the toll can be updated and confirmed. As a result, the route can be partially changed while exploring the first set route so that another route according to the intention of the user can be easily set in a short time period.
In the navigation system of the prior art, as disclosed in Japanese Patent Laid-Open No. 3899/1990, for example, a desired transit point or the like can be set as the condition for executing the search. However, if the transit point is later added to the designed route or if the route is partially changed, the route search is executed again from the start thereby to make the simple addition of a transit point or a partial change without a re-execution of the route search substantially impossible. While running on the designed route, it is likewise impossible to set a new detour or to change the route, without the route from the present location to the destination being newly searched again. When the re-searched route fails to match the desire of the user, the transit point could be set again to again search the route, but the route search has to be done over from the beginning. In any event, redoing and entire route search takes a long time. Still worse, there arises a problem that the initial route may be absolutely changed depending upon the first route, the road situations and the detour point. The present embodiment of the navigation system with its aforementioned detour searching functions can solve the above-specified problem so that it can change the route by only a partial search even in case a detour is designated for the first set route.
In the embodiment of the navigation system having the aforementioned detour searching function, the search area is automatically set by setting a circle which has its radius equal to a function of the distance between the detour point and the nearest intersection on the route, but the search area may also be set by searching the intersections on the route while using the distance from the nearest intersection as a criterion. Moreover, the aforementioned embodiment discloses the method for determining the shortest route as the method of searching the route passing through the detour point. However, the optimum road may be determined by using the Dijkstra method from not only the data such as the road and intersection information stored in the information storage section but also various information such as distance information, average degree of business travel on the road and the number of lanes of the road.
Here will be described an embodiment of the navigation system for displaying a more detailed map for a point closer to the set point when a map is to be displayed by reference to FIGS. 58 and 59. In FIG. 58, a present position detecting section 2001 detects the present position by using a variety of sensors, as will be described in the following, to output at least the coordinates of the present position and the type of the road of the present position. A starting point setting section 2002-1 sets the present position, which is initially output by the present position detecting section 2001, as the starting point and stores the starting point data coordinates in a starting point data storage section 2002-2. A destination (goal) setting section 2003-1 is arbitrarily set by the user by a later-described input section (or point setting section) and stores the set destination as destination data coordinates in a goal data storage section 2003-2. A transit point setting section 2003-3 may also be operated by the user and stores set transit point data coordinates in a transit point data storage section 2003-4. Distance calculating sections 2004-1, 2004-2 and 2004-3 calculate distances on the basis of the present position coordinates detected by the present position detecting section 2001 and the individual coordinates stored in the starting point data storage section 2002-2, the destination data storage section 2003-2 and the transit point data storage section 2003-4. A comparing decision section 2005 compares and decides the lengths of the individual distances and selects the shortest distance.
A layer table 2008 has numbered layers, FIG. 59b, each containing a distance and a road type (kind) wherein a layer number can be chosen either by the distance or the road type. A layer determining section 2006 determines the chosen layer from the shortest distance information from the comparing decision section 2005 by reference to the layer table 2008, or, when the layer number corresponding to the road type information from the present position detecting section 2001 is larger than the layer number chosen by the shortest distance information, then the layer determining section 2006 determines the chosen layer from the road type information from the present position detecting section 2001. In short, the layer determining section 2006 determines the lower-ranked layer (i.e., higher numbered layer) of (1) the layer corresponding to the distance information from the comparing decision section 2005 and (2) the layer corresponding to the road type information from the present position detecting section 2001.
Road data 2009 is stored, as shown in FIG. 59a, as road information together with node information, the road type and the layer number for each road. A map drawing section 2007 reads the road information from the road data 2009 and draws a display of the roads joined at the nodes such that the roads of a rank equal to or higher than that of the lowest ranked layer determined by the layer determining section 2006 are displayed in an emphasized manner. Moreover, the map drawing section 2007 may change the scale of the displayed map in accordance with the determined layer. In this way, a scale can be selected according to the amount of road information that can be viewed with clarity. Moreover, the names of intersections may be displayed on the screen for intersections within a range forward and backward of the present position by several tens meters when the road data 2009 includes such intersection names. Passage through an intersection can be confirmed by detecting the present position. Also, the name of the road being followed may be displayed as "NATIONAL ROAD NO. 19", for example.
An example of the construction of the road data having the layer structure to be used as the map drawing data in the aforementioned map drawing section 2007 is shown in FIG. 59a. This road data has, as the information of each road, the number of nodes forming the road, the road type, the layer No. and the coordinates of each of the actual nodes. In layer table of FIG. 59b, each layer No. has a corresponding listed distance form which the lowest ranked layer is determined based upon the shortest of the distance between the starting point and the present location and the distance between the present location and the destination. The distances in the table are such that the highest ranked layer 0 has the longest distance (100 Km) and the lower ranked layers have progressively shorter distances until the layer 7 has the shortest distance (1 Km). The layer 0 is assigned to an expressway; the layer 1 is assigned to an urban expressway; the layer 2 is assigned to a toll road; the layer 3 is assigned to a national road; the layer 4 is assigned to a prefectural road; the layer 5 is assigned to a local major road; the layer 6 is assigned to a general road; and the layer 7 is assigned to a general road including a lane. Thus, the layers of higher rank correspond to the roads necessary for running the longer distances. However, these layer Nos. are not determined exclusively by the road types but also by considering the types of roads to be joined to that road and are stored in the information storage section 1030. In case the road to be travelled from a national road to an interchange with an expressway is a general road, for example, the general road has to be displayed so that the driver may use the road information as route guidance to travel on the general road to the expressway interchange from the national road, and the road to be travelled has to be given the same layer No. as that of the national road even if it is a general road. On the other hand, even a toll road is given the same layer No. as that of a general road if it is travelled only when it leads to a near destination or is blinded, such as a toll road or a skyline around a pleasure resort. Thus, the layer No. is decided also by the relationship of a road with its joining roads and is stored in advance in the map data. In this way, the method of deciding the layer No. of a road may be optimized when the route search is performed in advance by an arbitrary combination of the starting point and the destination so that the layer No. in the map data may be decided on the basis of the search results.
The layer No. of the road to be displayed is decided according to the distances between the starting point and the present position and between the present position and the destination and by considering the layer No. of the road being followed. If, therefore, the distance between the present position and the destination exceeds 100 Km, the road of layer 0 is displayed in the emphasized manner. In case, however, a road of layer 3 is being followed at present, roads having layer numbers of 3 or lower are displayed in the emphasized manner. Moreover, more roads are sequentially added and displayed in the emphasized manner because more detailed roads are required as the destination is approached, for example, the roads of layer 4 are added when the destination is within the range of 20 Km, the roads of layer 5 are added within the range of 5 Km, the roads of layer 6 are added within the range of 2 Km, and the roads of layer 7 are added within the range of 1 Km.
In the aforementioned embodiment, in case a plurality of transit points or destinations are set, as shown in FIG. 64, the layer of a lower rank is determined by the shortest distance of the distance to the transit point A from the present position, and the distance to the transit point B from the present position. At an intermediate position between the transit points A and B, in which the layers set by the transit points A and B overlap, the layer of the shorter one of the distances between the present position of the vehicle and the points A and B is adopted. If the vehicle is positioned closer to the transit point B, the display is made according to the layer set at the transit point B. In the overlapping portion of the layers determined by the transit points A and B, on the other hand, the layer at the lower rank at the point A or B may be adopted independently of the distances between the present position and the points A and B.
By thus interchanging the layers according to the distances, the roads to be emphasized and displayed are determined to make it easy for the driver to view what road is followed to the destination. The reason why the layer No. of the road to be displayed on the screen is determined not only by the distance between the present location and the destination but also by the layer No. of the road being actually followed, is the necessity for displaying a detailed road having a lower rank so that the vehicle may return to a major road such as a national road when when the vehicle strays off the major road onto a road which is not displayed in the emphasized manner on the screen.
FIG. 60 is a diagram showing an example of the layer display area which is determined from the distance relation between a starting point and a destination, and FIGS. 61a-61d presents diagrams showing examples of the screen display to be changed according to the run from the starting point to the destination. While travelling from the starting point to the destination, the roads of layer 7 and lower layer numbers are emphasized at the starting point, but only roads of higher rank are emphasized as the present point moves further from the starting point. When the present position is over 70 Km and less than 100 Km from the starting point, roads of the layer 1 are emphasized, but the rank of the road layer being emphasized drops down to the next lower rank, layer 2, if the distance to the destination becomes less than 70 Km. An example of the emphasized display state of layer 7 (all the roads) while in the vicinity of the starting point is shown in FIG. 61a. Moreover, an example of the emphasized display of the roads up to the layer 3 at a point of 50 Km to the destination is shown in FIG. 61b. An example of the state in which the roads up to the layer 5 are emphasized and displayed because travel on a road of layer 4 is eminent, is shown in FIG. 61c. An example of the state, in which all the roads up to the layer 7 are displayed while in the vicinity of the destination, is shown in FIG. 61d.
Here will be described the entire construction and the processing flow of the navigation system according to the embodiment of FIGS. 62 and 63. In execution of the routine of the navigation system in the CPU 51 of FIG. 49, the destination (goal) is input first, as shown in FIG. 62, and the coordinates of the destination and the coordinates of the present location are stored (at Steps S2011 to S2013). When a transit point is input, the number and coordinates of the transit point are stored in Steps S2014 to S2016.
At the running time, moreover, the present position is calculated, as shown in Step 2021 of FIG. 63, and the distances from the coordinates of the destination and any stored transit points to the present position are determined to select the shortest distance (at Steps S2021 and S2022). On the basis of this shortest distance, the layer No. is determined from the layer table, step S2023, and is compared with the layer No. of the road of the present position (at Steps S2023 and S2024). In case the layer No. of the present road is higher, the map is drawn while emphasizing the roads having layer Nos. of higher rank than that of the present road (Steps S2025 and 2026). In case the determined layer No. is higher (lower rank), the map is drawn while emphasizing the roads at higher ranks than that of the layer No. (at Step S2026).
According to the foregoing embodiment of the navigation system for displaying a more detailed map as a set point is approached, the map data is classified in the layer structure so that roads of different ranks are automatically emphasized according to the distances from the starting point, the destination and the inputted transit points. As a result, even in case a plurality of points are set, a detailed map can be displayed when close to each of the set points whereas a coarse map can be displayed when between the individual points, depending upon the distances. Thus, there can be attained an advantage that the driver can easily acquire the necessary detailed map information to change the route from the present position in the map display when the traffic is cut off or in a snarl.
Specifically, in the map display system as disclosed in Japanese Patent Laid-Open No. 130412/1990, for example, the degree of detail of the map in an area to be displayed in the screen is changed by recognizing the type of road, on which is displayed the present position of a vehicle, and by controlling the reading of the display elements of the map according to the type of the recognized road. In case, however, a plurality of transit points other than the destination are set and located on major trunk roads, such as national roads, the degree of detail of the map being displayed is coarse showing only the trunk roads so that the reduced scales of the map have to be called for when detailed information of the regions of the transit points is desired. In case, moreover, the technique as disclosed in the map display system of Japanese Patent Laid-Open No. 206710/1984 is applied to the system capable of inputting a plurality of points such as the transit points and the destination, a reduced scale and road display level are decided according to the distance from the present location of the vehicle to a next transit point so that a wide map and a coarse road map are displayed just after passing a transit point. As a result, there arises a disadvantage that little information is displayed in case the driver wishes to change his future course from the displayed maps.
The aforementioned embodiment of the navigation system for displaying a more detailed map as a set point is approached solves the above problem by also providing the driver detailed map information after passing the set point, even in case a plurality of points such as the starting point, the transit points and the destination are set, and providing only the necessary map information at positions spaced from the set points.
While the foregoing embodiment describes the display of roads at higher rank than the determined layer in the emphasized manner along with non-emphasized roads of lower rank, the roads of the higher rank may be displayed exclusively leaving out the layers of lower rank. Alternatively, the hues and color densities of the roads displayed may be changed with the layers. Moreover, although the emphasized layers are determined according to the shorter one of the distances between the starting point and the present location and between the present location and the destination, the emphasized layers may be determined only according to the distance between the present location and the destination and the road on which the vehicle is located. In case the driver strays from the route, the present road being travelled is recognized so that roads at higher rank than that of the layer of the present road are displayed or displayed in the emphasized manner. If the proper name of an intersection can be searched and displayed by referring to the place name from the road data or the intersection data, the present position can be confirmed from the name of the intersection on the map, and the present position can be easily corrected by viewing the name of the intersection being passed.
Moreover, the navigation system according to the foregoing embodiment can be made so simple as to display the present position of the vehicle and the distance or direction to the destination or the transit points by setting the destination and the transit points or if it searches the route to the set destination and transit points and guides the driver along the designed route. | A vehicle navigation system includes a simulated run mode along with a normal navigation mode. In the simulated run mode, a simulated present position is calculated to move in accordance with simulated motion so that route guidance information is presented to the viewer in the same manner as during actual navigation. The simulated motion may be increased or decreased, may be stepped or continuous, and/or may be controlled in accordance with stored speed information on the roads of the route. | 6 |
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention is in the field of amphibious vehicles.
Background Art
[0002] U.S. Pat. No. 4,231,131 by Young discloses an inflatable boat where the floor of the boat is above the water line of the boat. The boat has a motor that is below the water line of the boat as the sole means of propulsion. This inflatable craft in incapable of travel across land or ice and does not have skirts such that it can ride on an air cushion of its own production.
[0003] U.S. Pat. No. 5,727,494 by Caserta et al. discloses an amphibious vehicle with wheels that may be retractable as well as pontoons or multiple hulls that may be retractable. The vehicle uses one engine for both land propulsion through its wheels and water propulsion using a propeller in the water. There is no mention of flexibility. A rigid vehicle will have disadvantages when going over waves as it will not absorb any of the wave's force but rather will be buffeted by the wave. Furthermore the vehicle must pause after entering water and before leaving water in order to retract or deploy the wheels. This has a disadvantage in not allowing for quick and smooth transitions between land and water.
[0004] U.S. Pat. No. 6,595,812 by Haney discloses a snow mobile with a floating hull so that it can float on water. The snow mobile has an endless belt with a plurality of longitudinally spaced apart integral lugs as its means of propulsion on snow, ice, and water. Such a belt suffers significant wear to its lugs when driven on dry land or paved surfaces as compared to a vehicle riding on a cushion of air. Furthermore while the skis for the snow mobile have suspension components to deal with rough terrain the entire vehicle is not constructed to flex and absorb contours in terrain or lessen the impact of waves while on the water.
SUMMARY OF THE INVENTION
[0005] An amphibious transformer vehicle (ATV) having front left and right skirts, rear left and right loop bags, and inflatable side and middle pontoon-skegs along a longitude of the vehicle. This vehicle is designed to move over water, snow, ice, ground, sand and other loose surfaces, as well as paved and other hard services as well as grass and light vegetation. It can make transitions between all the surfaces without need to stop or perform any modifications to the vehicle to transition between surfaces. This vehicle has advantages over other hovercraft and airboats that are designed with rigid frames and hulls. Based on a design using a flexible frame and structures that lean on flexible pontoon-skegs it can handle waves and obstacles without being damaged and it is not upset by a wide range of variations in terrain.
[0006] Like in a sidewall type hovercraft, flexible pontoon-skegs are working as side walls keeping the air volume and pressure underneath that is controlled by lifting fans.
[0007] Middle pontoon-skeg divides air chamber into two parts—left and right subchambers.
[0008] This efficiently replaces side hovercraft skirts, providing unprecedented stability at all modes of operating as well as steady air discharge that is working like grease between skegs, front skirts, rear loop bags and the surface. Air discharge is lifting a vehicle from the surface on a height (tip) of 1-2 inches, and making it fly above the surface like a hovercraft. A combination of flexible inflatable pontoons-skegs, a flexible front skirts and rear loop bags, a flexible tubing lower frame, flexible powertrain, and cabin independent modules acting as the vehicles suspension when traveling over the previously listed surfaces and to provide for a smooth ride. Depending on vehicle payload and operational conditions pressure inside pontoon-skegs is increased or decreased by automatic inflation system controlled by pilot from dashboard. Over flat terrain for higher speeds and better fuel economy pressure in the pontoon-skegs must be set at a high pressure between 1.5 and 3.0 pounds per square inch (psi). Over high waves and rough terrain for reducing air leakage from underneath chambers and improving flexibility that helps to pass obstacles, the pressure in the pontoon-skegs must be decreased down to between 0.5 and 1.5 psi. From wear and tear inflatable pontoon-skegs are protected by easily replaceable polyethylene shells, that are attached to the inflatable pontoon-skegs by lacing.
[0009] Amphibious transformer vehicle consists of three major independent modules—lower flexible tubing frame, flexible powertrain, and flexible cabin. Each of the modules could be customized for certain needs without any modifications required to be done to other modules.
[0010] A lower frame designed as a construction scaffold or tubing cross mesh The frame is built primarily of longitudinal stringers and cross stringers. The stringers are joined. The stringers can be joined by welding, clamping, fastening or other joining means.
[0011] In a preferred embodiment the stringers are joined by special crimp clamps machined from solid aluminum bars. A powertrain module and a cabin module are attached to the lower frame by crimp clamps as well. The lower frame clamps have openings for the longitudinal stringers and cross stringers at tow end of the clamp. The openings can be pass through openings such that the stringers pass through the clamps. In a preferred embodiment the openings are positioned such that the clamped stringers would be held in right angles (90 degrees) to each other. The outside edge of the frame clamps have a small gap and a perpendicular bolt hole. When a bolt is placed in the bolt hole and tightened it closed the small gap and acts to increase frictional forcers between the lower frame clamps and the lower frame stringers The clamps have a single pass through opening to allow it to fit on a lower frame stringers with a small gap in the opening and a perpendicular bolt hole. The powertrain and cabin clamps uses predrilled bolt holes so that a powertrain and cabin may be attached to the lower frame, exactly at the certain points.
[0012] In this preferred embodiment by clamping rather than screwing into the lower frame stringers this avoids placing additional point stresses on the lower frame stringers which may lead to cracks and lose resistance to the loads in the lower frame stringers.
[0013] The brackets have openings for the longitudinal members and cross members at two ends of the bracket.
[0014] In an alternative embodiment the brackets have a fixing means such as a screw or bolt to further secure the brackets to the frame members.
[0015] At least three inflatable pontoons are underneath the frame and are all parallel to one another. At least two longitudinal members are connected to each of the pontoons. In a preferred embodiment the longitudinal members pass through loops along the length of the pontoon. The loops have gaps such that a frame bracket connects to the longitudinal frame members and are attachable to the cross frame members.
[0016] The frame is constructed so that it is flexible and has the ability to conform and absorb changes in the surface on which the craft is on. This allows the craft to crest waves, ride on uneven ice and other uneven surfaces, and to transition between surfaces such as land and water, ice and water, dry land and snow, water and snow covered land, etc. smoothly.
[0017] In a preferred embodiment the frame members are tubular. In a further embodiment the tubular frame members are made of an aluminum alloy chosen for its flexibility and lightness while still providing strong though flexible frame. A further advantage of aluminum is it maintains flexibility and suffers little or no mechanical deformation in many conditions and in many different operating temperatures.
[0018] Between each pair of adjacent inflatable pontoons there is an inflatable skirt. In a craft with three inflatable pontoons there will be two inflatable skirts, for each additional inflatable pontoon there would be an additional inflatable skirt. The inflatable pontoons are sealed so that they are air tight. The inflatable pontoons have valves for inflation and deflation. These valves are either manually or automatically controlled. The inflatable skirts are not air tight. The inflatable skirts are designed such that air escapes only from the bottom of the skirt so that the craft rides on a cushion of air like a hovercraft. The combination of inflatable pontoons and inflatable skirts work such that the craft is supported on land and floats on water whether or not the inflatable skirts are inflated.
[0019] The inflatable pontoons and inflatable skirts are preferably made out a polyurethane coated fabric.
[0020] The inflatable nature of the pontoons and skirts means the frame and inflatable sections are easier to store or ship.
[0021] A section of the frame toward rear of the craft has an additional support frame. The support frame bears the additional load of at least one engine or motor, at least one fuel cell, at least two skirt inflating fans, and at least one main propulsion fan with rudders. The engine or motor may be electric or internal combustion.
[0022] The support frame and components mounted to it are detachable for easier and greater shipping and storage density.
[0023] In a preferred embodiment the craft has an internal combustion engine.
[0024] In a preferred embodiment the engine is connected at both ends of its drive shaft. To the front facing end there is a mechanical linkage connecting the engine to the at least two skirt inflating fans. The skirt inflating fans are variable in speed so that the amount of air cushion beneath the craft is controllable. To the rear facing end there is another mechanical linkage connecting the drive shaft of the motor to the main propulsion fan.
[0025] The mechanical linkage is preferably a belt or chain driven linkage with gears or pulleys connecting the driveshaft of the engine to the main propulsion fan. In another embodiment there is a driveshaft extension linkage from the engine to the drive main propulsion fan. In a different embodiment the engine is connected to a transmission and the transmission is then mechanically linked to the main propulsion fan.
[0026] In another embodiment the at least two skirt inflating fans and at least one main propulsion fan are driven by electric motors and the fuel cell is a hydrogen fuel cell, battery, or some other means to store electrical energy. In this embodiment there may or may not be an additional engine acting as generator to recharge the batter or other electrical storage means.
[0027] In any embodiment the one of or all of the engine or motor, fuel cell, and supporting parts such as control units, fluid tanks, radiators, and so on are individually or together covered by hoods for additional protection.
[0028] Each of the skirt inflating fans and the at least one main propulsion fan have an intake side and an exhaust side. The intake side of each fan has a protective mesh to catch objects and prevent them from passing through the fans in order to protect the fan blades from harm.
[0029] Towards the front end of the craft there is a control console. The console controls the speed of the skirt inflating fans and the at least one main propulsion fan. The console also controls the rudders on the at least one main propulsion fan thereby controlling the direction of the craft. The console is linked to control mechanisms for the skirt inflating fans, main propulsion, engine or motor, and rudders by mechanical, electrical, or hydraulic means.
[0030] Also the front of the craft can be configured in multiple configurations. In one embodiment the from of the craft has a platform with seats for passengers. In another embodiment the front of the platform is configured to haul cargo. In either embodiment the front of the craft may have additional framework to support a shelter for the passenger or cargo area. With or without a shelter the craft may be equipped with a windshield. The windshield may additionally have a windshield wiper.
[0031] In a preferred embodiment the craft is equipped with headlights.
[0032] In another embodiment the ATV has at least two inflatable pontoon-skegs being parallel and adjacent with a space between the at least two inflatable pontoon-skegs running a longitude of the ATV. Two of the at least two inflatable pontoon-skegs that are parallel and adjacent with the space between forms a pontoon-skeg pair. Each inflatable pontoon-skeg is only a component in up to two pontoon-skeg pairs. The ATV has at least one pontoon-skeg pair. In the space between the at least two inflatable pontoon-skegs in the at least one pontoon-skeg pair there is a front skirt and a rear loop bag. An air chamber cell is formed by the pontoon-skegs of a pontoon-skeg pair as a pair of sidewalls the front skirt and the rear loop bag. The air chamber cell maintains an air pressure and volume controlled by a lifting fan. Connected to and on top of the at least one pontoon-skeg pair there is a flexible frame. Connected to the flexible frame there are modules including a powertrain module, a pilot dashboard, and a cargo module or cabin module. The modules are connected to the flexible frame by a plurality of module clamps. The lifting fan is part of the powertrain module. The ATV being capable of traveling over varied terrain including water, snow, ice, ground, sand and other loose surfaces, paved and other hard services, grass, and light vegetation.
[0033] The specific embodiments described herein are intended to further explain the best mode known for practicing the disclosure and to enable others skilled in the art to utilize the disclosure in such, or other, embodiments and with various modifications required by the particular applications or uses of the present disclosure. The specific techniques, conditions, materials, and proportions set forth to illustrate the principles and practice of the invention are exemplary only and should not be taken as limiting the scope of the invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The present invention will now be discussed in further detail below with reference to the accompanying figures in which:
[0035] FIG. 1 shows the amphibious transformer vehicle (ATV) from a side view;
[0036] FIG. 2 shows the ATV from a side view;
[0037] FIG. 3 shows the ATV from a top view;
[0038] FIG. 4 shows the ATV from a rear view;
[0039] FIG. 5 shows the ATV from a front view;
[0040] FIG. 6 shows the ATV from a bottom view;
[0041] FIG. 7 shows the ATV from a front top perspective view;
[0042] FIG. 8 shows the ATV from a rear top perspective view;
[0043] FIG. 9 shows the ATV from a front bottom perspective view;
[0044] FIG. 10 shows the ATV's flexible frame from a front top perspective view;
[0045] FIG. 11 shows the ATV's flexible frame and pontoon-skegs from a rear top perspective view;
[0046] FIG. 12 shows the ATV's flexible frame and pontoon-skegs from a front bottom perspective view;
[0047] FIG. 13 shows the ATV's powertrain module from a front top perspective view;
[0048] FIG. 14 shows the ATV's powertrain module from a front bottom perspective view;
[0049] FIG. 15 shows the ATV's powertrain module mounted to the flexible frame from a rear top perspective view;
[0050] FIG. 16 shows the ATV's pontoon-skegs, air chamber cell, and lifting fans in a cross sectional front top perspective view;
[0051] FIG. 17 shows the ATV's pontoon-skegs, air chamber cell, and lifting fans in a cross sectional rear bottom perspective view;
[0052] FIG. 18 shows the ATV's pilot dashboard and chair on a cargo module with a canopy frame in a rear top perspective view;
[0053] FIG. 19 shows the ATV's pilot dashboard and chair on a passenger module with a canopy frame in a rear top perspective view;
[0054] FIG. 20 shows the ATV's frame members and crimp clamps;
[0055] FIG. 21 shows the ATV's crimp clamps;
[0056] FIG. 22 shows the ATV's module clamps.
[0057] FIG. 23 demonstrates the flexibility of the ATV's frame pieces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] Reference is being made to FIGS. 1-22 . An amphibious transformer vehicle (ATV) 000 with pontoon-skegs 101 on the bottom. Mounted on top of the pontoon-skegs 101 are longitudinal stringers 201 and connected to those are cross stringers 203 . In a preferred embodiment the longitudinal stringers 201 and cross stringers 203 are connected by frame crimp clamps 205 .
[0059] The longitudinal stringers 201 and cross stringers 203 together form a flexible frame 200 on which are connected to all other modules by module crimp clamps 207 .
[0060] The longitudinal stringers 201 are connected to the pontoon-skegs 101 by passing through pontoon-skeg loops 103 . Between each pair of pontoon-skegs 101 there is an air chamber formed by the pair of pontoon-skegs 101 the front skirt 109 , a rear skirt 113 and a rear loop bag 111 . The top of the air chamber is defined by air chamber top 107 . The amount of air pressure in the air chamber is managed by adjusting a lifting fan 701 which pass through air chamber top 107 . Each pair of pontoon-skegs 101 with air chamber has one lift fan 701 . In a three pontoon-skeg 101 embodiment as shown there are two parallel air chambers. The pontoon-skegs 101 are also inflatable with pontoon-skeg air chamber 105 as a hollow space for air. The pontoon-skegs 101 are air tight, though in alternative embodiments they may have their internal pressure adjusted by a pontoon-skeg valve and pontoon-skeg compressor (not shown).
[0061] The pontoon-skegs 101 , front skirt 109 , rear skirt 113 , air chamber top 107 , and rear loop bag 111 are all flexible. The pontoon-skegs 101 , front skirt 109 , rear skirt 113 , air chamber top 107 , and rear loop bag 111 I along with the lift fans 701 act to keep an air volume and pressure underneath the ATV 000 like a hovercraft. The pontoon-skegs 101 , front skirt 109 , rear skirt 113 , air chamber top 107 , rear loop bag 11 land the flexible frame 200 allow the ATV 000 to transition smoothly between many different types of terrain including land and water, ice and water, dry land and snow, water and snow covered land, etc. smoothly.
[0062] The inflatable skirts defined by pontoon-skegs 101 , front skirt 109 , rear skirt 113 , air chamber top 107 , and rear loop bag 111 are not air tight. The inflatable skirts are designed such that air escapes only from the bottom of the skirt so that the ATV 000 rides on a cushion of air like a hovercraft. The combination of inflatable pontoon-skegs 101 and inflatable skirts work such that the ATV 000 is supported on land and floats on water whether or not the inflatable skirts are inflated.
[0063] The inflatable pontoon-skegs 101 and inflatable skirts are preferably made out a polyurethane coated fabric. The inflatable nature of the pontoon-skegs 101 and skirts means the frame and inflatable sections are easier to store or ship.
[0064] Depending on vehicle payload and operational conditions pressure inside pontoon-skegs 101 is increased or decreased by automatic inflation system controlled by pilot from pilot dashboard 301 . Over flat terrain for higher speeds and better fuel economy pressure in the pontoon-skegs 101 must be set at a high pressure between 2.5 and 3.0 pounds per square inch (psi). Over high waves and rough terrain for reducing air leakage from underneath chambers and improving flexibility that helps to pass obstacles, the pressure in the pontoon-skegs must be decreased down to between 0.1 and 0.15 psi. From wear and tear inflatable pontoon-skegs are protected by easily replaceable polyethylene shells (outer surface of pontoon-skegs 101 as shown), which are attached to the inflatable pontoon-skegs by lacing (not shown).
[0065] Amphibious transformer vehicle consists of three major independent modules—flexible frame 200 , flexible powertrain 600 , and either flexible passenger cabin 400 or flexible cargo platform 500 . Each of the modules could be customized for certain needs without any modifications required to be done to other modules.
[0066] A lower frame designed as a construction scaffold or tubing cross mesh The frame is built primarily of longitudinal stringers 201 and cross stringers 203 . The stringers are joined. The stringers can be joined by welding, clamping, fastening or other joining means. The flexible frame and design of the ATV allow for the ATV to traverse at least three foot drops when traveling in a forward direction. In a preferred embodiment the ATV 000 and flexible frame 200 are built to function for at least 10,000 duty hours without structural failure.
[0067] In a preferred embodiment the stringers are joined by special frame crimp clamps 205 . The frame crimp clamps 205 are preferably machined from solid aluminum blocks. The flexible powertrain module 600 and flexible passenger cabin module 400 or flexible cargo platform 500 are attached to the flexible frame 200 by module crimp clamps 207 .
[0068] The frame crimp clamps 205 have openings 205 B for the longitudinal stringers 201 and cross stringers 203 at the end of the frame crimp clamp body 205 A. The openings 205 B can be pass through openings such that the stringers pass through the clamps. In a preferred embodiment the frame crimp clamps 205 and the module crimp clamps 207 are machined from solid aluminum bars for increased structural rigidity and to decrease the likelihood of structurally compromising defects.
[0069] In a preferred embodiment the openings are positioned such that the clamped stringers would be held in right angles (90 degrees) to each other 205 as shown in FIGS. 20 and 21 . The outside edge of the frame crimp clamp body 205 A has a small gap and a perpendicular bolt hole with frame crimp clamp nut and bolt 205 C passing through. When the frame crimp clamp nut and bolt 205 C is placed in the bolt hole and tightened it closed the small gap and acts to increase frictional forcers between the frame crimp clamps the frame stringers 201 and 203 . The module crimp clamps 207 have an opening 207 B. The module crimp clamp body 207 A has an upper and lower part. The two parts of the module crimp clamp body 207 A are connected by module crimp clamp nuts and bolts 207 C. When the module crimp clamp nuts and bolts 207 C is placed in the bolt hole and tightened it closes the gap between the two parts of the module crimp clamp body 207 A and acts to increase frictional forcers between the module crimp clamps 207 the cross stringers 203 . The module crimp clamp body 207 A has a module stud 207 D that protrudes from the module crimp clamp 207 and is what the flexible modules 600 , 500 or 400 are bolted onto.
[0070] At least three inflatable pontoon-skegs 101 are underneath the flexible frame 200 and are all parallel to one another. At least two longitudinal stringers 201 are connected to each of the pontoon-skegs 101 . In a preferred embodiment the longitudinal stringers 201 pass through pontoon-skeg loops 103 along the length of the pontoon-skeg 101 . The pontoon-skeg loops 103 have gaps such that a frame crimp clamp 205 are attached to the longitudinal stringers 201 and are attachable to the cross stringers 203 .
[0071] In a preferred embodiment the longitudinal stringers 201 and cross stringers 203 are tubular. In a further embodiment the flexible frame stringers 201 and 203 are made of an aluminum alloy chosen for its flexibility and lightness while still providing strong though flexible frame. A further advantage of aluminum is it maintains flexibility and suffers little or no mechanical deformation in many conditions and in many different operating temperatures.
[0072] FIG. 23 shows the flexibility of the longitudinal stringers 201 and flexible frame 200 . The longitudinal stringers 201 and flexible frame 200 can curve up to 20 degrees which corresponds to length A. In a preferred embodiment the longitudinal stringers 201 have a length B of 6 meters. In this preferred embodiment the 20 degrees of flexibility in either direction, up or down, mean length A is equal to 1 meter.
[0073] Flexible powertrain module 600 includes powertrain frame 221 which connects to flexible frame 200 by module crimp clamps 207 . A propulsion fan support 223 is connected to powertrain frame 221 and braced by propulsion fan support braces 225 . The powertrain frame 221 is also connected to engine and lift fan support frame 227 .
[0074] The engine and lift fan support frame 227 houses power transfer gear between the lift fan power shafts 607 which connect the engine to the lift fans 701 . The engine is covered by engine cover 621 .
[0075] When the engine used is an internal combustion engine 601 there is a propulsion fan transfer case 603 which may be a transmission, torque converter, reduction gear, or flywheel. The propulsion fan transfer case 603 is connected to propulsion fan drive shaft 605 which passes through propulsion fan support 223 . Propulsion fan drive shaft 605 is connected to propulsion fan pulley 707 by propulsion fan pulley belt 705 . Propulsion fan 703 is mounted to propulsion fan pulley 707 which is also mounted to the propulsion fan support 223 . Propulsion fan 703 is surrounded by propulsion fan housing 711 which is mounted to propulsion fan support 223 . Steering rudders 721 are mounted to the propulsion fan housing 711 .
[0076] Internal combustion engine 601 has air intake 611 , radiator 615 , and exhaust 613 . The radiator 615 is mounted to the propulsion fan support 223 in a preferred embodiment for better cooling efficiency and means the propulsion fan 703 acts as a radiator fan.
[0077] In a preferred embodiment a rotating beacon light 801 is mounted on top of the propulsion fan support 223 for increased visibility of the ATV 000 .
[0078] Flexible passenger cabin 400 and flexible cargo platform 500 have flexible module frame 211 . Flexible module frame 211 and flexible module platform 209 connect to flexible frame 200 by module crimp clamps 207 . At the front of the flexible passenger cabin 400 or flexible cargo platform 500 is windshield 251 which is mounted to flexible module frame 211 . A canopy 231 may also be mounted to flexible module frame 211 providing cover to pilot and passengers or cargo. Behind the windshield 251 are a pilot dashboard 301 with controls for the ATV 000 and a pilot's seat 303 . The pilot dashboard 301 and pilot's seat 303 are mounted to flexible module platform 209 . The pilot dashboard 301 is connected to the flexible powertrain module 600 electronically so that a pilot controls the lift fans 701 , propulsion fan 703 , and steering rudders 721 .
[0079] Behind pilot's seat 303 is either empty space for cargo or passenger seats 401 .
[0080] In a preferred embodiment headlights 803 are mounted to flexible module frame 211 at the front of the ATV 000 .
[0081] The specific embodiments described herein are intended to further explain the best mode known for practicing the disclosure and to enable others skilled in the art to utilize the disclosure in such, or other, embodiments and with various modifications required by the particular applications or uses of the present disclosure. The specific techniques, conditions, materials, and proportions set forth to illustrate the principles and practice of the invention are exemplary only and should not be taken as limiting the scope of the invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.
[0082] It will be appreciated by a person skilled in the art that numerous variations and/or modifications may be made to the present invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects to be illustrative and not restrictive. | The invention concerns an amphibious transformer vehicle (ATV) having flexible pontoon-skegs and a flexible frame allowing the ATV which carries passenger or cargo to smoothly transition between varying types of terrain and handle waves and uneven terrain. This vehicle is designed to move over water, snow, ice, ground, sand and other loose surfaces, as well as paved and other hard services as well as grass and light vegetation. It can make transitions between all the surfaces without need to stop or perform any modifications to the vehicle to transition between surfaces. This vehicle has advantages over other hovercraft and airboats that are designed with rigid frames and hulls. Based on a design using a flexible frame and structures that lean on flexible pontoon-skegs it can handle waves and obstacles without being damaged and it is not upset by a wide range of variations in terrain. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/208,979 filed Aug. 22, 2005, now allowed, entitled “Integrated High Frequency Balanced-to-Unbalanced Transformers”, which claims the benefit of U.S. Provisional Patent Application No. 60/605,511 filed Aug. 31, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to semiconductor integrated circuits, and more particularly to integrated circuit inductors that are magnetically-coupled for the purpose of creating a high frequency transformer.
[0004] 2. Prior Art
[0005] In wireless communications, an antenna is commonly coupled, typically by means of passive components, to a transformer. In many cases, a balanced-to-unbalanced (BALUN) transformer is used. Such a transformer allows the conversion of a single-ended signal into a differential signal and vice versa. In wireless communications, the antenna receives a single-ended radio frequency (RF) signal. The signal is converted to a differential signal using a BALUN transformer. The operation of BALUN transformers is well-known in the art, and such transformers are usually represented by the schematic 10 shown in FIG. 1A . The unbalanced side of the BALUN transformer has two ends marked 12 and 14 respectively. The balanced side of the BALUN transformer has three connections, two on each end of the inductor marked 22 and 26 respectively, and one at the center of the inductor, marked 24 . The balanced side provides for a differential mode. In some cases the inductors of the transformer are wound around a core, directly impacting the mutual inductance between the primary and secondary inductors and therefore the performance of the transformer. Typically node 14 of the primary inductor and node 24 of the secondary inductor are AC grounded, as shown in FIG. 1B .
[0006] With the advent of solid state electronics, the ability to integrate components in a single semiconductor device has increased manyfold. This allows the reduction in size, power consumption, and cost, and further provides overall improvement in system performance. It is therefore natural that many attempts have been made to integrate transformers, including BALUN transformers, in order to take advantage of these features. Providing a symmetrical BALUN transformer has been known to be a challenge in the art, as specifically shown in U.S. Pat. No. 6,608,364 by Carpentier (hereinafter “Carpentier”) and U.S. Pat. No. 6,707,367 by Castaneda al. (hereinafter “Castaneda”). Carpentier suggests an implementation of a BALUN transformer that has five metallization layers, therefore requiring a complex manufacturing process having many layers often restricting conductor routing over the BALUN transformer. Castaneda suggests an elaborate scheme to provide a symmetrical BALUN transformer, also requiring several layers of metal and dielectric as shown in the various Figs. of Castaneda. Another example may be found in U.S. Pat. No. 6,882,263 by Yang et al. Symmetrical primary and secondary windings of an on-chip BALUN transformer are shown. However, the issue of capacitive coupling between the primary and secondary windings is not addressed, as the windings are essentially positioned such that a maximum capacitive coupling is achieved, having a disadvantage in operation at high frequencies, for example several GHz, as the capacitive coupling will tend to short-circuit the BALUN at these higher frequencies.
[0007] As the demand for integrated circuit radios increases, many attempts have been made to integrate transformers and/or transformer BALUNs onto radio frequency integrated circuits. However, such integration has been limited due to flux leakage, capacitive coupling limits, and significant series resistance. To reduce these limitations, advances have been made in transformer IC design including coplanar interleaved transformers, toroidal and concentric transformers, overlay transformers and symmetric coplanar transformers. Coplanar interleaved transformers have the primary and secondary windings interleaved on the same integrated circuit layer, where the primary and secondary windings are constructed of planer metal traces. While coplanar interleaved transformers reduce size and are widely used, they suffer from low quality (Q) factor, small coupling coefficients, and, if used as a BALUN, the center tap is often at an undesirable location, resulting in an asymmetric geometry. As is known, asymmetry of a transformer winding causes an imbalance in the resulting differential signal and/or an imbalance in the resulting single ended signal from a differential signal.
[0008] The advent of nm-scale CMOS RFIC design poses new challenges in the design of cost-effective integrated telecommunication transceivers. Despite the fact that the geometry of active devices in such processes is significantly scaled down, passive devices do not follow: integrated resistors, capacitors and inductors, tend to occupy the same silicon area as in more conventional CMOS or BiCMOS processes. From all passive devices, the integrated inductor is obviously the most area hungry. On the other hand, real estate is much more expensive in advanced sub-micron processes such as 90 nm or—even worse—in a 65 nm technology node so the design of area effective integrated inductors becomes imperative.
[0009] Therefore, for the development of large L inductor structures, a multi-layer device is typically proposed. The conventional multi-layer inductor structure however, suffers from low self-resonance frequency mainly due to the increased inter layer parasitic capacitance: metal segments running on different layers form excellent Metal-Insulator-Metal structures that drastically affect the electrical behavior of the integrated inductor. U.S. Pat. No. 6,759,937 is an example for this class of solutions. While desired values may be calculated based on this solution it suffers from the limitations of the conventional multi-layer inductor structure.
[0010] There is therefore a need in the art for a BALUN transformer which is essentially symmetrical, can be implemented in a minimal number of layers of metal, and still provide the electrical characteristics of a BALUN transformer, and especially a reduced capacitive coupling, for the purposes of RF applications, for example in the gigahertz range. Furthermore, there is a need in the art for a design of an area effective inductor that overcomes the deficiencies of prior art solutions. It would be further advantageous if the electrical characteristics of the inductor are of high quality, and especially the reduction of the capacitive coupling, for the purposes of RF applications, for example in the gigahertz range.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a schematic drawing of a BALUN transformer.
[0012] FIG. 1B is a schematic drawing of a BALUN transformer with a grounded node of the primary coil and a grounded center node of secondary coil.
[0013] FIG. 2 is an exemplary layout of a primary inductor of a first BALUN transformer using a single metal layer.
[0014] FIG. 3 is an exemplary layout of a symmetrical secondary inductor of the first BALUN transformer having a displacement with respect to the primary inductor.
[0015] FIG. 4 is an exemplary layout of the shunts of the first BALUN transformer.
[0016] FIG. 5 is a layout of the first BALUN transformer showing the relationship between all three metal layers.
[0017] FIG. 6 is an exemplary layout of a pseudo-differential and symmetrical primary inductor of a second embodiment of BALUN transformer.
[0018] FIG. 7 is an exemplary layout of a symmetrical secondary inductor of the second BALUN transformer having a displacement in respect to the primary inductor.
[0019] FIG. 8 is an exemplary layout of the shunts for the primary inductor of the second BALUN transformer.
[0020] FIG. 9 is an exemplary layout of the shunts for the secondary inductor of the second BALUN transformer.
[0021] FIG. 10 is a layout of the second BALUN transformer showing the relationship between all four metal layers.
[0022] FIG. 11 is a diagram of a portion of primary coil metal layer and the secondary coil metal layer showing the displacement between the respective windings.
[0023] FIG. 12 is a flowchart of the process steps respective of the manufacture of the BALUN transforms in accordance with the disclosed invention.
[0024] FIG. 13A is a schematic of a full 3D inductor designed in accordance with the principles of the disclosed invention.
[0025] FIG. 13B is a schematic of the top part of the 3D inductor of FIG. 12 .
[0026] FIG. 13C is a schematic of the bottom part of the 3D inductor of FIG. 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Deficiencies of the prior art have lead to a need to provide BALUN transformers that are more efficient in their design, particularly in the number of metallization layers used for their implementation without significantly adversely affecting the BALUN transformer performance. The solution of the present invention accomplishes this target by having the windings of the primary inductor in one metal layer and the windings of the secondary inductors in another metal layer not only vertically separated from, but also horizontally displaced from the first metal layer. The displacement reduces the capacitive coupling between the primary and secondary coils. Furthermore, the implementations shown enable the use of only three or four layers of metal for a BALUN transformer. It should be noted that the displacement should be such that a substantial magnetic coupling between the primary and secondary inductors of the BALUN is still achieved to ensure the proper performance of the BALUN.
[0028] Reference is now made to FIGS. 2 through 4 where each of the three metal layers comprising a BALUN transformer 500 , shown in FIG. 10 , are implemented in accordance with the disclosed invention are shown. The implementation makes use of three metal layers, metal layer 100 , metal layer 200 , and metal layer 300 . A person skilled-in-the-art will realize that it is not required that the metal layers used are consecutive metal layers, and specific choices may be made for the desired characteristics of the BALUN transformer, such as BALUN transformer 10 , including, but not limited to, the grounding of both one of the nodes, for example node 14 , of the primary inductor and the center node 24 of the secondary inductor.
[0029] In FIG. 2 , a primary coil is composed of a continuous winding 210 and ends 12 and 14 , implemented on a metal layer 100 , and designed to be pseudo-symmetrical, i.e., essentially symmetrical, with a slight asymmetry when curving to implement an internal winding. In FIG. 3 a secondary coil, implemented in metal layer 300 , is composed of winding segment 310 having ends 312 and 26 , winding segment 320 having ends 22 and 322 , and winding segment 330 having ends 332 and 334 . The complete coil of the secondary coil is achieved by the use of shunt 410 , connecting ends 322 and 334 of winding segments 320 and 330 respectively, and shunt 420 , connecting ends 312 and 332 of winding segments 310 and 330 respectively. The shunts are shown in FIG. 4 .
[0030] Winding segments 310 , 320 and 330 of the secondary coil of FIG. 3 have a displacement with respect to winding 110 of the primary coil of FIG. 2 , as explained in more detail below. The displacement reduces the horizontal overlap between the primary and secondary coils and hence reduces the capacitive coupling between them. Preferably the displacement is such that there is less than fifty percent overlap in the conductive paths between the windings of the secondary and the primary windings, excluding the shunts. A non-overlapping implementation is also possible as long as there is sufficient magnetic coupling between the primary and secondary inductors of the BALUN. In some embodiments of the disclosed invention, the input nodes of the primary inductor are physically one-hundred and eighty degrees from the outputs of the secondary inductor, further achieving symmetry. FIG. 5 shows such an embodiment, with the center tap 24 of the secondary being connected to node 14 , typically both being grounded or coupled to a circuit common by a single connection thereto.
[0031] Referring now specifically to FIG. 5 , a top view of the three metal layers comprising BALUN transformer 10 are shown. In one preferred embodiment, metal layer 100 is the bottom layer, metal layer 200 is the middle layer and metal layer 300 is the upper layer. In particular, the primary coil metal layer 100 would be deposited over an insulator such as silicon dioxide (SiO 2 ), for example on a substrate, typically a silicon substrate, and then patterned using conventional photolithography techniques. Notably, metal layer 100 may be any one of the metal layers available for use in the device. Then another SiO 2 , layer is deposited, followed by the depositing and patterned of another metal layer 200 to form the shunts. A further SiO 2 is deposited and windows opened (etched) therein to expose the ends of the shunts for VIAs, and in the embodiment being described, an opening through the last two SiO 2 layers to expose node 14 of the primary inductor. Then a final metal layer is deposited and patterned, making electrical contact with the shunts the form the complete secondary winding, and providing a common connection to one primary node ( 14 ) and the center node 24 of the secondary winding. It should be further noted that it is not required that the metal layers, used in the BALUNs of the present invention, be consecutive metal layers. Hence if a semiconductor device has available a total of seven metal layers, then if three metal layers are used for the BALUN, any three of the seven metal layers may be of use.
[0032] By using this arrangement, the vertical distance between the primary coil and the secondary coil is further increased and therefore contributes to a reduction in the capacitive coupling between the coils. The primary coil is accessed at nodes 12 and 14 in metal layer 100 . Since node 14 is connected to the center node 24 of the secondary inductor, it is further possible to access node 14 in metal layer 200 . The secondary coil ends 22 and 26 are accessed in metal layer 300 , while center node 24 of the secondary coil is accessed at end 24 in metal layer 300 , as well as through node 14 in metal layer 100 as explained above.
[0033] In one alternate embodiment, the order of the layers may be reversed, namely layer 300 , then layer 200 and finally layer 199 . In another embodiment of the disclosed invention, metal layer 300 follows metal layer 100 in the vertical stack, with the last metal layer being metal layer 200 . Connection between layers is achieved by the use of VIAs or stacked VIA holes which are well-known in the art. The inventors have noted that this implementation provides for minimal losses and has a narrowband balancing.
[0034] Typical external diameter for a BALUN transformer in accordance with the disclosed invention is between 200 and 800 micron. Spacing between turns in the primary coil is typically 5 to 10 microns, and between turns of the secondary coil is typically 5 microns. A conduction path width of the primary inductor is typically between 10 and 20 microns and the secondary inductor path width is typically 5 microns. Therefore, in a preferred embodiment of the invention, with a fifty percent overlap of the secondary with respect to the primary, only 2.5 micron of width, or less, of the secondary inductor will be in overlap with the windings of the primary inductor. The typical numbers provided herein are of course exemplary only, and are not intended to limit the scope of the disclosed invention.
[0035] Reference is now made to FIGS. 6 through 9 where each of the four metal layers comprising a BALUN transformer 1000 , shown in FIG. 10 in accordance with another embodiment of the present invention are shown. This embodiment is designed to provide broadband balancing. The implementation makes use of four metal layers, metal layer 100 , metal layer 200 , metal layer 300 , and metal layer 400 . These layers are shown in FIGS. 6 through 9 . A person skilled-in-the-art will realize that it is not required that the metal layers used be consecutive metal layers, and specific choices may be made to accommodate the specific characteristics of BALUN transformer 1000 . The schematic of BALUN transformer 1000 is identical to the schematic shown for BALUN transformer 10 in FIG. 1B , and therefore node designation shall again remain the same.
[0036] In FIG. 6 , a primary coil is composed of a winding segment 610 having ends 12 and 612 , and a winding segment 620 having ends 622 and 14 . Winding segments 610 and 620 are implemented in a patterned metal layer 100 . In FIG. 8 , there is shown a shunt 810 implemented in patterned metal layer 200 . Shunt 810 connects ends 612 and 622 of windings 610 and 620 respectively. By connecting winding segments 610 and 620 , shunt 810 completes an implementation of a primary coil of BALUN transformer 1000 , creating a pseudo-differential inductor, having only two spirals. In FIG. 7 a secondary coil is composed of winding segment 710 having ends 22 and 712 , winding segment 720 having ends 26 and 722 , and winding segment 730 having ends 732 and 734 . Segments 710 , 720 and 730 of the secondary coil of BALUN transformer 1000 are implemented in patterned metal layer 400 . In FIG. 9 there are shown shunts 910 and 920 implemented in patterned metal layer 300 . Shunt 910 connects ends 722 and 734 of windings 720 and 730 , and shunt 920 connects ends 712 and 732 of windings 710 and 730 . By connecting winding segments 710 , 720 and 730 , shunts 910 and 920 complete an implantation of a differential secondary coil of BALUN transformer 1000 , where typically center node 24 is grounded, and connected to one of the nodes of the primary coil, for example node 14 . Winding segments 710 , 720 and 730 have a displacement with respect to winding segments 610 and 620 of the primary coil, as explained in more detail below. The displacement reduces the overlap between the primary and secondary coils and hence the capacitive coupling between them. Preferably the displacement is such that there is less than fifty percent overlap in conductive path width between the windings of the secondary and the primary windings, excluding the shunts. A non-overlapping implementation is also possible as long as there is sufficient magnetic coupling between the primary and secondary inductors of the BALUN. In one embodiment of the disclosed invention, the output nodes of the primary inductor are physically one-hundred and eighty degrees from the outputs of the secondary inductor, further allowing for achieving symmetry.
[0037] Referring now to FIG. 10 , the four metal layers comprising BALUN transformer 1000 are shown. In one preferred embodiment, metal layer 100 is the bottom layer, metal layer 200 is a first middle layer followed by metal layer 300 , and metal layer 400 is the upper layer. However, a person skilled-in-the-art would easily note that a reverse order could be used, or in fact, any order that would not cause a restriction on the connection between the different metal layers. The primary coil is accessed at ends 12 and 14 in metal layer 100 . End 14 may be further accessed via node 24 of the secondary coil, connected through shunt 24 shown in FIG. 8 . The secondary coil ends 22 and 26 are accessed in metal layer 400 . Center node 24 of the secondary coil is accessed via metal layer 200 which is also connected, for example by use of a VIA to node 14 in metal layer 100 . Connection between layers is achieved by the use of VIA or stacked VIA holes which are well-known in the art. The fabrication process in general may be similar to that previously described.
[0038] In the BALUNs of the present invention, each layer is separated from adjacent layers by an electrically insulative (dielectric) layer, preferably SiO 2 , though other substrates and other electrically insulative layers could be used if desired. In that regard, silicon and SiO 2 are preferred as being most compatible with integrated circuit fabrication processes. The metal layers may be of various metals, though high electrical conductivity metals are preferred, such as aluminum, gold or silver. It should be further noted that it is not required that the metal layers, used in the BALUNs of the present invention, be consecutive metal layers. Hence if a semiconductor device has available a total of seven metal layers, then if three metal layers are used for the BALUN, any three of the seven metal layers may be of use.
[0039] The inventors have noted that the foregoing implementation provides for minimal losses and has a broadband balancing. Typical external diameter for a BALUN transformer in accordance with the disclosed invention is between 200 and 800 micron. Spacing between winds in the primary coil are typically 5 to 10 microns, and between windings of the secondary coil are typically 5 microns. A path width of the primary inductor is typically between 10 and 20 microns and the secondary inductor is typically 5 microns. Therefore, in a preferred embodiment of the invention, with a fifty percent overlap, only 2.5 micron of width, or less, of the secondary inductor conductive path will be in overlap with the windings of the primary inductor. Again, the typical numbers provided herein are exemplary purposes only and are not intended to limit the scope of the disclosed invention.
[0040] Reference is now made to FIG. 11 where a diagram of a first portion 1110 of a primary coil metal layer and a second portion 1120 -A and a third portion 1120 -B of a secondary coil metal layer are shown. The layout of the second portion and third portion is in displacement with respect to the first portion. By avoiding full coverage between the primary and secondary coils, the parasitic coupling capacity is reduced and overall performance of the BALUN transformer improved. This separation further allows the use of a wider first portion and therefore reduces the resistance of the primary inductor.
[0041] Reference is now made to FIG. 12 where an exemplary flowchart 1200 of the process of manufacture of the BALUN transformers disclosed herein is shown. In one embodiment of the manufacturing process, in step S 1210 A there is created in a first metal layer an essentially pseudo-symmetrical winding. Alternatively, step S 1210 B is used where there is created a first winding that is symmetrical, as explained above with respect to FIG. 6 . In step S 1220 there is deposited a layer of non-conducting material that is an insulator between one layer of metal and another layer of metal, and has further known dielectric characteristics. Therefore, when depositing another metal plate on top of the dielectric, there will be formed a parasitic capacitor, known also as a coupling capacitance, between the two layers of metal, reducing the performance of the BALUN. In accordance with the disclosed invention, in step S 1230 there is created a symmetrical second winding, as may be seen with respect to FIGS. 3 and 7 , the second winding being concentric with, but horizontally displaced from the turns of the first winding. In one embodiment, the overlap between the second winding and the first winding is no more than fifty percent of the conductive path width of the second winding, excluding shunts. A non-overlapping implementation is also possible as long as there is sufficient magnetic coupling between the primary and secondary inductors of the BALUN. In some embodiments of the disclosed invention, the output nodes of the primary inductor are physically one-hundred and eighty degrees from the outputs of the secondary inductor, further providing symmetry. In step S 1240 , shunts are created to ensure continuous conducting paths through each of the first winding and the second winding. A person skilled in the art would readily recognize that the shunts may be created at multiple metal layers and hence the specific order shown herein should not be viewed as a limitation of the invention. Furthermore, it should be noted that the preferred manufacturing processes in general are well-known in the art, and are not provided herein in great detail in order to maintain clarity of the disclosed invention. Also while certain preferred embodiments of the present invention have been disclosed and described herein for purposes of illustration and not for purposes of limitation, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. As an example, while in embodiments shown herein with respect of FIGS. 6, 7 and 8 , where the primary inductor has two turns and the secondary inductor has three turns, other configurations may be used. For example, and without limitation to the disclosed invention, embodiments of a BALUN having three turns in the primary inductor and five turns in the secondary inductor, or, four turns in the primary inductor and seven turns in the secondary inductor, are also possible.
[0042] The principles discussed hereinabove may be also used to design large L inductors. This way, the overlap capacitance between the different metal layers is reduced and the self-resonance frequency is not affected significantly. Reference is now made to FIG. 13A through 13C that show a large L inductor designed in accordance with the principles of the disclosed invention. FIG. 13A shows a schematic drawing of the overall “3-D” inductor 1300 structure. The inductor 1300 is comprised of a top inductor 1310 , shown in FIG. 13B , and a bottom inductor 1320 , shown in FIG. 13C . The top inductor 1310 generally corresponds to the upper portion discussed above with respect of the BALUN. The bottom inductor 1310 generally corresponds to the lower portion discussed above with respect of the BALUN. In accordance with the principles of the disclosed invention the winding of the top inductor is displaced with respect to the bottom inductor, thereby reducing the overlap between the metals comprising the top inductor and the bottom inductor. The reduced overlap further accounts for the reduction in the parasitic capacitance between the windings and thereby contributing to the overall superior design over prior art solutions.
[0043] The construction of a large L inductor in accordance with the principles of the disclosed invention is as follows: First the top inductor 1310 is followed from the outer winding to the inner winding. Once the inner winding is reached, a pair of metal bridge segments (not shown) transfer the spiral windings to the bottom inductor 1320 which is now deployed from the inner winding to the outer winding, each winding being in displacement to windings of the top inductor 1310 . The bridges connect the edges 1312 and 1314 of the top inductor 1310 to the edges 1322 and 1324 of the bottom inductor 1320 respectively. The center tap is placed at the outer spiral of bottom part. The current flow is always in the same winding sense so the mutual inductance developed is in favor of the overall spiral inductance. The ports of the inductor are ports 1316 and 1318 . The center tap 1326 in the bottom inductor is in fact the center of the large L inductor. In one embodiment of the disclosed invention the overlap between the conductive paths of the top inductor and the bottom inductor does not exceed fifty percent of the width of at least one of the conductive paths.
[0044] Reference is now made to FIG. 14 where a cross section 1400 , corresponding to cross section A-A from FIG. 13A , is shown. In the enlarged cross section it can be seen, that in accordance with the principles of the disclosed inventions, the windings of the top inductor 1310 are placed in a displacement to the windings of the bottom inductor 1320 . In one embodiment of the disclosed invention an inductor may be created using a sandwich of two metal layers, the effective thickness of the spiral is increased and, therefore, the quality factor of the device is kept as high as possible. Surface 1410 is the face of the portion of the integrated circuit while surface 1420 is the back side and the substrate of the integrated circuit.
[0045] While a preferred embodiment of the present invention has been disclosed and described herein for purposes of illustration and not for purposes of limitation, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | Integrated high frequency balanced-to-unbalanced transformers and inductors suitable for operation in high frequencies, such as radio frequencies. Embodiments disclosed give consideration to issues related to the layout of the top and bottom inductors for the minimization of capacitive effects between layers. A displacement between the conductive paths of the top inductor and the bottom inductor is shown that provides for superior performance over prior art solutions. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
A Continuation-in-Part of METHOD FOR PREPARATION OF CALCIUM-ENRICHED CITRATE COMPOSITIONS AND PRODUCTS THEREOF (Ser. No. 08/270,283), filed Jul. 5, 1994, now abandoned.
BACKGROUND OF THE INVENTION
This invention is related to the method of manufacture of mineral-enriched citrate compositions, wherein one obtains by lemon juice extraction at least some or all of the minerals contained in the shell of raw fresh eggs. The shell is removed from the egg and processed by the lemon citrate juice. Specifically, lemon juice derivatives such as calcium carbonate, calcium citrate, magnesium carbonate, magnesium citrate and tri-calcium phosphate, tri-calcium citrate are processed to create a mineral-enriched citrate composition. The lemon juice, which is thus enriched with extracted eggshell minerals, may be made available as powdered concentrate. In some applications, lime juice may be substituted for lemon juice. The product is particularly useful in enhancing growth of finger nails.
THE PRIOR ART
______________________________________INVENTOR PATENT NO.______________________________________SALEEB et al. 5,219,602VIDAL et al. 5,149,522ZEIDLER et al. 5,053,238WALSDORF et al. 4,814,177PAK 4,772,467Japan:SUGITANI 60-16576KUSHIBIKI 100185SHINA 6291164UEDA 153937SHINA 01-67157______________________________________
While vinegar will also dissolve egg shell it does not produce the desired end product: calcium citrate. Vinegar is acetic acid and would produce an acetate salt. In order to be effective, calcium must be absorbed by the intestines. Calcium citrate has been shown to be superior to other calcium salts such as calcium carbonate, calcium oxalate, calcium oxide. Calcium citrate is most efficient in its absorption in the intestines. From there, of course, it goes into the bloodstream to be delivered to the target organs, teeth, bones, nails, as well as to participate in other bodily biochemistries. The goal is not just to dissolve egg shell, but to produce an effective end product.
The patents of PAK and WALSDORF et al. describe the production of calcium citrate dietary supplement which is made from calcium carbonate (dry chemical) and citric acid (also dry chemical). In the background to the invention, the superior absorptivity of calcium as the citrate salt is explained and references.
However PAK and WALSDORF do make use of the same chemical reaction as Applicant does, namely the reaction of calcium carbonate with citric acid to form calcium citrate and carbon dioxide and water:
3CaCO+2C.sub.6 H.sub.5 O.sub.7 →Ca.sub.3 (C.sub.6 H.sub.5 O.sub.7).sub.2 +CO.sub.2 +3H.sub.2 O (CO.sub.2 is given off as a gas)
Applicant's product also provides additional constituents from both the shell and the juice which are involved in calcium uptake, namely isocitric and ascorbic acids. Also provided by Applicant's product is a variety of other trace minerals, namely manganese, magnesium iron, potassium and phosphorous. All are utilized by the body for nail growth.
Applicant does not use binders or carriers to form tablets. Binders and carriers interfere with absorption because they are hard to digest in the stomach. Tablets and pills are often excreted without complete digestion.
Applicant's product is freeze dried. Water is removed by freezing the final liquid and then pulling a very strong vacuum on it. This is a variation of Boyle's law. Liquids will go to the gas phase at the right combination or pressure and temperature. Water "boils"--goes to a gas--by heating it to 212° F. at atmospheric pressure. Lower the pressure--pull a vacuum--and the temperature required to vaporize water also goes down. Freeze drying takes water from the solid phase (ice) directly to the gas phase by reducing the pressure and temperature substantially. Without added heat, the integrity of Applicant's product is preserved. Heat destroys ascorbic acid.
Applicant's end product is a mineral-enriched citrate composition. SUGITANI's end product is a mayonnaise with unreacted eggshells suspended therein. Ingesting SUGITANI's mayonnaise will not enhance nail growth. In SUGITANI there is not enough of the lemon/shell reaction product and what is there is dispersed in large quantities of oil.
Applicant does not spray dry as taught by VIDAL. Spray drying requires heat. Applicant avoids heat because it destroys certain vitamins, namely ascorbic acid.
Applicant's method of manufacture enhances nail growth because the end product contains large amounts of calcium citrate along with other trace minerals and vitamins necessary for calcium absorption and, consequently, nail growth.
Lemon and lime juice solubilize maximum calcium from egg shells because they contain the most citric acid per unit volume, thereby providing a final product more dense in calcium citrate.
SUMMARY OF THE INVENTION
Process and product for the formulation of an edible composition from reacting lemon or lime juice with fresh eggshells to obtain the minerals: calcium carbonate, manganese carbonate and tri-calcium phosphate, combining the juice and mineral extracts. The resultant product may be used for drinks, powder mixtures and/or capsule concentrate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Whereas most fruit juices contain organic acids which have characteristics similar to those of lemon juice or lime juice, none of said organic acids except lemon and lime juice have the efficacy to extract mineral compositions from the raw fresh eggshell. Lemon and lime juice, per se, contain the following organic acids: 1-malic, malic, citric, isocitric, citric/isocitric, 1-ascorbic acid. Likewise, domestic egg shells, per se, contain composite metal salts: calcium carbonate, manganese carbonate and tri-calcium phosphate. To extract the metal salts herein, one employs the extraction characteristics of the lemon or lime juice to solubilize eggshells which have been removed from the egg membranes, the albumen or egg white and the yolk.
The known chemical compositions of lemon juice and lime juice, as well as orange juice, grapefruit juice and apple cider vinegar may be summarized, as follows:
__________________________________________________________________________Chemical Compositions of Juices Used in Eggshell Calcium ExtractionStudy Grapefruit Apple CiderIn mg/100 g Lemon Juice Lime Juice Orange Juice Juice Vinegar__________________________________________________________________________Calcium 7.0 mg 9.0 mg 11.0 mg 9.0 mg 4.35 mgIron 0.03 mg 0.03 mg 0.20 mg 0.20 mg 0.62 mgMagnesium 6.0 mg 6.0 mg 11.0 mg 12.0 mg --Phosphorus 6.0 mg 7.0 mg 17.0 mg 15.0 mg --Potassium 124.0 mg 109.0 mg 200.0 mg 162.0 mg --Sodium 1.0 mg 1.0 mg 1.0 mg 1.0 mg 20.0 mgVitamin C 46.0 mg 29.3 mg 50.0 mg 38.0 mg 0.94 mgThiamine (B1) 0.030 mg 0.020 mg 0.090 mg 0.040 mg --Riboflavin (B2) 0.010 mg 0.010 mg 0.030 mg 0.020 mg --Niacin 0.100 mg 0.100 mg 0.400 mg 0.200 mg --Moisture 90.73 g 90.21 g 88.30 g 90.00 g 98.00 gProtein 0.38 g 0.44 g 0.70 g 0.50 g 0.10 gFat 0.00 g 0.10 g 0.20 g 0.10 g 0.03 gAsh 0.26 g 0.24 g 0.40 g 0.20 g 1.0 gCabohydrates 8.63 g 9.01 g 10.40 g 9.20 g 0.91 gEnergy (kcal) 25 kcal 27 kcal 45 kcal 39 kcal 40 kcal__________________________________________________________________________
The following examples depict the invention.
__________________________________________________________________________Eggshell Calcium Extraction Study__________________________________________________________________________EXAMPLE I:Type of Liquid Used: Lemon JuiceTime eggshells were put into liquid: 4:30 p.m. 3/12/96Time eggshells were removed from liquid: 2:30 p.m. 3/13/96Total time eggshells were immersed in liquid: 22 hoursVolume of liquid used: 6 quartsInitial weight of liquid: 11.80 pounds Weight of eggshells: 294.7 gramsFinal weight of liquid: 11.20 pounds Final weight of eggshells after drying: 255.3 gramsWeight of Extracted eggshell: 39.4 grams Percent eggshell extracted: 13.37%Initial pH: 2.31Final pH: 3.32Calcium content of liquid rep #1: 602 mg/100 gCalcium content of liquid rep #2: 607 mg/100 gEXAMPLE II:Type of Liquid Used: Stirred Lemon JuiceTime eggshells were put into liquid: 10:00 a.m. 3/16/96Time stirring was started: 12:07 p.m. 3/16/96Time eggshells were removed from liquid and stirring stopped: 5:07 p.m.3/13/96Total time eggshells were immersed in liquid: 7 hoursTime eggshells were stirred: 5 hoursVolume of liquid used: 500 mLInitial weight of eggshells: 44.0 grams Final weight of eggshells after drying: 21.7 gramsWeight of Extracted eggshell: 22.3 grams Percent eggshell extracted: 50.68%Initial pH: 2.31Final pH: 5.88Calcium content of liquid rep #1: 1500 mg/100 gEXAMPLE IIIType of Liquid Used: Stirred Lemon JuiceTime eggshells were put into liquid: 4:30 p.m. 3/12/96Time stirring was started: 4:30 p.m. 3/12/96Time eggshells were removed from liquid and stirring stopped: 9:30 a.m.3/13/96Total time eggshells were immersed in liquid: 17 hoursTime eggshelld were stirred: 17 hoursVolume of liquid used: 385.9 gInitial weight of eggshells: 21.23 grams Final weight of eggshells after drying: 0.00 gramsWeight of Extracted eggshell: 21.23 grams Percent eggshell extracted: 100.00%Initial pH: 2.31Final pH: 5.97Calcium content of liquid rep #1: 2039 mg/100 gEXAMPLE IVType of Liquid Usd: Lime JuiceTime eggshells were put into liquid: 4:30 p.m. 3/12/96Time eggshells were removed from liquid: 2:30 p.m. 3/13/96Total time eggshells were immersed in liquid: 22 hoursVolume of liquid used: 6 quartsInitial weight of liquid: 11.95 pounds Weight of eggshells: 294.7 gramsFinal weight of liquid: 11.95 pounds Final weight of eggshells after drying: 252.0 gramsWeight of Extracted eggshell: 42.7 grams Percent eggshell extracted: 14.49%Initial pH: 2.36AFinal pH: 3.48Calcium content of liquid rep #1: 686 mg/100 gCalcium content of liquid rep #2: 686 mg/100 gEXAMPLE V:Type of Liquid Used: Stirred Lime JuiceTime eggshells were put into liquid: 10:00 a.m. 3/16/96Time stirring was started: 12:07 p.m. 3/16/96Time eggshells were removed from liquid and stirring stopped: 5:07 p.m.3/13/96Total time eggshells were immersed in liquid: 7 hoursTikme eggshells were stirred: 5 hoursVolume of liquid used: 500 mLInitial weight of eggshells: 44.0 grams Final weight of eggshells after drying: 23.6 gramsWeight of Extracted eggshell: 20.4 grams Percent eggshell extracted: 46.36%Initial pH: 2.36Final pH: 5.82Calcium content of liquid rep #1: 1560 mg/100 g__________________________________________________________________________
TABLE 1__________________________________________________________________________Eggshell Calcium Extraction Study Summary (Sedentary Juices) Lemon Lime Orange Grapefruit Apple Cider Juice Juice Juice Juice Vinegar__________________________________________________________________________Volume of Liquid 6 quarts 6 quarts 6 quarts 6 quarts 6 quartsInitial Weight of Eggshells 294.7 g 294.7 g 294.5 g 294.6 g 294.6 gFinal Weight of Eggshells 255.3 g 252.0 g 263.0 g 258.8 g 125.5 gWeight of Extracted Eggshell 39.4 g 42.7 g 31.5 g 35.8 g 169.1 gPercent Eggshell Extracted 13.37% 14.49% 10.70% 12.15% 57.40%Initial pH 2.31 2.36 3.58 3.17 3.16Final pH 3.32 3.48 5.02 5.18 4.78Calcium Content 605 mg/100 g 686 mg/100 g 289 mg/100 g 297 mg/100 g 1280 mg/100 g__________________________________________________________________________
TABLE 2__________________________________________________________________________Eggshell Calcium Extraction Study Summary (Stirred Juices) Lemon Lime Orange Grapefruit Apple Cider Juice Juice Juice Juice Vinegar__________________________________________________________________________Volume of Liquid 500 mL 500 mL 500 mL 500 mL 500 mLInitial Weight of Eggshells 44.0 grams 44.0 grams 44.0 grams 44.0 grams 44.0 gramsFinal Weight of Eggshells 21.7 grams 23.6 grams 39.9 grams 36.8 grams 21.7 gramsWeight of Extracted Eggshells 22.3 grams 20.4 grams 4.1 grams 7.2 grams 22.3 gramsPercent Eggshell Extracted 50.68% 46.36% 9.3% 16.36% 50.68%Initial pH 2.31 2.36 3.58 3.17 3.16Final pH 5.88 5.82 5.26 5.54 5.08Calcium Content 1500 mg/100 g 1560 mg/100 g 239 mg/100 g 336 mg/100 g 1330 mg/100 g__________________________________________________________________________
LEMON JUICE EGGSHELL CALCIUM EXTRACTION
Eggshell Preparation:
1) Fresh eggs are washed in a mild soap, rinsed with water and allowed to dry at room temperature (70° to 75° F.).
2. After drying, the eggs are cracked and the egg yolks and whites are discarded. The eggshell is then washed thoroughly in mild soap and allowed to dry completely. The drying process generally takes approximately 48 hours.
Fresh Lemon Juice Preparation:
1. Fresh lemons are cut into halves. These halves are then squeezed to extract the juice. An automatic juicer can be used, as well as a small hand juicer.
2. The fresh lemon juice is measured into the appropriate batch size.
*NOTE: The lemon juice is used the same day that it is squeezed.
Reconstituted Lemon Juice:
1. The lemon juice concentrate is stored at 32° F. until needed. It is thawed and reconstituted with 5.8 parts of water to 1 part lemon juice concentrate.
*NOTE: The reconstituted juice is used the same day that it is reconstituted.
Calcium Extraction Method:
1. The prepared lemon juice is poured into large containers and the pH is taken to determine the acidity. A pH in the range of 2.30-2.50 is the ideal pH, and is very important in the effectiveness of the extraction process.
2. The eggshells are weighed.
3. The eggshell halves are then placed into the lemon juice and the mixture is stirred until all of the eggshells are completely covered with the lemon juice. The mixture is stirred slowly, every half hour for the first 2-4 hours in order to ensure coverage of all of the eggshells.
4. When the eggshells are placed into the lemon juice, a reaction will begin to take place almost immediately. Bubbles of carbon dioxide begin floating to the surface of the liquid and a foam will appear at the air/liquid/interface. This reaction is allowed to continue for 22 to 24 hours at room temperature (70°-75° F.).
5. After 22 to 24 hours, the liquid is again stirred and the remaining eggshells are carefully lifted out of the juice mixture. These shells are placed on a tray and allowed to dry. After the shell remnants are dry (this usually takes 24-48 hours), they are weighed in order to determine the amount of the eggshell/calcium that was extracted into the lemon juice.
6. The final percent extraction of the eggshell is calculated. Again, the pH is tested on the lemon juice/eggshell mixture, in order to determine the acidity of the product. The pH should have increased considerably, depending on the amount of calcium extracted into the juice mixture. Generally, a pH of 4.5 to 6.5 is desirable after the eggshell calcium extraction.
7. The mixture is then filtered to remove any large particles of eggshell that might have remained in the bottom of the mixture.
8. The mixture is then immediately transferred to a large kettle, where it is heated to a temperature of 184° F.-190° F., and held at that temperature for five minutes. This is done in order to pasteurize the product for health safety.
9. The mixture is then transferred, while still hot, to sterile gallon containers. These containers are stored in refrigerated storage until the mixture is used in the liquid state or prepared for capsulation by removing the moisture, via freeze drying.
Freeze-Drying:
1. The mixture is transferred from gallon containers into 1 gallon plastic Zip-Loc® bags. These bags are placed into a freezer and allowed to freeze completely solid. This usually takes between 34 and 48 hours.
2. Once frozen, the frozen juice mixture is removed from the Zip-Loc® bags and is placed into sterile metal trays. These trays are placed into a small, non-commercial freeze dryer (it is only non-commercial because of its size and a larger commercial version can be used to dry the product), and remains there until all of the moisture is gone from the product. Once completely dry, the product is a fine yellowish-white powder that can be easily inserted into a capsule for pill consumption.
STIRRED LEMON JUICE EGGSHELL CALCIUM EXTRACTION
Eggshell Preparation:
1. Fresh eggs are washed in a mild soap, rinsed with water and allowed to dry at room temperature (70°-75° F.).
2. After drying, the eggs are cracked and the egg yolks and whites are discarded. The eggshell is then washed thoroughly in mild soap and allowed to dry completely. The drying process generally takes approximately 48 hours.
3. Eggshells are crushed into small pieces (no larger than a 1/2 cm square).
Fresh Lemon Juice Preparation:
1. Fresh lemons are cut into halves. These halves are then squeezed to extract the juice. An automatic juicer can be used as well as a small hand juicer.
2. The fresh lemon juice is measured into the appropriate batch size.
*NOTE: The reconstituted juice is used the same day that it is reconstituted.
Calcium Extraction Method:
1. The juice is placed in a container that can have any type of mechanical stirrer placed into it.
2. The stirring device is turned on and the juice is allowed to begin stirring. The eggshells are then added to the stirring liquid.
3. The liquid is allowed to stir for a specified amount of time (usually 6 hrs. or overnight).
4. As the eggshells are placed into the lemon juice a reaction will begin to take place almost immediately. Bubbles of carbon dioxide begin floating to the surface of the liquid, and a foam will appear at the air/liquid interface. This reaction is allowed to continue at room temperature 70°-75° F.
5. After the allotted amount of time, liquid is removed from the stirring device and strained through a sieve to remove any remaining eggshells, membrane or large pieces of pulp. The portion of the liquid that is caught in the sieve is placed on a tray and allowed to dry. After the remnants are dry (this usually takes 24-48 hours), they are weighted in order to determine the amount of the eggshell/calcium that was extracted into the lemon juice.
6. The final percent extraction of the eggshell is calculated. Again, the pH is tested on the lemon juice/eggshell mixture in order to determine the acidity of the product. The pH should have increased considerably depending on the amount of calcium extracted into the juice mixture. Generally, a pH of 4.5 to 6.5 is desirable after the eggshell calcium extraction.
7. The mixture is then immediately transferred to a large kettle where it is heated to a temperature of 184° F.-190° F., and held at that temperature for five minutes. This is done in order to pasteurize the product for health safety.
8. The mixture is then transferred while still hot to sterile gallon containers. These containers are stored in refrigerated storage until the mixture is used in the liquid state, or prepared for capsulation by removing the moisture, via freeze drying.
Freeze-Drying:
1. The mixture is transferred from gallon containers into 1 gallon Zip-Loc® bags. These bags are placed into a freezer and allowed to freeze completely solid. This usually takes between 24 and 48 hours.
2. Once frozen, the frozen juice mixture is removed from the Zip-Loc® bags and is placed into sterile metal trays. These trays are placed into a small, non-commercial freeze dryer (it is only non-commercial, because of its size and a larger commercial version can be used to dry the product), and remain there until all of the moisture is gone from the product. Once completely dry, the product is a fine yellowish-white powder than can easily be inserted into a capsule for pill consumption.
LIME JUICE EGGSHELL CALCIUM EXTRACTION
Eggshell Preparation:
1) Fresh eggs are washed in a mild soap, rinsed with water and allowed to dry at room temperature (70° to 75° F.).
2. After drying, the eggs are cracked and the egg yolks and whites are discarded. The eggshell is then washed thoroughly in mild soap and allowed to dry completely. The drying process generally takes approximately 48 hours.
Fresh Lime Juice Preparation:
1. Fresh limes are cut into halves. These halves are then squeezed to extract the juice. An automatic juicer can be used, as well as a small hand juicer.
2. The fresh lime juice is measured into the appropriate batch size.
*NOTE: The lime juice is used the same day that it is squeezed.
Reconstituted Lime Juice:
1. The lime juice concentrate is stored at 32° F. until needed. It is thawed and reconstituted with 5.8 parts of water to 1 part lime juice concentrate.
*NOTE: The reconstituted juice is used the same day that it is reconstituted.
Calcium Extraction Method:
1. The prepared lime juice is poured into large containers and the pH is taken to determine the acidity. A pH in the range of 2.30-2.50 is the ideal pH, and is very important in the effectiveness of the extraction process.
2. The eggshells are weighed.
3. The eggshell halves are then placed into the lime juice and the mixture is stirred until all of the eggshells are completely covered with the lime juice. The mixture is stirred slowly, every half hour for the first 2-4 hours in order to ensure coverage of all of the eggshells.
4. When the eggshells are placed into the lime juice, a reaction will begin to take place almost immediately. Bubbles of carbon dioxide begin floating to the surface of the liquid and a foam will appear at the air/liquid/interface. This reaction is allowed to continue for 22 to 24 hours at room temperature (70°-75° F.).
5. After 22 to 24 hours, the liquid is again stirred and the remaining eggshells are carefully lifted out of the juice mixture. These shells are placed on a tray and allowed to dry. After the shell remnants are dry (this usually takes 24-48 hours), they are weighed in order to determine the amount of the eggshell/calcium that was extracted into the lime juice.
6. The final percent extraction of the eggshell is calculated. Again, the pH is tested on the lime juice/eggshell mixture, in order to determine the acidity of the product. The pH should have increased considerably, depending on the amount of calcium extracted into the juice mixture. Generally, a pH of 4.5 to 6.5 is desirable after the eggshell calcium extraction.
7. The mixture is then filtered to remove any large particles of eggshell that might have remained in the bottom of the mixture.
8. The mixture is then immediately transferred to a large kettle, where it is heated to a temperature of 184° F.-190° F., and held at that temperature for five minutes. This is done in order to pasteurize the product for health safety.
9. The mixture is then transferred, while still hot, to sterile gallon containers. These containers are stored in refrigerated storage until the mixture is used in the liquid state or prepared for capsulation by removing the moisture, via freeze drying.
Freeze-Drying:
1. The mixture is transferred from gallon containers into 1 gallon plastic Zip-Loc® bags. These bags are placed into a freezer and allowed to freeze completely solid. This usually takes between 34 and 48 hours.
2. Once frozen, the frozen juice mixture is removed from the Zip-Loc® bags and is placed into sterile metal trays. These trays are placed into a small, non-commercial freeze dryer (it is only non-commercial because of its size and a larger commercial version can be used to dry the product), and remains there until all of the moisture is gone from the product. Once completely dry, the product is a fine yellowish-white powder that can be easily inserted into a capsule for pill consumption.
STIRRED LIME JUICE EGGSHELL CALCIUM EXTRACTION
Eggshell Preparation:
1. Fresh eggs are washed in a mild soap, rinsed with water and allowed to dry at room temperature (70°-75° C.).
2. After drying, the eggs are cracked and the egg yolks and whites are discarded. The eggshell is then washed thoroughly in mild soap and allowed to dry completely. The drying process generally takes approximately 48 hours.
3. Eggshells are crushed into small pieces (no larger than a 1/2 cm square).
Fresh Lime Juice Preparation:
1. Fresh limes are cut into halves. These halves are then squeezed to extract the juice. An automatic juicer can be used as well as a small hand juicer.
2. The fresh lime juice is measured into the appropriate batch size.
*NOTE: The reconstituted juice is used the same day that it is reconstituted.
Calcium Extraction Method:
1. The juice is placed in a container that can have any type of mechanical stirrer placed into it.
2. The stirring device is turned on and the juice is allowed to begin stirring. The eggshells are then added to the stirring liquid.
3. The liquid is allowed to stir for a specified amount of time (usually 6 hrs. or overnight).
4. As the eggshells are placed into the lemon juice a reaction will begin to take place almost immediately. Bubbles of carbon dioxide begin floating to the surface of the liquid, and a foam will appear at the air/liquid interface. This reaction is allowed to continue at room temperature 70°-75° F.).
5. After the allotted amount of time, liquid is removed from the stirring device and strained through a sieve to remove any remaining eggshells, membrane or large pieces of pulp. The portion of the liquid that is caught in the sieve is placed on a tray and allowed to dry. After the remnants are dry (this usually takes 24-48 hours), they are weighted in order to determine the amount of the eggshell/calcium that was extracted into the lime juice.
6. The final percent extraction of the eggshell is calculated. Again, the pH is tested on the lime juice/eggshell mixture in order to determine the acidity of the product. The pH should have increased considerably depending on the amount of calcium extracted into the juice mixture. Generally, a pH of 4.5 to 6.5 is desirable after the eggshell calcium extraction.
7. The mixture is then immediately transferred to a large kettle where it is heated to a temperature of 184° F.-190° F., and held at that temperature for five minutes. This is done in order to pasteurize the product for health safety.
8. The mixture is then transferred while still hot to sterile gallon containers. These containers are stored in refrigerated storage until the mixture is used in the liquid state, or prepared for capsulation by removing the moisture, via freeze drying.
Freeze-Drying:
1. The mixture is transferred from gallon containers into 1 gallon Zip-Loc® bags. These bags are placed into a freezer and allowed to freeze completely solid. This usually takes between 24 and 48 hours.
2. Once frozen, the frozen juice mixture is removed from the Zip-Loc® bags and is placed into sterile metal trays. These trays are placed into a small, non-commercial freeze dryer (it is only non-commercial, because of its size and a larger commercial version can be used to dry the product), and remain there until all of the moisture is gone from the product. Once completely dry, the product is a fine yellowish-white powder that can easily be inserted into a capsule or pill for consumption.
The mineral-enriched citrate compositions achieved according to the present invention are to include the following ingredients calculated upon a dry product basis:
______________________________________Sugars:Fructose 6 g/100 gGlucose 8 g/100 gSucrose 4 g/100 gAcids:L-Malic acid 18 g/100 gMalic acid 1.6 g/100 gCitric acid 40 g/100 gIsocitric acid 350 mg/100 gL-ascorbic acid 250 mg/100 gMinerals:Potassium 1400 mg/100 gSodium 13 mg/100 gCalcium 18 g/100 gMagnesium 170 mg/100 gPhosphorous 200 mg/100 gSulfur 34 mg/100 g______________________________________
As will be apparent, the mineral enriched citrate compositions achieved by the present method include not only calcium citrate but also critical trace minerals, namely manganese, magnesium, iron, potassium and phosphorous which are utilized in the body for nail growth. Indeed, it is believed that the trace minerals greatly enhance the absorption of calcium within the human body. | Method for preparing mineral-enriched citrate compostions for enhancement of fingernail growth. Lemon or lime juice are reacted with the shells of raw fresh eggs to extract minerals such as calcium carbonate, calcium citrate, as well as trace minerals. The enriched citrate composition is particularly useful in enhancing growth of fingernails. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/JP2012/050001, filed Jan. 2, 2012, published in Japanese, which claims priority from Japanese Patent Application No. 2011-001015, filed Jan. 6, 2011, both of which are hereby incorporated herein by reference.
TECHNICAL FIELD
The present invention relates generally to a metal halide lamp. More specifically, this invention relates to a metal halide lamp for use in irradiating light of ultraviolet rays to cause a photochemical reaction which is suitable for use with, for example, a drying process of inks and paints and a curing process of resins and the like.
BACKGROUND ART
In recent years, metal halide lamps for irradiating light of ultraviolet rays are utilized in a wide variety of fields such as a printing process, a painting process and a resin sealing process. As metal halide lamps for use in these processes, there have hitherto been developed lamps capable of producing light of higher illumination level in order to efficiently carry out the treatments such as printing, painting and sealing in a short period of time. A high-pressure mercury lamp is a main current of a light source but there has been known a metal halide lamp of which luminous efficiency in the ultraviolet region is higher than that of the high-pressure mercury lamp. A metal halide lamp includes an arc tube into which metals are sealed as halides to produce light of a spectrum peculiar to metals.
The inventors of the present application are aware of the following patent literatures concerning such metal halide lamps for use in irradiating light of ultraviolet rays. Relevant parts in the respective patent literatures will be cited and mentioned.
CITATION LIST
Patent Literature
Patent Literature 1: Japanese unexamined patent publication No. 50-044675 (Date of laid-open: Apr. 22, 1975) “Metal vapor discharge lamp” (Applicant: IWASAKI ELECTRIC CO., LTD.)
Patent Literature 2: Japanese unexamined patent publication No. 52-16886 (Date of laid-open: Feb. 8, 1977) “Metal vapor discharge lamp” (Japanese examined patent publication No. 58-018743, Japanese Patent No. 1,262,477) (Applicant: IWASAKI ELECTRIC CO., LTD.)
Patent Literature 3: Japanese unexamined patent publication No. 02-072551 (Date of laid-open: Mar. 12, 1990) “Metal vapor discharge lamp” (Applicant: TOSHIBA LIGHTING AND TECHNOLOGY CORPORATION)
Patent Literature 4: Japanese unexamined patent publication No. 10-069883 (Date of laid-open: Mar. 10, 1998) “Metal vapor discharge lamp” (Applicant: IWASAKI ELECTRIC CO., LTD.)
Patent Literature 5: Japanese unexamined patent publication No. 2002-008588 (Date of laid-open: Jan. 11, 2002) “Metal vapor discharge lamp” (Japanese patent No. 4,411,749) (Applicant: JAPAN STORAGE BATTERY CO., LTD.)
The patent literature 1 discloses a metal vapor discharge lamp including an arc tube into which a halogen of a quantity of 0.1×10 −6 to 1.0×10 −6 gram atom in a per cubic centimeter of internal volume of the arc tube and an iron of a quantity of ½ to 3 times the quantity of the halogen in atomic ratio are sealed (claim for patent).
The patent literature 2 discloses a metal vapor discharge lamp including an arc tube into which a halogen, an iron and a tin are sealed together with mercury of a quantity large enough to maintain an arc discharge and a rare gas of a proper quantity. A quantity of halogen sealed into the arc tube is selected to be 1.0×10 −5 to 1.0×10 −8 gram atom in a per cubic centimeter of internal volume of the arc tube, a total quantity of an iron and a tin relative to the quantity of the halogen is selected to be ½ to 3 in atomic ratio, a quantity of tin relative to the iron is selected to be 1/20 to 3 in atomic ratio and light energy is concentrated on the ultraviolet region of the wavelength ranging of from 280 to 420 [nm] (claim of Japanese examined patent publication).
The patent literature 3 discloses a metal vapor discharge lamp including an arc tube into which an iron, a tin and a halogen are sealed in addition to mercury and a rare gas. In this metal vapor discharge lamp, silver is added in addition to the above-described iron and tin. When the quantities of the iron, the tin, the silver and the halogen sealed into the arc tube are respectively expressed as [Fe], [Sn], [Ag] and [J] by an atom gram number, these quantities are selected so as to satisfy ([Fe]+[Sn])/[J]<0.5 and (2[Fe]+2[Sn]+[Ag])/[J]>1 (claim for patent).
The patent literature 4 discloses a metal vapor discharge lamp including an arc tube into which mercury, a rare gas, a halogen and, at least, more than one kind of metals of groups of an iron, cobalt and a nickel are sealed as luminescent materials. In this metal vapor discharge lamp, the quantities of the metals sealed into the arc tube except the mercury are selected so as to satisfy A×D×V+B (A represents a reciprocal number of a valence of the metal sealed into the arc tube, D represents a density of halogen sealed into the arc tube, this density being selected so as fall within the range of 1×10 −5 to 1×10 4 mol/cm 3 , V represents an interval volume in cm 3 of the arc tube and B represents a constant ranging of from 0.7×10 −4 to 3.6×10 −4 mol) (claim for patent).
The patent literature 5 discloses a metal vapor discharge lamp including an arc tube into which an iron is sealed as a main luminescent metal element and iodine is sealed as halogen. This metal vapor discharge lamp aims to increase emission intensity of light with a wavelength ranging from 450 to 500 nm without lowering starting performance (Abstract, paragraph [0008]). An argon gas is sealed into the arc tube as a starting rare gas and a partial pressure thereof is selected in a range of 5 to 10 [torr] (Abstract, paragraph [0020]). At least mercury is sealed into the arc tube thereof as a buffer gas, an iron is sealed into the arc tube thereof as a luminescent metal, iodine and bromine are sealed into the arc tube thereof as a halogen and a rare gas is sealed into the arc tube thereof as a starting gas. When (I) represents the sealed atom number of iodine per internal volume of the arc tube and (Br) represents the sealed atom number of bromine per internal volume of the arc tube, the quantity (Br)+(I) falls within the range of 2×10 −7 to 14×10 −7 (mol/cc) and the atomic ratio expressed by (Br):(I) falls within the range of 0:90 to 30:70 (claim 1 ).
Having compared these citations with the present invention simply, we may have the following compared results.
The patent literature 1 discloses only the metal vapor discharge lamp into which a halogen of a predetermined quantity and an iron of a quantity of ½ to 3 times the quantity of the halogen in atomic ratio are sealed.
The patent literature 2 discloses only the metal vapor discharge lamp into which a halogen of the predetermined quantity and the total quantity of iron and tin of ½ to 3 times the quantity of the halogen are sealed in atomic ratio.
The patent literature 3 discloses the iron, the tin, the silver and the halogen sealed into the lamp. Further, this patent literature has specified the quantities of the iron, the tin, the silver and the halogen.
The patent literature 4 discloses only the discharge lamp in which the required quantities of metals sealed into the lamp except mercury are specified in relation to the quantity of halogen.
The patent literature 5 aimed to increase the intensity of illumination of light with a wavelength ranging from 450 to 500 [nm], having observed starting performance. A pressure of an argon gas available as a starting rare gas is lowered in the range of 5 to 10 [torr] to thereby cancel deteriorated starting performance out. This patent literature is characterized by a wavelength of light and a pressure of a rare gas which are different from those of the inventive examples which will be described below. Further, having observed a quantity of an iron sealed into the lamp, it is to be noted that a quantity of (Fe) is selected in the range of 6×10 −7 [mol/cc], a quantity of (Sn) is selected in the range of 2×10 −7 [mol/cc] and a quantity of (I)+(Br) is selected in the range of 8×10 −7 [mol/cc] in the inventive example 1. Based on these numerical values, it is clear that (Fe) and (Sn) exist as iron halides and tin halides. Also, while the tin is merely replaced with a lead in the second inventive example, the tin or the iron is merely replaced with the iron in the third inventive example so that a relationship between the quantity of the metal and the quantity of the halogen is not changed at all. Accordingly, this patent literature is different from the present invention in which the quantity of the metal iron is increased independently of the quantity of the iron halides.
SUMMARY OF INVENTION
Technical Problem
The present invention is intended to provide a metal halide lamp for irradiating light of ultraviolet rays to cause a photochemical reaction for use in a drying process of inks and paints and a curing process of resins and the like. While a spectrum of light with a wavelength of 100 to 400 [nm] is generally referred to as light of ultraviolet rays, the present invention is intended to provide a metal halide lamp which can produce intense light of ultraviolet rays with a spectrum of, particularly, a wavelength ranging from 350 to 380 [nm] (the above light of ultraviolet rays will hereinafter be referred to as “light of ultraviolet rays near a wavelength 365 [nm]” which is a central wavelength).
The applicant of the present invention has paid attention to an iron (Fe) available as an luminescent material in the research and development of metal vapor discharge lamps and has proposed a metal vapor discharge lamp into which a halogen of a predetermined quantity and an iron of a quantity of ½ to 3 times the quantity of the halogen are sealed in atomic ratio in the patent literature 1. Further, in the patent literature 2, the applicant of the present invention has proposed a metal vapor discharge lamp into which an iron and a tin are sealed into the lamp in such a manner that a total quantity of the iron and the tin are selected to be ½ to 3 times the predetermined quantity of the halogen in atomic ratio and that the quantity of the tin is selected to be 1/20 to 3 times the quantity of the iron in atomic ratio.
A metal halide lamp containing irons shows a tendency such that iron and tungsten (W) of electrodes may react to each other to damage and deteriorate the electrodes under high temperature circumstances in which an arc discharge occurs.
Solution to Problem
In view of the above-described problems, an object of the present invention is to provide a novel ultraviolet ray irradiation metal halide lamp which can produce more intense light of ultraviolet rays with a wavelength near 365 [nm].
A metal halide lamp of the present invention is a metal halide lamp for producing mainly light of ultraviolet rays, said metal halide lamp comprising a lamp into which a rare gas and at least mercury and an iron are sealed to produce light with a high spectrum in ultraviolet rays, particularly, light with a wavelength of 350 to 380 [nm], in which said iron is supplied by iron iodide (FeI 2 ) and iron bromide (FeBr 2 ) as iron halide (FeX 2 ) and metal iron (Fe), when a quantity of the sealed iron is expressed such that A represents a quantity of metal iron (Fe) sealed into the lamp, B represents a quantity of iron iodide (FeI 2 ) sealed into the lamp and that C represents a quantity of iron bromide (FeBr 2 ) sealed into the lamp, respectively, the quantity A of said metal iron (Fe) falls within the range of 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ], the quantity (B+C) of said iron halide (FeX 2 ) falls within the range of 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ], and a ratio {C/(B+C)} of said iron bromide (FeBr 2 ) in said ion halide (FeX 2 ) falls within the range of {C/(B+C)}=5 to 70 [%].
Further, with respect to the above a metal halide lamp, said metal halide lamp may be characterized in that said quantity A of said metal iron (Fe) falls within the range of 0.5(B+C)≦A≦3.0(B+C) [mol/cm 3 ], said quantity (B+C) of said iron halide (FeX 2 ) falls within the range of 2.0×10 −7 ≦(B+C) 3.5×10 −7 [mol/cm 3 ], and said ratio {C/(B+C)} of said iron bromide (FeBr 2 ) in said iron halide (FeX 2 ) falls within the range of {C/(B+C)}=5 to 60 [%].
Further, with respect to the above a metal halide lamp, said metal halide lamp may further comprise an argon (Ar) gas of 2.0 [kPa] sealed therein as said rare gas.
Further in a method of manufacturing a metal halide lamp of the present invention, a rare gas and at least mercury and an iron being sealed into the lamp to produce light of ultraviolet rays with a high spectrum, particularly, light with a wavelength of 350 to 380 [nm], the sealed iron being offered by iron iodide (FeI 2 ) and iron bromide (FeBr 2 ) as metal halide (FeX 2 ) and metal iron (Fe), in the process to determine the composition of the luminescent material, a quantity A of the metal iron (Fe) being determined such that 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ] is satisfied, a quantity (B+C) of the iron halide (FeX 2 ) being determined such that 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ] is satisfied and a ratio {C/(B+C)} of the iron bromide (FeBr 2 ) in the iron halide (FeX 2 ) being determined such that {C/(B+C)}=5 to 70% is satisfied, when a quantity of the sealed iron is expressed such that A represents a quantity of metal iron (Fe) sealed into the lamp, B represents a quantity of iron iodide (FeI 2 ) sealed into the lamp and C represents a quantity of iron bromide (FeBr 2 ) sealed into the lamp, respectively, said method of manufacturing a metal halide lamp comprising the steps of: manufacturing a quartz tube into a predetermined shape and connecting quartz pipes serving as electrode fixing portions to respective ends of the quartz tube of a central portion which serves as a light-emitting portion in an envelope manufacturing process; fixing electrodes to said quartz tube in a sealing process and a fusion-welding process; evacuating the inside of said quartz tube in an exhausting process and sealing the halide, the metal iron, mercury, the rare gas (argon gas, etc.) determined in the process to determine the composition of said luminescent material into said quartz tube and sealing an exhausting portion; and fixing bases to respective ends of said quartz tube in a finishing process.
Advantageous Effects of Invention
According to the present invention, it is possible to provide a novel ultraviolet-irradiation metal halide lamp which can produce more intense light of ultraviolet rays with a wavelength near 365 [nm]. Moreover, if this lamp is used, then it is possible to efficiently irradiate a liquid crystal material substance with light required by a photochemical reaction. Thus, it is possible to manufacture a highly efficient liquid crystal panel as compared with a prior-art liquid crystal panel.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic cross-sectional view of a metal halide lamp according to an embodiment of the present invention.
FIG. 2 is a graph showing measured results obtained when lumen maintenance factors of respective lamps were measured in the experiments to calculate a preferable quantity A of a metal iron (Fe) available as a luminescent material at the first stage.
FIG. 3 is a graph showing measured results obtained when the intensities of illumination of respective lamps were measured in the experiments to calculate a preferable quantity (B+C) of an iron halide (FeX 2 ) available as a luminescent material at the second stage.
FIG. 4 is a graph showing measured results obtained when lumen maintenance factors of respective lamps were measured in the experiments to calculate a preferable ratio {C/(B+C)} between an iron iodide (B) and an iron bromide (C) composing a preferable iron halide (FeX 2 ) available as a luminescent material at the third stage.
FIG. 5 is a flowchart to which reference will be made in explaining a method of manufacturing the lamp shown in FIG. 1 .
DESCRIPTION OF EMBODIMENTS
Embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings. In the drawings, identical elements are denoted by identical reference numerals, respectively, and need not be described repeatedly. It should be noted that the embodiments of the present invention are used to explain the present invention by way of example and that these embodiments may not limit the scope of the present invention.
[Metal Halide Lamp]
A target metal halide lamp has physical sizes of its shape and the like which are identical to those of the lamp disclosed in the patent literature 4. FIG. 1 is a schematic cross-sectional view of this metal halide lamp 10 . This metal halide lamp includes a quartz arc tube 1 that has a pair of electrodes 2 , 2 provided within the arc tube. Each electrode includes an electrode tip end portion 2 a . This electrode tip end portion comprises an electrode stem made of a tungsten (W) or a thoriated tungsten containing a thorium of a quantity of approximately 2 [%] or an oxide-doped tungsten with a doped rare earth oxide and a tungsten wire wound around the electrode stem several times in a coil fashion. The respective electrodes 2 , 2 are connected to external lead wires through molybdenum foils 3 , 3 , respectively. The arc tube 1 is of a straight tube type and the inner diameter of the lamp tube is 20 mm, a distance between the electrodes (length of produced light) is 250 mm and an argon (Ar) gas of a pressure of 2.0 [kPa] (equivalent to approximately 15 [torr]) is sealed into the arc tube as a rare gas. Luminescent materials which are sealed into the arc tube will be described below.
[Compositions of Luminescent Materials]
Compositions of luminescent materials sealed into the lamp shown in FIG. 1 will be explained. A metal iron (Fe) and an iron halide (FeX 2 ) are used as luminescent materials. The iron halide, FeX 2 is made by a mixture of an iron iodide (FeI 2 ) and an iron bromide (FeBr 2 ).
In order to facilitate the explanation concerning the luminescent materials, respective elements will be marked below by symbols in which reference letter A represents a quantity of a metal iron (Fe) sealed into the lamp tube, B represents a quantity of an iron iodide (FeI 2 ) sealed into the lamp tube and C represents a quantity of an iron bromide (FeBr 2 ) sealed into the lamp tube. Accordingly, we may have the expression of an iron of luminescent material=metal iron (Fe)+iron halide (FeX 2 )=metal iron (Fe)+iron iodide (FeI 2 )+iron bromide (FeBr 2 )=A+B+C.
(First Stage: Studies on a Quantity of a Metal Iron Fe)
At the first stage, we have made experiments to obtain the preferable quantity A of the metal iron (Fe). To be concrete, under the condition that the iron of the luminescent material=metal iron (Fe)+Iron halide (FeX 2 )=A+(B+C) is satisfied, we have manufactured and evaluated a plurality of lamps while the quantity (B+C) of the iron halide was kept constant but the quantity A of the metal iron was being changed in the range of zero to 15 times the quantity (B+C) of the iron halide. A small quantity of a tin iodide (SnI 2 ) was used as an arc stabilizer. The iron halide may radically react with the tungsten (W) electrode under high temperature circumstances. In a like manner, the metal iron also may radically react with the tungsten (W) electrode. Accordingly, the preferable quantity A of the metal iron was evaluated by calculating time degradation characteristics of illuminance of the lamp.
TABLE 1 Time degradation characteristics of illuminance of lamp A/ C/ A B C B + C (B + C) (B + C) Sample Fe FeI 2 FeBr 2 FeX 2 Fe/ FeBr 2 / SnI 2 Nos. [mol/cm 3 ] [mol/cm 3 ] [mol/cm 3 ] [mol/cm 3 ] FeX 2 FeX 2 [mol/cm 3 ] 11 zero 2.0E−07 1.1E−07 3.1E−07 zero 0.365 0.20E−07 12 0.65E−07 0.2 13 1.5E−07 0.5 14 9.1E−07 3.0 15 31E−07 10.0 16 46E−07 15.0
Lamps used in experiments: metal halide lamp shown in FIG. 1
The table 1 shows data obtained from the respective lamps when the quantity (B+C) of the iron halide (FeX 2 ) sealed into the lamp was made constant while the quantities A of the metal iron (Fe) in the material sealed into the lamp were changed. The lamp used in the experiments is the lamp shown in FIG. 1 . It should be noted that the sample Nos. on the table 1 are denoted by a 10 number in order to avoid overlapping of samples used in other experiments.
There were prepared six kinds of sample Nos. 11 to 16 in which the quantity (B+C) of the iron halide (FeX 2 ) sealed into the lamp was made constant while the quantities A of the metal iron (Fe) sealed into the lamp were being changed in the range of zero to 46×10 −7 [mol/cm 3 ].
In order to calculate time degradation characteristics of illuminance of the lamp, illuminance of every sample was measured at a wavelength of 365 [nm] after elapse of time of zero, 500, 1000, 1500 and 2000 hours. The illuminance of those samples was calculated and obtained as relative values under the condition that illuminance obtained from each sample immediately after each sample was manufactured (without elapse of time) was set to 100 [%] (this illuminance will hereinafter be referred to as an “initial illuminance”). These relative values were set to lumen maintenance factor [%] obtained after each elapse of time. FIG. 2 is a graph showing the thus obtained lumen maintenance factors.
It is said that a metal halide lamp has a nominal lifetime of approximately 1,500 hours. The sample Nos. 14, 13 and 15 had lumen maintenance factor higher than 80 [%] of the initial illuminance after elapse of time of 1,500 hours. Illuminance of the sample Nos. 16, 12 and 11 was lowered to less than 80 [%] of the initial illuminance.
The sample No. 11 has the quantity A of the metal iron (Fe)=zero. The sample No. 12 has the smallest quantity A of the metal iron (Fe). The sample No. 16 has the largest quantity A of the metal iron (Fe).
In the first place, having compared the sample No. 11 (A=zero) and other samples (A≠zero) with each other, it became clear that samples which contain the quantity A of the metal iron in addition to the quantity (B+C) of the iron halide had higher lumen maintenance factor. Next, it became clear that lumen maintenance factor could be improved in the sample Nos. 12 to 14 in which the quantities A of the metal iron were increased, lumen maintenance factor of the sample No. 14 could reach the peak value and that lumen maintenance factor was lowered in the sample Nos. 14 to 16 in which the quantity A of the metal iron was further increased. This may be considered such that the peak value of the lumen maintenance factor lies between the sample Nos. 13 and 15, i.e. the peak value of the lumen maintenance factor exists near the sample No. 14.
The reason that the lumen maintenance factor of the sample No. 11 is degraded comparatively rapidly may be considered in such a manner that, while the iron exists within the lamp tube as the iron halide (FeI 2 ), the iron halide radically reacts with the tungsten (W) of the electrode under high temperature circumstances to produce chemical compounds with the result that irons which contribute to the emission of light are lost with elapse of time. This is also true in the lamp of the sample No. 12. The reason for this may be considered such that, since the metal iron (Fe) of a very small quantity gradually reacts with the tungsten (W) of the electrode under high temperature circumstances, irons which may contribute to the emission of light are exhausted finally in a comparatively short period of time.
The quantity A of the metal iron (Fe) in the sample No. 16 corresponds to 15 times of the quantity (B+C) of the iron halide FeX 2 . It may be considered that, since the metal iron of the excessively large quantity and the tungsten (W) of the electrode react with each other under high temperature circumstances, the electrode itself is damaged with elapse of time so that arc discharge is hindered to deteriorate illuminance of the sample of the lamp.
A study of the results shown in FIG. 2 reveals that the preferable lamps are those which can maintain illuminance higher than 80 [%] of the initial illuminance after elapse of time of 1,500 hours from a standpoint of maintaining the intensity of illumination of the lamp. A study of the table 1 reveals that the ratio of the quantity A of the metal iron (Fe) sealed into the lamp relative to the quantity (B+C) of the iron halide FeX 2 sealed into the lamp should preferably fall within the range of A/(B+C)=0.5 to 10.0 which correspond to the sample Nos. 13, 14 and 15. The quantity A should preferably be selected so as to fall within the range of 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ].
Further, the ratio of the quantity of the metal iron sealed into the lamp relative to the quantity of the iron halide sealed into the lamp should more preferably lie within the range of A/(B+C)=0.5 to 3.0 which correspond to the sample Nos. 13 and 14 that can maintain illuminance higher than 80 [%] of the initial illuminance even after elapse of time of 2,000 hours. The quantity A (quantity of metal iron) should be selected so to fall within the range of 0.5(B+C)≦A≦3.0(B+C) [mol/cm 3 ].
(Second Stage: Studies on Quantity of Iron Halide FeX 2 )
The preferable range of A (quantity of metal iron) became clear in the first stage. At the second stage, we have made experiments to calculate preferable quantities (B+C) of the iron halide (FeX 2 ) available as a preferable luminescent material within the range of the quantity A of the iron in the first stage.
Concretely, we have made the experiments with respect to the lamps in which the quantity A of the metal iron was kept constant but the quantity (B+C) of the iron halide was varied under the condition that an equality of irons in the luminescent material=metal iron (Fe)+iron halide (FeX 2 )=A+(B+C) is satisfied. At the same time, we have made the experiments on comparative examples of lamps in which case an iron halide is composed of only the iron iodide (FeI 2 ) (B only) and the iron halide is composed of a mixture (B+C) of the iron iodide (FeI 2 ) and the iron bromide (FeBr 2 ). A thallium iodide (TlI) of a small quantity was used as an arc stabilizer.
The metal iron and the iron of the iron halide are sealed into the lamps as the luminescent material in order to improve illuminance of the lamp. Accordingly, an optimum quantity (B+C) of iron halide was evaluated based on measured results of illuminance of lamps.
TABLE 2 Illuminance characteristics concerning iron halide A/ C/ A B C B + C (B + C) (B + C) 365 nm Sample Fe FeI 2 FeBr 2 FeX 2 Fe/ FeBr 2 / TlI Illuminance Nos. [mol/cm 3 ] [mol/cm 3 ] [mol/cm 3 ] [mol/cm 3 ] FeX 2 FeX 2 [mol/cm 3 ] [%] 21 13E−07 0.78E−07 zero 0.78E−07 16.6 zero 0.183E−07 100 22 1.2E−07 1.2E−07 11.1 109 23 1.6E−07 1.6E−07 8.3 115 24 2.3E−07 2.3E−07 5.5 113 25 0.39E−07 0.22E−07 0.62E−07 21.1 0.365 107 26 0.78E−07 0.45E−07 1.2E−07 10.6 0.365 118 27 1.2E−07 0.67E−07 1.8E−07 7.02 0.365 127 28 1.6E−07 0.9E−07 2.5E−07 5.3 0.365 129 29 2.0E−07 1.1E−07 3.1E−07 4.2 0.365 126 30 2.4E−07 1.3E−07 3.6E−07 3.6 0.355 124 31 3.5E−07 2.1E−07 5.7E−07 2.3 0.377 88
Lamp used in experiments: Metal halide lamp shown in FIG. 1
The lamp used in the experiments is the lamp shown in FIG. 1 . In the sample Nos. 21 to 31 shown on the table 2, the quantity A of the metal iron (Fe) in the luminescent material is kept constant so as to satisfy an equality of A=13×10 −7 [mol/cm 3 ]. The value thus selected as the quantity A is nearly a mean value of the sample Nos. 13, 14 and 15 which may fall within the preferable range. Sample Nos. on the table 2 are denoted by a 20 number and a 30 number in order to avoid overlapping of samples of lamps in other experiments.
The sample Nos. 21 to 24 may utilize only the iron iodide as the iron halide (FeX 2 ) (iron iodide B only) but they did not use the iron bromide (FeBr 2 ). The sample Nos. 25 to 31 use a mixture (B+C) of iron iodide and iron bromide as the iron halide.
In the sample Nos. 21 to 24 which use only the iron iodide B, the quantity of the iron bromide B is gradually varied so as to increase in the range of 0.78×10 −7 to 2.3×10 −7 [mol/cm 3 ]. Similarly, in the sample Nos. 25 to 31 which use the mixture (B+C) of the iron iodide and the iron bromide, the quantity (B+C) is gradually varied to so as to increase in the range of 0.62×10 −7 to 5.7×10 −7 [mol/cm 3 ].
Illuminance of the lamps was measured by an illuminometer suitable for use in measuring light with a wavelength of 365 [nm]. Measured data are shown on the table in such a manner that illuminance of the sample No. 21 is set to 100 [%] and that other measured data are shown thereon as relative values.
FIG. 3 is a graph showing measured results of illuminance of those samples of lamps. Having compared the samples of (B only) and the samples of (B+C) with each other, it became clear that all data show that illuminance of the samples of (B+C) was higher than illuminance of the samples of (B only) when the quantities of the iron halides are the same.
With respect to illuminance of the samples in which the iron halide is composed of only the iron iodide (B only), a study of this graph reveals that illuminance of the sample Nos. 21 to 23 in which the quantities of the iron iodide are increased could be improved. However, illuminance of sample Nos. 23 to 24 in which the quantities of the iron iodide were increased more was lowered conversely. With respect to illuminance of samples of (B+C), illuminance of sample Nos. 25 to 28 in which the quantity of the iron halide was increased could be improved. However, illuminance of sample Nos. 28 to 31 in which the quantity of the iron halide was increased more was gradually lowered conversely. As described above, with respect to both of the samples of (B only) and the samples of (B+C), there is a tendency that illuminance of the samples could be improved by the increase of the quantity of the iron halide, they reached their peak values by the constant quantity of the iron halide and that they are lowered by more increasing the quantity of the iron halide.
The iron is the luminescent material within the lamp. Accordingly, it might be considered that illuminance of the sample Nos. 21 to 23 and the sample Nos. 25 to 28 could be improved with the increase of the iron halide (FeX 2 ). On the other hand, illuminance of the sample Nos. 23 to 24 and the sample Nos. 28 to 31 was gradually lowered as the quantity of the iron halide is increased. The cause that illuminance of the samples was gradually lowered as the quantity of the iron halide was increased might be considered such that the peak value of illuminance was deviated from the wavelength of 365 [nm] and moved to other wavelengths.
A maximum value of relative illuminance of the lamp of (B only) lies near B=1.8×10 −7 [mol/cm 3 ] and it is nearly 115 [%]. Accordingly, in order to obtain the benefits provided by the lamp of (B+C) in comparison with the lamp (B only), relative illuminance of the lamp of (B+C) should preferably be selected so as to become higher than 115 [%]. A study of FIG. 3 reveals that illuminance of the lamp of (B+C) should preferably be selected so as to fall within the range of 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ]. On the table 2, data surrounded by the open rectangles along the (B+C) column of the sample Nos. 26 to 30 may correspond to the above-mentioned data. Further, relative illuminance of the lamp should more preferably be selected so as to fall within the range of 2.0×10 −7 ≦(B+C)≦3.5×10 −7 [mol/cm 3 ] in which relative illuminance is higher than 125 [%].
(Third Stage: Studies on Ratio of Iron Bromide (FeBr 2 ) in Iron Halide (FeX 2 ))
The preferable range of the quantity A of the metal iron became clear at the first stage and the preferable range of the quantity (B+C) of the iron halide became clear at the second stage.
At the third stage, we have made the experiments to calculate a preferable ratio between the iron iodide (B) and the iron bromide (C) composing the iron halide (B+C) within the range of the quantity A ascertained at the first stage and within the range of the quantity (B+C) of the iron halide ascertained at the second stage. Concretely, we have made the experiments on respective lamps in which, under the condition that an equality of iron of material sealed into the lamp=metal iron (Fe)+iron halide (FeX 2 )=A+(B+C) was satisfied, the quantity A and the quantity (B+C) were kept substantially constant within the ranges ascertained at the first and second stages and the ratio {C/(B+C)} of C relative to the quantity (B+C) was changed.
Irons of the metal iron (Fe) and the iron halide (FeX 2 ) are sealed into the lamp in order to improve illuminance of the lamp. On the other hand, the metal iron and the iron halide react with the tungsten (W) electrode. Accordingly, the preferable ratio {C/(B+C)} of the quantity of the iron bromide relative to the quantity of the iron halide was evaluated based on both standpoints of illuminance of the lamp and lumen maintenance factor.
TABLE 3 Illuminance characteristics and time degradation characteristics of lamps A/ C/ A B C B + C (B + C) (B + C) Sample Fe FeI 2 FeBr 2 FeX 2 Fe/ FeBr 2 / SnI 2 Illuminance Nos. [mol/cm 3 ] [mol/cm 3 ] [mol/cm 3 ] [mol/cm 3 ] Fx 2 FeX 2 [%] [mol/cm 3 ] [%] 41 9.1E−07 3.1E−07 zero 3.1E−07 3.0E−07 zero 0.52E−07 100 42 2.9E−07 0.11E−07 3.0E−07 3.7 102 43 2.9E−07 0.17E−07 3.1E−07 5.5 116 44 2.3E−07 0.67E−07 3.0E−07 22.3 117 45 2.0E−07 1.1E−07 3.1E−07 36.5 119 46 1.4E−07 1.1E−07 3.1E−07 55.2 118 47 1.0E−07 2.1E−07 3.2E−07 2.9E−07 67.7 119 48 7.8E−07 2.2E−07 3.0E−07 3.0E−07 74.2 118
Lamp used in experiments: metal halide lamp shown in FIG. 1
The lamp used in the experiments is the lamp shown in FIG. 1 . Based on the table 1 at the first stage and (the studies on the metal iron Fe) shown in FIG. 2 , it became clear that the quantity A should preferably be selected so as to fall within the range of 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ]. Further, based on the table 2 at the second stage and (the quantity of the iron halide FeX 2 ) shown in FIG. 3 , it became clear that the quantity (B+C) should preferably be selected so as to fall within the range of 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ]. At this third stage, the quantity A of the metal iron is made substantially constant such as 9.1×10 −7 [mol/cm 3 ] within the range calculated at the first stage. The quantity (B+C) of the iron halide also is made substantially constant such as 3.0×10 −7 to 3.2×10 −7 [mol/cm 3 ] within the range calculated at the second stage. On the table 3, data encircled by open rectangles in the column of A and the column of (B+C) correspond to the above quantity of the metal iron and the above quantity of the iron halide.
Under this condition, the ratio {C/(B+C)} of the quantity of the iron bromide relative to the quantity of the iron halide is gradually changed in the range of zero to 74.2 [%]. A tin iodide (SnI 2 ) of a small quantity is utilized as an arc stabilizer. It should be noted that sample Nos. on the table 3 are denoted by a 40 numbers in order to avoid overlapping of the samples in other experiments.
Illuminance data were measured by the illuminometer suitable for use in measuring light of a wavelength 365 [nm]. With respect to illuminance data, illuminance of the sample No. 41 which does not contain the iron iodide C is selected to be 100 [%] and illuminance data of the respective lamps are indicated by relative values.
When samples are evaluated, initial illuminance should have a significant difference relative to a sample No. 41, i.e. illuminance should preferably be increased more than 10 [%]. Excepting sample No. 42, samples Nos. 43 to 48 might satisfy this condition. Based on these samples, it became clear that the ratio of the quantity of the iron bromide relative to the quantity of the iron halide should preferably be selected so as to fall within the range of substantially {C/(B+C)}≧5 [%].
Next, in order to obtain time degradation characteristics of illuminance, illuminance of any sample was measured after elapse of time of zero, 500, 1000, 1500 and 2000 hours and relative values were calculated under the condition that the initial illuminance of each sample was set to 100 [%], whereafter these calculated relative values were obtained as lumen maintenance factor [%] per elapse of each time. FIG. 4 is a graph showing these lumen maintenance factors.
A study of the results shown in FIG. 4 reveals that preferable lamps are those which can maintain more than 80 [%] of the initial illuminance after elapse of time of 1,500 hours from a standpoint of maintaining illuminance of the lamp. From FIG. 4 , it became clear that the sample Nos. 44, 45, 43, 46 and 47 could satisfy the conditions of these lamps. Based on the table 3, it became clear that the quantities {C/(B+C)} of these sample Nos. 43 to 47 should preferably be selected so as to fall within the range of {C/(B+C)}=5 to 70 [%]. These samples should satisfy the conditions by which illuminance of the above-mentioned sample No. 41 could be improved more than 10 [%].
Further, referring to FIG. 4 , it is to be understood that the sample Nos. 44, 45, 43 and 46 which can maintain more than 80 [%] of the initial illuminance after elapse of time of 2,000 hours should be more preferable. From the table 3, it became clear that the ratio of the iron iodide relative to the iron halide should be more preferably selected so as to fall within the range of {C/(B+C)}=5 to 60 [%] of the sample Nos. 43 to 46.
The sample Nos. 41 and 42 in which the ratio of {C/(B+C)} is zero or very small had no significant difference for the initial illuminance as described above and lumen maintenance factors thereof also were low. Based on these results, it became clear that when the ratio of {C/(B+C)}=zero, that is, when the iron halide is made of only the iron iodide (B only), as compared with the case of (B+C), lumen maintenance factors thereof were low at the third stage in addition to the fact that the initial illuminance thereof was low as was clear from the second stage. The samples in which the ratios of {C/(B+C)} are very small have the same tendency.
The sample Nos. 43 to 45 in which the ratio of {C/(B+C)} was increased gradually could improve initial illuminance such as initial illuminance of 116, 117, 119 [%] progressively as shown on the table 3 so that lumen maintenance factors thereof could be improved as shown in FIG. 4 . However, sample Nos. 45 to 48 in which the ratio of {C/(B+C)} had further been increased reached the peak values thereof and lumen maintenance factors thereof also were lowered. That is, it became clear that, when the iron halide is composed of the mixture of the iron iodide and the iron bromide, the optimum peak value of the ratio {C/(B+C)} of the iron bromide relative to the quantity of the iron halide lies near the range of {C/(B+C)}=35 to 55 [%] which might cover the sample Nos. 45 and 46.
It became clear that, when the iron halide is composed of only the iron iodide (B only), resultant lamps should be inferior to those lamps composed of the mixture (B+C) of the iron halide of the iron iodide and the iron bromide from both of initial illuminance and lumen maintenance factor. Further, it became clear that good results of both of illuminance and lumen maintenance factor could be obtained by increasing the quantity of the iron bromide up to a certain quantity. However, since the iron bromide (FeBr 2 ) is relatively high in reactivity as compared with the iron iodide (FeI 2 ), if the iron bromide has an excessively large ratio in the iron halide, then such iron bromide can easily react with the tungsten (W) electrodes, thereby to lower lumen maintenance factor.
[Manufacturing Method of Metal Halide Lamp]
A method of manufacturing this metal halide lamp will be described with reference to FIG. 5 .
In a process for manufacturing an envelope of a lamp at a step S 1 , a quartz tube (depicted by reference numeral 1 in FIG. 1 ) is manufactured as a quartz tube of a desired shape. Quartz tubes that may serve as electrode fixing portions are connected to respective ends of the quartz tube 1 at its central portion which serves as a light-emitting portion of a lamp. A thin pipe (exhaust pipe) that serves both as a conduit to introduce a sealed material into the quartz tube and which serves also as an exhausting conduit within the quartz tube is connected in advance to the quartz tube at its central portion in the direction perpendicular to the quartz tube by fusion-welding (not shown).
In a temporary exhausting process at a step S 2 , the electrodes are sealed into the envelope and the envelope was evacuated, whereafter an inert gas such as an argon gas of a very small pressure was sealed into the envelope.
In a sealing process and a fusion-welding process at a step S 3 , the electrodes 2 , 2 are fixed to the quartz tube.
In an exhausting process at a step S 4 , after the arc tube 1 was evacuated, halides and metal irons having predetermined compositions which will be described next and other elements such as mercury and a rare gas (argon gas, etc.) are sealed into the quartz tube and the exhaust pipe is sealed by a tipoff. Here, a high-purity iron reagent is used as the metal iron.
With respect to the iron and the iron halide sealed into the arc tube at this stage, the quantity A of the metal iron is determined so as to fall within the range of 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ] at the above-mentioned first stage, the quantity (B+C) of the iron halide is determined so as to fall within the range of 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ] at the second stage and the preferable ratio {C/(B+C)} of the quantity C of the iron bromide (FeBr 2 ) relative to the quantity B of the iron iodide comprising the iron halide is determined so as to fall within the range of {C/(B+C)}=5 to 70% at the third stage.
In a finishing process at a step S 5 , bases are fixed to the respective ends of the quartz tube 1 .
Advantageous Effects of Invention
(1) Through the experiments at the first stage, the preferable quantity A of the metal iron (Fe) could be determined as a sealed material with respect to irons which are luminescent materials. This quantity should preferably be selected so as to fall within the range of 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ]. More preferably, this quantity should be selected so as to fall within the range of 0.5(B+C)≦A≦3.0(B+C) [mol/cm 3 ]
(2) Through the experiments at the second stage, illuminance of the lamp could be improved by adding the iron halide FeX 2 to the metal iron Fe to thereby increase the quantity of the iron as the luminescent material. That is, it became clear that illuminance of the lamp of (B only) and illuminance of the lamp of (B+C) could be improved by increasing the quantity of the iron halide, illuminance of the lamp could reach the peak value by a certain quantity of iron halide and that illuminance of the lamp tends to be lowered by further increasing the quantity of the iron halide more.
(3) Through the experiments at the second stage, illuminance of the lamp of (B only) and illuminance of the lamp of (B+C) were compared with each other. When the quantity of the iron halide (FeX 2 ) is the same, it became clear that illuminance of the lamp of (B+C) was higher than that of lamp of (B only).
(4) Through the experiments at the second stage, under the condition of the preferable quantity A of the metal iron (Fe) obtained at the first experiment, there could be determined the preferable quantity (B+C) of the iron halide (FeX 2 ).
This preferable quantity of the metal iron should preferably be selected so as to fall within the range of 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ]. This quantity should more preferably be selected so as to fall within the range of 2.0×10 −7 ≦(B+C)≦3.5×10 −7 [mol/cm 3 ].
(5) Through the experiments at the third stage, the lamp in which the iron halide is composed of only the iron iodide (B only) and the lamp in which the iron halide is composed of the mixture of the iron iodide and the iron bromide (B+C) were compared with each other. It became clear that the lamp in which the iron halide is composed of the mixture of the iron iodide and the iron bromide (B+C) is superior in lumen maintenance factor to the lamp in which the iron halide is composed of only the iron iodide (B only).
(6) Through the experiments at the third stage, there could be determined the preferable ratio {C/(B+C)} between the quantity B of the iron iodide (FeI 2 ) and the quantity C of the iron bromide (FeBr 2 ) comprising the iron halide (FeX 2 ).
This ratio should preferably be selected so as to fall within the range of {C/(B+C)}=5 to 70 [%]. This ratio should more preferably be selected so as to fall within the range of {C/(B+C)}=5 to 60 [%].
By determining the compositions of the sealed materials on the basis of the data concerning the quantities of the luminescent materials obtained from the above-mentioned experiments and stages (1) to (6), it became possible to manufacture a metal halide lamp for irradiating light of ultraviolet rays to cause a photochemical reaction and of which initial illuminance and lumen maintenance factor are high when light of ultraviolet rays has a wavelength of 350 to 380 [nm]. Moreover, since this wavelength region is such one that is most effective for causing a photochemical reaction to form a liquid crystal orientation, it becomes possible to manufacture a liquid crystal panel which can efficiently irradiate the material of the liquid crystal with light and which can realize more sufficiently accurate high-definition images than those of the prior-art.
Modified Example and Summary
While the examples of the metal halide lamp according to the present invention have been described so far, these examples are described by way of example and may not limit the scope of the present invention. Changes easily made on the present invention by those skilled in the art, such as addition, deletion modification and improvement may fall within the scope of the present invention.
For example, in the above-mentioned embodiments, the range of the preferable quantity A of the metal iron was calculated at the first stage. At the second stage, the range of the preferable quantity (B+C) of the iron halide was calculated under the condition of the preferable quantity A obtained in the first stage. At the third stage, under the condition of the range of the quantity A and the range of the quantity (B+C) obtained in the second and third stages, the range of the ratio {C/(B+C)} of the quantity C of the iron bromide relative to the preferable quantity (B+C) of the iron halide was calculated. The scope of the present invention is not limited to the decisions of this order.
When the range of the preferable quantity (B+C) and the range of the ratio {C/(B+C)} are determined, the range of the quantity (B+C) is determined first and the ratio {C/(B+C)} is determined next from a time standpoint. However, the order in which the range of the quantity A and the range of the quantity (B+C) are determined may not be limited to the above-mentioned one and it may be changed freely. In the patent literature 1, the applicant of the present invention has proposed the metal vapor discharge lamp into which a halogen of a predetermined quantity and “iron” of a quantity ½ to 3 times the quantity of the halogen in atomic ratio are sealed. Based on this experience, the range of the quantity (B+C) can be determined while the quantity A of the iron is being made constant.
Accordingly, if the order that has been described so far in the above-mentioned embodiments is selected as the order to determine the first luminescent material, the present invention is not limited thereto and the following second and third modified examples are made possible.
1. Second order to decide the first luminescent material
(first stage) the quantity A is made constant and the range of the quantity (B+C) is determined; (second stage) the quantity (B+C) is made constant and the range of the quantity A is determined; and (third stage) the quantity A and the quantity (B+C) are made constant and the range of the ratio {C/(B+C)} is determined.
2. Third order to decide the first luminescent material
(first stage) the quantity A is made constant and the range of the quantity (B+C) is determined; (second stage) the quantity A and the quantity (B+C) are respectively made constant and the range of the ratio {C/(B+C)} is determined; and (third stage) the quantity (B+C) and the ratio (C/(B+C)) are respectively made constant and the range of the quantity A is determined.
The technical scope of the present invention may be determined based on the descriptions of the scope of the appended claims.
REFERENCE SIGNS LIST
1 : arc tube, 2 : electrode, 2 a : electrode tip end portion, 3 : molybdenum foil, 10 : metal halide lamp,
A: quantity of metal iron (Fe) sealed into lamp, B: quantity of iron iodide (FeI 2 ) sealed into lamp, C: quantity of iron bromide (FeBr 2 ) sealed into lamp | The present invention is to provide a novel ultraviolet irradiation metal halide lamp which can produce more intense light of ultraviolet region with a wavelength near 365 [nm]. This lamp is a metal halide lamp to produce mainly light of ultraviolet region. In order to produce light with a high spectrum in ultraviolet region, particularly, light of a wavelength of 350 to 380 [nm], at least mercury (Hg) and an iron are sealed into this lamp together with a rare gas. The sealed iron into the lamp is supplied by iron iodide (FeI 2 ) and iron bromide (FeBr 2 ) as iron halide (FeX 2 ) and metal iron (Fe). When a quantity of materials sealed into the lamp is expressed such that A represents a quantity of metal iron sealed into the lamp, B represents a quantity of iron iodide sealed into the lamp and C represents a quantity of iron bromide sealed into the lamp, respectively, the quantity A of the metal iron falls within the range of 0.5(B+C)≦A≦10.0(B+C) [mol/cm 3 ], the quantity (B+C) of the iron halide falls within the range of 1.0×10 −7 ≦(B+C)≦4.5×10 −7 [mol/cm 3 ] and a ratio {C/(B+C)} of the iron iodide (FeBr 2 ) in the iron halide (FeX 2 ) falls within the range of {C/(B+C)}=5 to 70%. | 7 |
The invention generally relates to building frame members which are adapted for receiving structural panels, particularly structural panels with sheet metal surfaces and elongated reinforcing steel members. Reference is made to Disclosure Document No. 399540, filed by the inventor on Jun. 25, 1996, which generally describes the enclosed invention, together with frame members adapted to receive similar panels in other building structures.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,373,678, issued to Hesser on Dec. 20, 1994, teaches an improved structural panel in which a light-weight structural material is enclosed between two portions of sheet metal and the combinant panel is further strengthened by reinforcing steel bars which are housed and enclosed within the structural panel sheets.
When uniform structural panels are used to construct all or significant portions of a building, it is useful to formulate a standardized means of framing and positioning the various structural panels. A building will only be as strong as its weakest member. Accordingly, it is important to position and frame the structural panels with framing members which are capable of securing and holding the various portions of such building or structure and will also allow the flexibility of providing a variety of building accessories or options.
Aluminum is a useful material for constructing such building frame members. Aluminum has high strength properties for structural metal applications, has a high resistance to corrosion, is easily fabricated, is reasonably light weight, can be welded or mechanically fastened together, and otherwise has properties making it acceptable as a building material. For instance, it does not become permanently magnetized in the presence of a permanent magnetic field.
Aluminum is also desirable for other reasons. For instance, it is easy to work with and fabricate frame members from aluminum. This is because the appropriate alloys or blends of aluminum can be produced by an extrusion process. Extruding is a very efficient and reliable way to fabricate such building components and is desirable.
Standardization is also very helpful in this regard. There are a variety of building components which lend themselves to standardization. For instance, a typical house will have a pitched roof which extends from eave members along opposite sides through a pitched roof to a ridge top. Additionally, a building will normally have an interior baseboard. Most buildings, whether residential or commercial, will also have a need for conduits and passageways through which electrical, communications, and other wiring or cabling may be passed. Finally, most buildings will require a series of windows or other openings along exterior walls. Accordingly, it is helpful to be able to develop standardized apparatus which may be appropriate to each of these purposes.
Prefabricated, or other forms of standardized or hasty structures, require roofs just like any other. Roofs are complicated portions of the building, typically requiring substructures such as ridge beams, trusses, eaves, and roof framing beams. The pitch of a roof dictates many specific requirements of construction and also may provide important building advantages, as will be discussed in greater detail later. In the construction of such structures, it would be helpful to be able to adjust the pitch of the roof as required for a given construction situation.
U.S. Pat. No. 5,423,157, entitled "Longitudinally Assembled Roof Structure and Method For Making Same", issued to Watanabe, et al, on Jun. 13, 1995, in fact, teaches a roof which is manufactured of longitudinally aligned roof panels. Generally, Watanabe teaches roof panels which comprise interlocking sections so that such panels assemble to one another as they rise from the eaves to the roof-ridge. It can be seen that it would be both difficult and compromise the integrity of the roof panels if it were necessary to cut or sever a given roof panel. This is because it would interrupt the structural integrity of the roof panel as well as the fact that a significant coupling member would be lost by cutting off one of the sides.
Similarly, U.S. Pat. No. 4,729,202, issued to Furland, on Mar. 8, 1988, teaches another roof structure comprising pre-cut roof panels which are longitudinally disposed from eaves to roof-ridge. In the case of Furland, certain fasteners are taught. As with Watanabe, Furland deals with the means of interlocking the longitudinally disposed roof panels to one another.
What is not provided in the prior art is a roof-ridge apparatus which is uniquely adapted to receive roof panels and to permit a roof to be constructed with variable pitch so that it will not be necessary to cut or trim longitudinally disposed roof panels in order to fit the size of a given building. It would also be useful to find such an apparatus which could be manufactured through an extrusion process.
SUMMARY OF THE INVENTION
U.S. Pat. No. 5,373,678, issued to Hesser, on Dec. 20, 1994, teaches a structural wall apparatus. Incorporated within Hesser's structural wall apparatus are building panels which comprise an outer and inner metal skin spaced by an intermediate insulating core of foamed polymer. Each such panel is adapted to have at least one interlocking edge with a metal line tongue in a metal line groove adapted to facilitate interconnection of panels as they are longitudinally interconnected. The panels taught by Hesser also comprise a reenforcing member to the metal skin with a strengthening flange portion on the other side of the metal line groove. Fasteners may be passed through various portions of the interconnecting grooves and flanges in order to facilitate the connection.
While the mechanism taught by Hesser enables adjacent structural panels to interconnect, it does not teach a means of framing the structural panels so as to specifically accommodate certain portions of a building structure, such as the roof, the eaves, the foundational frame members, and the frames for doors and windows.
Such structural panels can be easily fabricated in mass quantities. With appropriate interconnecting members, they can be used for rapid structure of strong and reliable buildings. One of the advantages of such structural panels is in the standardization of the sizes and interconnecting members which not only make them easy to work with but also easy and quick to assemble and train construction workers for accomplishing even what would ordinarily be complicated tasks. Such standardization also facilitates the ability to standardize certain building accessories.
It is well known that roofs are typically made with a pitch. The pitch serves multiple purposes. One purpose is to prevent the accumulation of rainwater or snow or other foreign objects on the roof in order to prevent corrosion or to prevent foreign articles from resting out of sight on the roof. Other purposes may include aesthetics or ventilation considerations. The pitch of the roof may be anywhere from a gradual or shallow angle to a steep or a sharp angle.
Perhaps the most critical portion of any roof structure is the ridge top. At the ridge top, the two sloping halves come together. It is important that the two converging halves fit precisely together so that water intrusion or air filtration will not occur. The ridge connection must be structurally strong and the beam between the halves must cause two sloping members to fit together.
It should be noted that buildings constructed with structural panels such as those taught by Hesser are designed with a variety of pitches generally ranging from a 3" rise in 12" of run to a 12" rise in 12" of run. It is desirable, therefore, to have available a roof ridge member that can accommodate a variety of building designs.
The Inventor has solved this problem by providing a roof ridge member with frame receiving members for receiving the edges of the structural panel members taught by Hesser and further comprise an elongated rotating sleeve member for providing a stable and reliable ridge which can adjust between a range of pitches sufficient to permit any reasonable roof pitch.
It is, then, an object of the present invention to provide a structural beam between the sloped halves of a structural panel roof that will withstand the forces of wind and other elements.
It is a further object that the ridge beam can be thermally broken.
It is, then, an object of the present invention to provide a roof framing structure for framing a roof comprising structural panels such as those taught in Hesser.
It is a further object of the present invention to teach such a roof framing apparatus which can accommodate roofs of adjustable pitch.
It is a further object of the present invention to provide a roof ridge mechanism which will work with a reasonable range of roof pitches as may be required to accommodate specific buildings.
It is a further object of the present invention to provide such a roof ridge apparatus which may be manufactured through an extrusion process.
It is a further object that the beam enables the construction of free standing rigid structures that do not need an elaborate and expensive truss system to support the roof.
It is a further object of the invention to enable the connection of the two sloping roof halves with a thru-bolt connection.
It is a further object of the invention to provide a structural connection at the panel ends which efficiently handles and manages the transfer of positive and negative windloads through the aluminum "U" channel to the foundation.
It is a further object of the invention to improve the current method of framing roof panels in order to better withstand the positive or negative windloads which may be placed upon the building foundation.
Other features and advantages of the present invention will be apparent from the following description in which the preferred embodiments have been set forth in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In describing the preferred embodiments of the invention reference will be made to the series of figures and drawings briefly described below.
FIG. 1 depicts the basic frame member adapted to receive structural panels as taught in Hesser.
FIG. 2 depicts a cross-section of a roof ridge member according to the present invention with an outer sleeve member.
FIG. 3 depicts a cross-section of a roof ridge member with an inner rotating axle member.
FIG. 4 depicts the cross section of all pieces of the ridge apparatus assembled.
FIGS. 5A and 5B depict two roofs of varying pitch joined with the same roof ridge apparatus.
While certain drawings have been provided in order to teach the principles and operation of the present invention, it should be understood that, in the detailed description which follows, reference may be made to components or apparatus which are not included in the drawings. Such components and apparatus should be considered as part of the description, even if not included in such a drawing. Likewise, the drawings may include an element, structure, or mechanism which is not described in the textual description of the invention which follows. The invention and description should also be understood to include such a mechanism, component, or element which is depicted in the drawing but not specifically described.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. While the invention will be described in connection with a preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention defined in the appended claims.
While the following description will seek to improve understanding of the invention by describing the various components and elements, it should be considered that certain apparatus may be sufficiently and adequately explained by the accompanying drawings, which are fully incorporated herein, and not require further description. All such apparatus should be considered as part of the specification of the invention for all purposes.
As depicted in FIG. 1, a fundamental apparatus for receiving such structural panels is a three-sided frame member which generally describes a "U" or "C" (10). Such would comprise three connected flat sides (11, 12, 13) with two parallel side members (11, 12) which are joined by a perpendicular base member (13). The spacing (14) between the two side members (11, 12) would be such as to snugly receive a structural panel, such as the one taught by Hesser.
Such a general frame structure (10) may easily be manufactured with an extrusion process since all of the surfaces are both straight and uniform. In this manner such a frame member may be fabricated of any desired length and may be cut to any length. Generally speaking, in the extrusion process, an elongated apparatus with a continuous cross section can be manufactured by heating a desired metal (such as an aluminum alloy) and forcing the metal through a cross-sectional die. As the molten aluminum assumes the cross-sectional shape of the form and passes through, it begins to cool and harden. This results in an elongated metallic structure with the desired cross section and of any desired length. This is an efficient and cost-effective means of manufacturing a variety of objects, including frame members, which also produces a consistent structure. Such extrusion method is mentioned by way of general familiarization and is not claimed, in and of itself, as part of this invention. However, the potential for the utilization of extrusion in the practice of this invention is an important consideration when considering its advantages and utility.
While not necessary, as further depicted in FIG. 1, it can be seen that such members may be constructed with a thermal break (15) which reduces the thermal transmission of heat or cold from the outer frame surface to the inner frame surface. This feature is particularly useful for buildings erected in cold climates. The thermal (refer to thermal break U.S. Pat. No. 3,204,324 to "Wilson") break comprises a cavity section (15) with ribbed members (17). The cavity section (15) may be filled with an adhesive binding material (18), such as a liquid urethane, while a portion (16) of the outer cavity (19) can be cut away so as to break the normal continuity in the aluminum base member (10). The structural integrity of the base member (10) through this region is now provided by the binding material (18) and a reduction in thermal transmission is achieved while maintaining the structural integrity of the "C" shaped frame (10) or the structural panel (60) which may be housed within. Such a thermal break (15) may be positioned along the length of any structural panel wall section being contained by the frame section to maintain continuity in the thermally broken and insulated building system.
It should be noted that such thermal breaks can be easily incorporated into an extrusion. It should also be noted that thermal breaks are already well known in the construction art and are not the subject of the present invention. Certain further modifications, innovations, and adaptations of frame members made with thermal breaks, however, are taught herein as means of accomplishing the objectives of the present invention. Such modifications, innovations, and adaptations are the subject of the claims of the present invention.
In these cases one or two positioning platforms (151, 152) could be positioned and inwardly disposed from either side member (12, 13) of the frame (10). Such positioning platforms (151, 152) would have planar surfaces (153, 154) which were perpendicular from the side members (12, 13). If two positioning platforms are used, they are lined up within the same plane. It can be seen that such positioning platforms (151, 152) could easily be included in an extrusion form.
Additionally, such a frame member (10) is amenable to the placement of fastening screws or bolts (21) at any point along its length. Channels (22) may be drilled which pass through the frame member (10), as well as the encased or framed structural panel (20) which may receive a fastening member (21) to hold the structural panel (61) stable within or between the side panels (11, 12) of the frame member (10).
Making reference now to FIG. 2 it can be seen that the basic frame member structure has been substantially modified to form a first roof panel receiving member (110) in order to receive the top edge of a structural roof panel member (61) in a frame (30) which is further adapted with exterior arched flanges (31, 32) which arc out from the base portion (33) and lower side member (35) so as to have inner surfaces (91, 92) which geometrically define two portions of the same circle. Additionally, the base portion (33) of the frame member (30) is angled slightly from the upper side member (34) to the lower side member (35). The importance of this will be discussed later.
Making reference now to FIG. 3 it can be seen that this same modified basic frame member structure has been substantially reproduced in order to form a second roof panel receiving member (120) in order to receive the top edge of a structural roof panel member (61) in a frame (30) which is further adapted with interior arched flanges (81, 82) which arc out from the base portion (33) and lower side member (35) so as to have outer surfaces (93, 94) which geometrically define two portions of the same circle. The circle defined by these flanges (81, 82) is of a dimension to snugly fit and rotate within the circling flanges (31, 32) of the first roof top frame (110) frame. Additionally, the base portion (33) of the frame member (30) is angled slightly from the upper side member (34) to the lower side member (35). The importance of this will be discussed later. The top of this frame side further comprises a fixture (129) for receiving a roof top shroud.
Making reference to FIG. 4, which is the cross section of an assembled roof ridge apparatus, it can be seen that the exterior arch flanges (31, 32) and the interior arch flanges (81, 82) are adapted to rotate about one another within a reasonable range of rotation. The above-described angled base members (30, 50) facilitate this relationship by allowing greater angles through which the rotation may occur.
Making further reference to FIG. 4, it can be seen that locking means could, need not, be applied to the cooperating pairs of flanges (31, 81), or (32, 82). Such locking means could comprise a bolt (162) which could be passed through a hole (163) drilled in an outer flange (31) and a corresponding hole (164) drilled in an inner flange (81). Such locking means can be seen to be possible for either flange pair, but the invention may also be practiced without such locking means. FIG. 4 further shows a shroud (140) comprising two ends joined at an apex and attached to roof top frame members (119,129).
It may now be seen that the cooperating roof ridge frame members rotate about one another so as to accommodate a wide range of pitches for the roof. Of course, it should also be seen that these maximum and minimum pitch angles could be selected to fall within the range of pitches from 3:12 to 12:12, which are generally the minimum and maximum acceptable pitches used with standard roof construction. FIGS. 5A and 5B depict two roofs of varying pitch, but which comprise the same roof member components, particularly referring to the respective roof ridge assembly components and roof panels.
While the apparatus herein has been taught for use with a structural panel of the type of Hesser, it should be noted that such could be used with a variety of structural components, including solid-core structural panels, structural beams (such as four by four wood members commonly used for major frame portions of wooden structures), composite panels; and a variety of others. These frame members have particularly been adapted for use with the Hesser-type panels because a need existed to provide more secure and versatile framing of structural panels which included metal skins and foam interiors. The panels taught herein have thermal expansions which generally are adaptable to fit within a foam material. It should also be noted that for thinner structural panel-type components a thermal break may not be needed. In such a case an offset could be provided simply to accommodate a fastener or the offset could be disposed of altogether.
Thermal breaks should not be considered a necessary part of the invention as taught herein, but have been included the descriptions and drawings in order to demonstrate that the principles of the present invention can work with frame members which may require a thermal break because of their size or other parameters.
Generally speaking, these frames may be adapted to accept panel thicknesses ranging from about two inches to ten inches. When manufactured of aluminum through the extrusion process, they may be manufactured from aluminum of high-strength alloys commonly known as 6005, 6061, or 6063.
The drawings and descriptions further have depicted some rather specific geometrical shapes for the adaptations which receive the window frame, electric conduit shroud, or other features. It can readily be seen that these specific geometrical shapes are not critical to the invention, but what is critical to the invention is that some receiving channel or area be provided to receive the desired structural component, whether it be a conduit or an edge for framing a door or a window.
While the following description will seek to improve understanding of the invention by describing the various components and elements, it should be considered that certain apparatus may be sufficiently and adequately explained by the accompanying drawings, which are fully incorporated herein, and not require further description. All such apparatus should be considered as part of the specification of the invention for all purposes.
It should be noted that those configurations of the present invention which provide for fasteners to be passed through both sides of a frame and an enclosed structural panel utilize the practice of through-bolting. Such improves the ability of the frame to handle both positive and negative wind loads.
Modification and variation can be made to the disclosed embodiments without departing from the subject and spirit of the invention as defined in the following claims. Such modifications and variations, as included within the scope of these claims, are meant to be considered part of the invention as described. | The invention comprises a ridge beam apparatus which is adjustable to receive roof halves in a variety of roof pitches. Such adjustability results from inner and outer sleeves which may rotate about each other through a reasonable range of pitches. The apparatus is suitable for manufacture through the extrusion process. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. § 119, of German patent application DE 10 2007 035 350.4, filed Jul. 27, 2007; the prior application is herewith incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a feed line for a hydraulic system, in particular of a motor vehicle, such as, for example, a power steering system. The invention also pertains to a hydraulic system provided with such a feed line, in particular a hydraulic system for a motor vehicle.
[0003] It is known that, under unfavorable conditions, in hydraulic systems the hydrostatic pressure of the hydraulic medium may locally undershoot the vapor pressure of the hydraulic medium at the prevailing temperature, thus often leading to cavitation phenomena or at least to disturbing noises. In specific driving situations, for example when the steering wheel is quickly shifted to the steering stops during parking, the risk of the occurrence of cavitation is increased, because the pressure in the hydraulic steering system of the vehicle abruptly changes locally on account of the stress on the vehicle wheels which is caused by the forces.
SUMMARY OF THE INVENTION
[0004] It is accordingly an object of the invention to provide a hydraulic feed line and a corresponding hydraulic system which overcome the above-mentioned disadvantages of the heretofore-known devices and methods of this general type and which safely prevent cavitation from occurring.
[0005] With the foregoing and other objects in view there is provided, in accordance with the invention, a feed line for a hydraulic system, in particular in a motor vehicle. The hydraulic feed line comprises:
[0006] a dimensionally variable body forming the feed line, at least over a part of a longitudinal extent thereof, the dimensionally variable body having an elastically deformable body wall, at least in regions thereof;
[0007] wherein, when hydraulic medium flow passes through the dimensionally variable body, a cross section of the dimensionally variable body is varied as a function of a pressure of the hydraulic medium.
[0008] In other words, the objects of the invention are achieved in that the feed line is formed, at least over part of its length, by a dimensionally variable body, the body wall of which is elastically deformable, at least in regions. When the hydraulic medium passes through the dimensionally variable body, the cross section of the dimensionally variable body can be varied as a function of the pressure of the hydraulic medium.
[0009] The dimensionally variable body may basically be configured as desired, and may be configured, for example, as a flexible, elastically deformable hose body.
[0010] In one embodiment of the invention, the dimensionally variable body is surrounded by an outer body.
[0011] In a preferred embodiment of the invention, the outer body may basically be formed as desired, for example as an outer hose.
[0012] According to a refinement of the invention, the hose body is produced from a comparatively easily expandable material, while the outer body is produced from an only slightly expandable or non-expandable material. The outer body can consequently offer counter-forces to the pressure forces exerted on the inside of the outer body by the expandable hose body and can absorb higher pressure forces, as compared with the hose body.
[0013] According to a refinement of the invention, in the position of rest, that is to say without the action of pressure by the hydraulic medium (i.e., substantial pressure equilibrium between the exterior pressure and the pressure of the hydraulic medium), the hose body has, at least over part of its longitudinal extent, an initial cross section of flat shape and/or of approximately oval shape. The flat or oval shape approaches a circular shape during the expansion of the hose body as a result of the increasing action of pressure by the hydraulic medium flowing through the hose body. The term “flat” means in this text that the cross section has an extent appreciably lower (for example, by the factor two) in one direction of space running perpendicularly with respect to the axial direction of the hose body than in the other direction of space running perpendicularly with respect to the axial direction of the hose body.
[0014] Advantageously, the hose body may have, at least over part of its length, a substantially wavy or wave-shaped cross section, that is an axial corrugation. In another embodiment of the invention, the hose body has, at least over part of its longitudinal extent, an substantially star-shaped cross section.
[0015] Basically any other suitable shapes may, of course, also be considered for the cross-sectional shape of the hose body.
[0016] For example, the hose body is produced from a material which comprises rubber. If the hose body is of multilayer form, at least one layer of the hose body is produced from a material which comprises rubber.
[0017] For example, the outer hose is produced from a material which comprises an elastomer. If the outer hose is of multilayer form, at least one layer of the outer hose is produced from a material which comprises an elastomer. For example, the elastomer referred to comprises chlorosulfonated polyethylene (CSM).
[0018] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0019] Although the invention is illustrated and described herein as embodied in feed line for a hydraulic system and hydraulic system, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0020] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
[0021] FIG. 1 is a diagrammatic longitudinal section through a portion of a feed line according to the invention;
[0022] FIG. 2 is a diagrammatic cross section taken through the hose body of the structure of FIG. 1 in the position of rest;
[0023] FIG. 3 is a similar view of the hose body of FIG. 2 in the pressure-loaded, expanded state; and
[0024] FIG. 4 is a cross section through a hose body of star-shaped cross section surrounded by an outer hose.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, the diagrammatic illustration shows a section along the longitudinal direction of a feed line 1 according to the invention. The feed line 1 is an integral part of a hydraulic system with a hydraulic volume as an accumulator. A hose body 2 of a first exemplary embodiment (designated below briefly as a “first hose body”) is integrated, pressure-tight, into the feed line 1 . In the position of rest, the first hose body 2 possesses an oval cross-sectional shape. The first hose body 2 is formed from a flexible, elastically deformable material, extends between a first rigid feed line tube 3 (illustrated only partially) and a second rigid feed line tube 4 (likewise illustrated only partially). It is fluidically connected between the two feed line tubes 3 , 4 . The feed line tubes 3 , 4 have in each case a circular cross section.
[0026] The hose body is surrounded by an outer hose 5 of circular cross section. The gap formed between the first hose body and the outer hose is filled with air.
[0027] The two feed line tubes 3 , 4 are provided, at their ends that are disposed inside the outer hose 5 and facing one another, with a first connection part 30 and with a second connection part 40 , respectively. The two connection parts 30 , 40 are in each case of hollow-cylindrical design. The first hose body 2 , with its first longitudinal end 20 , sealingly surrounds the outer circumference of the first connection part 30 . Correspondingly, the first hose body 2 , with its second longitudinal end 21 , sealingly surrounds the outer circumference of the second connection part 40 .
[0028] The first hose body 2 is deformed under the influence of the hydrostatic pressure of the hydraulic medium flowing through the first hose body 2 . In this case, with an increasing pressure, the first hose body 2 expands in the radial direction from an initial shape, which the first hose body 2 assumes in the position of repose, and thus experiences an increase in volume. When the pressure in the hydraulic system falls again, the first hose body 2 contracts and endeavors to resume its original initial shape. During the contraction of the first hose body 2 , hydraulic medium is discharged out of the first hose body 2 into the feed line tubes 3 , 4 , with the result that the undershooting of the vapor pressure in the feed line tubes 3 , 4 is counteracted. To some extent, the first hose body 2 forms an accumulator for a compensating quantity of hydraulic medium for the compensation of pressure fluctuations in the hydraulic system.
[0029] A flexible, elastically deformable hose body 2 and a functionally appropriate volume adaptation of the hose body 2 may also be provided in that a twist angle deviating from what is known as the neutral angle is selected for the hose body 2 . The neutral angle amounts to approximately 54.7° for the twist angle. The neutral angle is characterized by a force equilibrium between axial and tangential forces. The twist angle designates the angle between the longitudinal axis of the hose body 2 and the individual fibers of the braiding. A functionally appropriate volume flexibility of the hose body 2 arises in the case of a twist angle of between preferably approximately 38° and 48°. The twist angle may amount, for example, to approximately 43°.
[0030] The outer hose 5 disposed coaxially with the two feed line tubes 3 , 4 and with the hose body 2 has a higher pressure loadability and a higher rigidity, as compared with the first hose body 2 . The outer hose 5 can consequently offer counterforces to the radial pressure forces exerted by the expanding hose body on the cylindrical inner wall of the outer body and can absorb higher pressure forces, as compared with the hose body 2 .
[0031] FIG. 2 shows a cross section of the first hose body 2 in the position of rest. In the position of rest, the cross section of the first hose body 2 has an oval shape which, as compared with a round cross-sectional shape in the position of rest, gives the hose body 2 particularly more advantageous elastic properties which are effected, for example, in high flexibility during the contraction of the hose body.
[0032] FIG. 3 shows a cross section of the first hose body 2 in the expanded state. The cross section then has an approximately circular shape.
[0033] FIG. 4 shows a cross section through a second hose body 2 ′ and an outer hose 5 surrounding the latter. The second hose body 2 ′ has a wavy (undulating, corrugated) cross section similar to an accordion bellows shape which gives the second hose body 2 ′ particularly advantageous elastic properties, such as, for example, the ability, even under comparatively low pressures, to react with a relatively high expansion. The longitudinal elevations 6 , in each case arranged, offset to one another, circularly at the same angle, extend in the radial direction outward from the core part 7 and in the axial direction, parallel to one another, over the entire longitudinal extent of the second hose body 2 ′. The core part 7 , having an annular cross section, is delimited inwardly by a cylindrical inner face. The second hose body 2 ′ may also have a star-shaped cross section.
[0034] The design variances of the hose body 2 or 2 ′ which are shown in FIGS. 1 to 4 are suitable both for use in conjunction with an outer hose, that is to say in a so-called hose-in-hose variant, and for use as a shaped hose without a corresponding further hose, for example outer hose 5 . | The feed line for a hydraulic system, in particular of a motor vehicle, is formed, at least over part of its longitudinal extent, by a dimensionally variable body. The wall of the dimensionally variable body is elastically deformable, at least in regions, so that, when the flow passes through the dimensionally variable body, the cross section of the dimensionally variable body can be varied as a function of the pressure of the hydraulic medium. | 5 |
SCOPE OF THE INVENTION
[0001] The present invention relates to a firearm with various defence and safety mechanisms, which combines a high level of defence and effective protection by virtue of its unique characteristics with the advantage of providing greater safety, in order to go some way towards reducing the high firearms accident rate among adults and children.
PRIOR ART
[0002] Some safety devices which can be adapted to various models of firearms are already known, as well as certain firearms that are built with a particular basic safety system in order to prevent them from being used incorrectly or inadvertently, thereby causing an accident.
[0003] Some safety devices satisfactorily fulfill their function, but they have certain inconveniences, namely the fact that once they are installed the firearm becomes useless as a means of defence, unless the key remains with it, which totally defeats the intended purpose. Firearms, which are designed to incorporate an additional safety system, for example a button, lever, catch or even the removal of the magazine in order to prevent accidental firing, have proven to be very ineffective as a means of preventing accidents.
SUMMARY OF THE INVENTION
[0004] The present invention does not propose to remove the risk of accidents caused by firearms, because this would be an impossible task, but rather to help substantially reduce the risk of accident, in order to reverse the growing trend of the increasingly high numbers of accidents recorded. For this purpose, a non-lethal personal defence system is presented, which has aggressive lines and design and at the same time is aesthetically pleasing, hardwearing, childproof and accident-proof.
[0005] This new firearm gives rise to a new classification in light weapons, the Rotating Percussion Handguns, to which this patent refers. It presents a whole range of attributes and characteristics, in particular the absence of a trigger (the most sensitive element common to all light weapons). The simple and obvious way in which a trigger is fired makes it the main factor responsible for the high rate of accidents among children and adults, as it can be inadvertently activated by anyone's hand, or rather finger, causing any conventional light calibre weapon to fire.
[0006] Rotating Percussion Handguns increase by more than twofold the level of effective protection against accidents by virtue of the fact that the trigger found in any light weapon is removed. In fact, it is not possible to activate this type of firearm using only one finger and it cannot even be fired with only one hand.
[0007] In the present invention, its original and unconventional method of firing means that in principle it will be difficult for someone who is not familiar with the system to use it. It is activated by rotating the handle and consequently the internal percussion mechanism in relation to the main static body, which requires the use of two hands, one to rotate the handle in relation to the set of barrels and the other to hold the barrels in place in order to prevent them from rotating with the handle. This means that it is impossible to operate the firearm with only one hand, which contributes substantially to preventing accidents.
[0008] Another feature of the safety system is that the nominal diameter of the handle that activates the firing mechanism is slightly enlarged, so that the normal-sized hand of a four or five-year old child would not be able to grip the diameter of the handle and operate the firing mechanism, thereby causing an accident. At the same time, the strength that is required to activate the percussion system can be adjusted and calculated so that a small child would not be able activate it.
[0009] The mechanical safety device that locks the firearm and prevents it from being fired is in itself another fundamental feature of the present invention. In all similar low-calibre weapons the “on/off” safety systems use catch, lever or button mechanisms which, when they are unlocked, leave the firing mechanism cocked and ready to fire as soon as the trigger is touched with a single movement, thus making it extremely easy for the gun to be fired accidentally.
[0010] In the case of the present invention, in spite of its simplicity, a system is designed wherein it is necessary to rotate the safety wheel several times around the locking pin in order to move it vertically upwards or downwards, this being the only way of unlocking or locking the firing mechanism. Thus, various rotating movements of the safety wheel are required in order for the firing mechanism to be activated and not simply a single movement, as is normally the case with light weapons. The system can also be locked by manually tightening it, which prevents a child from unlocking it.
[0011] Another characteristic of the firearm of the present invention is that it does not have the unstable hammer (though this in itself is not a novel feature), which also causes so many accidents when firearms are banged against an obstacle accidentally or during play or are carelessly dropped, thus causing them to detonate.
[0012] We have opted for a cartridge as the ideal ammunition for this purpose, in order to provide the user with a greater level of protection, since a weapon that fires a large number of projectiles covering a certain area is more efficient than one that fires a single projectile at the same area. This feature, which is intrinsic to the use of a cartridge as the chosen ammunition, will increase the likelihood of the target being hit by at least some of the projectiles even if the weapon is fired from a greater distance. The ammunition chosen is also the lowest calibre cartridge available on the market, since it has a very low kinetic energy load due to the small size of the lead projectiles and the fact that the propelling load is low, which will safeguard the physical integrity of a possible assailant, by wounding but not killing, unless the gun is fired at point-blank range and a vital organ is hit. This will avoid complicated legal problems and remorse felt for taking someone's life, even if it were a case of legitimate self-defence.
[0013] Another important feature is that this gun can be fired inside a pressurised aircraft in transit in any atmospheric plane, as its projectile load does not have enough kinetic energy to break a window or even to penetrate the considerable thickness of the various different layers of fuselage material and therefore depressurise the interior, meaning that this firearm can be used as an excellent weapon of defence in the fight against air terrorism in commercial aircraft in the cockpit and control cabin, which are areas that are restricted to the crew.
[0014] However, in other cases, it can also be adapted by making the necessary alterations, in order to fire ammunition of any type and calibre.
[0015] The new type of laser sight used in this handgun, is also object of this patent, and was projected to be used with weapons that fire shot shell type ammunition, and is designated as Progressive Impact Area Indicator—P.I.A.I., it makes possible to accurately choose the area of the target to be hit, by enlarging or reducing the area of dispersion indicator, proportionally to the distance to the target, giving the user a precise notion of the aiming area, therefore avoiding unnecessary errors while at the same time the laser area indicator functions as a persuasive warning element.
[0016] Another important feature of the present invention is the simple design of the parts and mechanisms which constitute the Rotating Percussion Handgun, thus making it a reliable and relatively economical weapon with low production costs and minimum maintenance, consisting of a fairly small set of parts that are easy to produce on an industrial scale.
[0017] The various essential parts mentioned in this description and the drawings can be used individually or together in any combination with other elements having different characteristics and uses. It may therefore be understood that this invention is not restricted to the elements and characteristics described and illustrated herein and that other variations can be included in the spirit of the invention. This applies to the firing mechanism incorporated into the handle, the ejection mechanism, the rotating safety locking and tightening system, the laser sight which functions accordingly to distance, the R.D.W.S. middle weapon bayonet system, the detachable handle, the variable number of barrels and the possibility of detaching them.
[0000] Use and Performance
[0018] Childproof and accident-proof non-lethal, short-range, small-calibre household defence system, designed to provide users with greater effective protection, while at the same time offering a high level of safety when the firearm is handled, thus giving it four intended uses:
[0019] as a firearm able to fire four consecutive cartridges, comprising eight rounds of ammunition, four in the chambers and four more in a special container inside the handle;
[0020] as a self-defence baton in possible body combat, by virtue of its ergonomic format as well as its actual weight;
[0021] as an optional extra means of defence, characterised by the use of a secondary defence system during the critical period of time when the ammunition runs out and the firearm is open and is being reloaded, this system being known as the “Reload Defence Weapon System” (R.D.W.S.), in the form of a middle weapon bayonet type built into and supported by the firing handle;
[0022] by folding the handle in relation to the barrels on its hinge and opening it to a certain angle, will separate the firearm into two parts, i.e. the set of barrels which can be used as a smaller baton or throwing weapon and the handle with a built-in bayonet constituting a dagger, which serves as a very useful last resort weapon, in the event of a possible direct confrontation with one or more attackers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention is described and explained hereunder with reference to the attached drawings, which represent a non-restricted embodiment. In the drawings:
[0024] FIG. 1 shows general views representing the whole of the firearm, with the grip closed, depicting a plan view (a), a side view (b), a view from below (c), a rear view (d) and a front view (e).
[0025] FIG. 2 shows a view from above representing the axis of the longitudinal cross-section C 1 -C 1 with the grip closed; FIG. 2 a represents the longitudinal central cross-section of FIG. 2 .
[0026] FIG. 3 shows an aerial view of the detailed view C 2 , which represents the percussion and firing mechanism with the most important parts duly indicated and numbered.
[0027] FIG. 4 shows an exploded perspective view of all the component parts of the childproof and accident-proof Rotating Percussion Handgun, which are duly numbered and individually arranged.
[0028] FIG. 5 shows an exploded isometric perspective view of the various parts which constitute the present percussion and firing mechanism.
[0029] FIG. 6 shows isometric perspective views representing the safety locking system, in both the assembled 6 ( b ) and exploded 6 ( a ) versions, with the various elements numbered and individually arranged and also showing the optional bayonet system.
[0030] FIG. 7 shows isometric perspective views representing the semi-automatic cartridge ejection system, in both the assembled 7 ( a ) and exploded 7 ( b ) versions, all the parts being numbered, and arranged according to their layout.
[0031] FIG. 8 shows various views representing the part ( 8 )—ramps disc-depicted in elevation (a), in plan view (b), in a view from below (c), and in an auxiliary perspective view (d), and it also shows an auxiliary view of the set of guiding ramps ( 62 ), pre-firing points ( 63 ) and firing or resting points ( 61 ).
[0032] FIG. 9 shows various views representing the part ( 11 )—striker guiding disc-depicted in elevation (a), in plan view (b), in a view from below (c), and in auxiliary perspective views from above (d) and from below (e).
[0033] FIG. 10 shows a perspective view of the firearm when opened and in the loaded position, with the optional R.D.W.S. system; FIG. 10 a shows a perspective view of the handle separated from the barrels with the firearm in the unloaded position, also depicting the bayonet element.
[0034] FIG. 11 show the demonstration of the integrated Progressive Impact Area Indicator laser sight.
DETAILED DESCRIPTION OF THE INVENTION
[0035] As can be seen from the Figures, the firearm is generically represented in FIGS. 1 and 2 . FIG. 3 , which illustrates the mechanical percussion and firing system (c) situated inside the rotating handle (B), shows in the resting position the striker ( 20 ) inserted by its ends and balanced between the return spring ( 25 ) and the compression spring ( 24 ) by means of the kinetically-supported cylindrical threaded adjustment block ( 21 ) for adjusting the impact force of the striker ( 20 ), which at the same time adjusts the position of the striker in relation to the plane (P 6 ) of the disc with projections ( 8 ) ( FIG. 8 d ).
[0036] The ramps disc ( 8 ) displays a set of guiding ramps ( 82 ) ( FIG. 8 e ) which, when the whole constituted by the firing handle ( FIG. 5 ) rotates, rest(s) inside the annular recess ( 81 ) ( FIG. 9 e ).
[0037] The return spring ( 25 ) is supported at one end inside a housing ( 52 ) in the plane (P 1 ) ( FIG. 9 e ) of the guiding disc ( 11 ) of the striker ( FIG. 9 d ), with the other end resting on the plane (P 3 ) ( FIG. 5 ) of the adjustment unit ( 21 ). The compression spring ( 24 ) rests on the plane (P 4 ) of the adjustment unit ( 21 ), and is compressed in relation to the plane (P 5 ) of the percussion assembly support ring ( 17 ) which supports the percussion assembly. The ring ( 17 ) functions as a housing for the rubber block ( 23 ) which damps the kinetic energy of the recoil resulting from the detonating gases, which is attached to the head of the screw ( 18 ) under a certain amount of pressure, being limited on the outside of its diameter by the inside of the resistant tube ( 26 ) of the handle.
[0038] The firing set (C) consists of the striker ( 20 ), adjustment block ( 21 ), return spring ( 25 ), compression spring ( 24 ), and it is surrounded by the transporting tube ( 22 ), which in turn is attached by means of an external thread to the threaded housing ( 52 ) ( FIG. 9 e ) in the striker guiding disc ( 11 ), which tube must have along its length a minimum clearance between the end ( 54 ) of the tube ( 22 ) and the plane (P 5 ) of the percussion assembly support ring ( 17 ), in order to allow movement with a minimum amount of friction between the various parts that make up the mechanism.
[0039] The screw ( 18 ) acts as a central axis of the firing mechanism, around which the set comprising the striker ( 20 ), the support and adjustment block ( 21 ), the return spring ( 25 ), the compression spring ( 24 ), the transporting tube ( 22 ) and the striker guiding disc ( 11 ), rotates according to a translatory movement restricted by the planes of the ramps disc ( 8 ) and of the percussion assembly support ring ( 17 ), both of which are static.
[0040] The screw ( 18 ) also has its end ( 55 ) threaded inside the central threaded hole ( 56 ) ( FIG. 8 d ) of the ramps disc ( 8 ), being surrounded by the supporting tube ( 19 ) the purpose of which is to solidly attach the percussion assembly support ring ( 17 ), being the end of the tube ( 19 ) resting against the plane (P 6 ) ( FIG. 8 d ) of the disc with projections ( 8 ), tightly and freely passing through the cylindrical hole ( 58 ) ( FIG. 9 e ) of the striker guiding disc ( 11 ).
[0041] The whole set of parts described above is inserted longitudinally inside the housing tube ( 26 ), the end ( 59 ) of which is solidly attached to the circular surface ( 60 ) of the striker guiding disc ( 11 ) by means of an appropriate screw or thread, the outer handle ( 50 ) being attached thereto by means of two screws ( 51 ), which are concentric and diametrically opposite, thus allowing the whole percussion assembly to rotate and thus cause the firing of a shot.
[0042] This rotating movement will release from its resting position the internal mechanism of the handle, which, when rotating movement is transmitted to it around its longitudinal axis, will force the firing set ( FIG. 5 ) consisting of the striker ( 20 ), adjustment block ( 21 ), return spring ( 25 ) and compression spring ( 24 ) inserted inside the transporting tube ( 22 ), coupled to the striker guiding disc ( 11 ) situated at a certain distance from the central axis ( 52 ), to execute a translatory movement around the longitudinal axis of the handle.
[0043] In this way, the striker ( 20 ) is forced, from its resting point ( 61 ) ( FIG. 8 d ), to commence a firing cycle, starting by sliding along one of the various guiding ramps ( 62 ) which will transmit through the compression spring ( 24 )—resting on the percussion assembly support ring ( 17 ) fixed to the head of the central screw ( 18 ) at a distance corresponding to the length of the tube ( 19 ) which houses the screw that supports the whole firing system—sufficient kinetic energy to the body of the striker ( 20 ), so that when the pre-firing point ( 63 ) is reached and the striker is released from the tension exerted in the compression spring ( 24 ), it will move forward with enough force to detonate the shell.
[0044] The firing cycle is completed when the striker returns to the resting point ( 61 ) coinciding with the starting point for another cycle.
[0045] The rotating safety locking and tightening system ( FIG. 6 ) is a mechanism designed to prevent the rotating movement of the rotating firing handle around its own axis, consequently activating the percussion system. Various rotating movements of the safety wheel ( 16 ) are required in order to lock or unlock the active safety system (D) using the force exerted by the tightening of the safety wheel ( 16 ). This wheel has a central threaded hole through which the rotationally static threaded safety pin ( 13 ) passes, limited to movement according to its vertical axis, moving up or down as the wheel ( 16 ), limited by its top and bottom planes, is manually rotated around its axis in one direction or in the opposite direction.
[0046] The wheel ( 16 ) and the pin ( 13 ) are both housed inside the part ( 15 ) that supports the system ( FIG. 6 a ), which is attached by means of a screw ( 44 ) and an indentation ( 64 ) in the safety locking assembly ( 12 ), and at the same time is the vertical guide of the safety pin ( 13 ).
[0047] When rotating movement is transmitted to the system, the pin ( 13 ) totally recoils to the level of the top plane (P 7 ) ( FIG. 6 a ) of its guiding part ( 15 ), corresponding to the activated safety position. The other end ( 66 ) locks the mechanism of the rotating firing handle when it is inserted inside one of four holes ( 67 ) ( FIG. 6 ) in the striker guiding disc ( 11 ) equal in number to the number of barrels.
[0048] When the safety wheel ( 16 ) is rotated in the opposite direction, the pin ( 13 ) rises, unlocking the locking system and releasing the rotating firing handle, while at the same time the top end ( 68 ) of the pin becomes visible in the form of a projection in relation to the top plane of the guiding part ( 15 ).
[0049] The opening and closing ( FIG. 6 ) of the firearm is achieved by means of a similar system, using the closing wheel ( 14 ) assembled inside the safety locking assembly ( 12 ), said wheel being restricted in its top and bottom planes and only having the rotating movement allowed by the safety pin ( 13 ) and by the wheel slot ( 83 ) of the part ( 12 ).
[0050] The firearm includes several barrels ( 3 ) ( FIG. 4 ), four in the case of the embodiment presented, though this number may vary according to the alterations made. The barrels are assembled longitudinally and are arranged parallel to each other, their ends ( 69 ) being solidly threaded or fitted into an appropriate housing ( 70 ) ( FIG. 7 ) inside the disc ( 2 ) which supports the barrels ( FIG. 4 ). In turn, this disc is joined to the outer frame ( 1 ) by means of a thread, fitting together or screws ( 39 ), the barrels being fixed at their other end ( 71 ) by the barrel support disc ( 4 ) which attaches and supports the set (E) ( FIG. 2 a ) of barrels.
[0051] The barrels, when they are inserted into the holes ( 72 ) in the disc ( 4 ), bump against this disc at the point where they project outwards ( 73 ). The disc ( 4 ) has a central hole through which freely passes with a minimum clearance the screw ( 5 ) that fixes to the plane (P 8 ) ( FIG. 8 ) the set of barrels ( 3 ), the outer frame ( 1 ) and the tube ( 45 ) that supports the ejection system to the plane (P 9 ) ( FIG. 7 ) of the supporting disc ( 2 ) in an appropriate threaded housing which does not extend beyond the limits of the plane (P 10 ).
[0052] The whole formed by the firing barrels ( 3 ) and by the outer frame ( 1 ) can be separated ( FIG. 10 ) by means of its hinge ( 6 - 9 ) ( FIGS. 4 and 10 ). This hinge has limited rotating movement within the whole, constituted by the rotating handle and the remaining elements, which can be removed by reducing the angle between them and the longitudinal axis of the handle. It has a recess ( 74 ) ( FIGS. 6 and 10 ) in line with the transverse axis of the handle, causing the system to separate into two parts. One of these parts can be optionally fitted with an internal or external bayonet ( 10 ) ( FIG. 6 ), coupled to the middle weapon on top of the ramps disc ( 8 ).
[0053] The ejection system ( FIG. 7 ) comprises an ammunition holder disc ( 40 ) of a considerable thickness mounted on plane (P 11 ) ( FIG. 7 b ) by means of four longitudinal parallel threaded shafts ( 41 ), which are inserted at one end into the guiding holes ( 75 ) existing for this purpose in the ammunition holder disc ( 40 ) and at the other end of the part ( 2 ).
[0054] The shafts ( 41 ) are coupled and attached by the set of screws ( 48 ) to the part ( 46 ) which supports the movement of the ejection system. The part ( 46 ) is in turn mounted on a longitudinal elastic system consisting of a spring ( 47 ) ( FIGS. 4 and 7 ) supported at the appropriate point by the cylindrical projection ( 76 ) of the tube ( 45 ) ( FIG. 7 ).
[0055] This whole set of parts, with the exception of the ammunition holder disc ( 40 ) is housed inside the outer frame ( 1 ).
[0056] The foldaway grip (G, 31 ) ( FIGS. 2 and 4 ), which has an ergonomic design, is fitted around the outer frame ( 1 ) when it is in the closed position. This grip can rotate and its rotating movement occurs around the axis ( 77 ) defined by the two lateral supports ( 77 ) ( FIG. 4 ), which are screwed or fitted into two laterally opposite holes on the outer frame ( 1 ).
[0057] The grip, when it is in the open position, has four functions: as a grip during the act of firing, as an auxiliary sight (F) ( FIG. 2 ) for firing, as a vertical stabilising tripod and as a system for activating the laser. The laser system ( FIG. 11 ) is activated by pressing the 'spring button ( 35 ) ( FIG. 4 ), a service switch for the internal laser sight system which functions progressively according to distance, the grip ( 31 ) reaching at this point its maximum open position angle in relation to its own longitudinal axis. Under these conditions, the grip presses the switch button ( 35 ) ( FIG. 4 ) which is situated at the bottom of the tube ( 1 ), at a precise point, thereby activating the laser system.
[0058] The set of barrels ( 3 ) can be separated from the handle ( FIG. 10 a ) by reducing the angle of the set of barrels in relation to the longitudinal axis of the handle by means of the hinge system. The parts comprising this hinge system are firmly coupled by means of welding and/or screwing to the set of barrels and to the ramps disc ( 8 ), on side A and side B respectively ( FIG. 10 ). One of the sides has a recess ( 74 ) ( FIG. 6 a ) and the other has a transverse shaft ( 79 ) ( FIG. 10 a ), which are released due to the rotating action and thus allow the whole structure to separate.
[0059] Inside the handle, as well as the percussion mechanism, there is a container ( 80 ) ( FIG. 3 ) for carrying extra ammunition which is closed by means of a cover ( 30 ) ( FIG. 5 ).
[0060] Reference is also made to the existence of a sword-like hand protector attached to the handle, being either fixed or having rotational movement (not shown in the Figures), of a cord to be attached to the user's wrist coming from inside the handle through the central hole in the cover ( 30 ) and of a sight marker ( 7 ) ( FIG. 4 ) in the form of a hexagonal screw with a conical tip, threaded to the top exit end of the outer frame ( 1 ).
[0061] It is considered that no further details need to be added to this description in order for any person skilled in the art to understand the present invention and the advantages that it offers. The materials, shapes and dimensions and the layout of the components can be altered, provided that this does not modify the essence of the present embodiment. The contents of this specification should always be considered in their broadest and not restricted terms. | The present invention relates to a small-calibre defence system, characterised by the use of an unconventional process, with the following main characteristics: the absence of a trigger and hammer, which are replaced by firing mechanisms in the form of a handle (B) inside which the percussion system (C) is activated by rotating it in relation to the barrels (E), thus forcing the striker to move up a ramp thereby compressing the tensor system, after which it is released and the firearm is detonated, this merely being an example of what the invention covers; the novelty of its design, which has been devised in order to make it difficult or impossible for a child to activate it; it is assembled longitudinally in multiple barrels (E), with a manually tightened rotating safety lock (D), contrary to the buttons and catches of similar firearms; it has a integrated Progressive Impact Area Indicator laser sight (F) which functions progressively according to distance; and it has a foldaway grip (G). | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of European Patent Office application No. 08011428.3 EP filed Jun. 24, 2008, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The present invention relates to a method for cooling a component of a turbine.
BACKGROUND OF INVENTION
In order to achieve high component efficiencies for a turbine and ultimately a gas turbine cycle itself small tip clearances are required. This is even more important for small gas turbines where the relative clearance is increased due to manufacturing limitations and tolerances. One way of controlling the tip clearance in the turbine is to actively cool the casing. For example, the thermal expansion of the casing is matched with the rotor to minimize the clearance without taking the risk of interference during transient and hot restarts.
This type of cooling requires cooling air being bled from the compressor. In small gas turbines having a lower overall pressure ratio and fewer bleed points in the compressor the available air supply is often of a much higher pressure and temperature than needed to perform the cooling task on the turbine casing. This may have at least two effects, one being that due to the higher temperature of the cooling air a minimum clearance can not be achieved at all or only by using excessive mass flows, the other being that after the cooling task the air is released in the flue gases still having a surplus pressure without producing any work which generates additional performance losses.
The first category of solutions is the use of a higher pressure and temperature of the cooling air than required. Another alternative and improvement of the first category is to pre-cool the air before it is applied to the turbine casing. This can be done in a heat exchanger, for example an air-air heat exchanger, an air-water heat exchanger or an air-fuel heat exchanger, or by injecting evaporating water into the air stream. The pre- cooling requires more components and/or more systems, adds costs and potentially decreases the reliability and availability.
A different approach is to use a low expansion material in the turbine casing which allows the turbine rotor to perform the vast portion of the relative movement between the blade tip and the casing minimizing the clearance during operation. This solution does not require any extra cooling air, is able to deal with transient movements but is slow and requires expensive materials in large components, which means that it adds costs.
In U.S. Pat. No. 5,611,197 a closed circuit air cooled turbine where air is bled from the compressor and is used to cool the turbine casing is described. After cooling the turbine casing the air is passed through a heat exchanger and is then injected in the compressor.
In EP 1 013 937 B1 a compressor bleed point at the tip region of the compressor blade row is disclosed.
In U.S. Pat. No. 6,422,807 B1 a closed circuit cooling of a turbine casing where the cooling medium is circulated through internal cavities and where the accumulated heat is removed in heat exchangers is described.
In U.S. Pat. No. 4,329,114 an active clearance control system for a compressor based on convective flow is disclosed.
In U.S. Pat. No. 6,412,270 B1 a method of mixing two bleed streams for a compressor using an ejector before using air for cooling or sealing purposes in a turbine is described.
In U.S. Pat. No. 4,711,084 the use of an ejector in a compressor low pressure air bleed conduit to increase the pressure is shown.
In U.S. Pat. No. 4,645,415 a cooling system where the cooling air is cooled by the flow through a secondary air path of a turbofan gas turbine is described.
SUMMARY OF INVENTION
It is a first objective of the present invention to provide an advantageous method for cooling a component of a turbine. It is a second objective of the present invention to provide an advantageous turbine.
The first objective is solved by a method for cooling a component of a turbine as claimed in the claims. The second objective is solved by a turbine as claimed in the claims. The depending claims define further developments of the invention.
In the inventive method for cooling a component of a turbine a fluid with a pressure below 1 bar is guided away from the component. The invention is based on the use of sub atmospheric pressure to create a sufficient pressure drop to achieve the heat transfer coefficients required for cooling the component. This increases the effectiveness which is due to the low temperature of the fluid used and the optimized pressure ratio for the task. The method is characterized in a low complexity which is due to the absence of a fluid cooler to reach a low supply temperature. It is also a system which is mainly self controlling.
The low pressure in the cooling circuit, i.e. below 1 bar, of the fluid corresponds to a low temperature of the fluid. In order to reduce the temperature of the component of the turbine it is necessary to remove a certain amount of heat, e.g. to maintain a certain heat flux through the component. The same heat flux can be achieved in different ways depending on how the cooling air temperature, the feed pressure, the pressure drop (velocity) and the mass flow are combined. The present invention is based on the use of a fluid with a low pressure and a corresponding low temperature in order not to penalize the overall turbine cycle. The mass flow is matched to the available, in this case generated, pressure drop and temperature to achieve the required heat flux.
Advantageously, the downstream pressure of the fluid in the cooling circuit may be between 0.5 bar and 0.9 bar, preferably between 0.7 bar and 0.8 bar.
The component of the turbine may be a turbine casing or a component of the stator of the turbine. In this case the reduced temperature of the casing or the stator will also reduce the tip clearance. The tip clearance is a function of the temperature difference between the rotor and the stator/casing.
Preferably, air is used as fluid. Moreover, the fluid can be taken from a compressor inlet duct or from an enclosure surrounding the turbine or from a space which comprises at least one part of a fuel system for a gas turbine. Preferably the fluid can be taken from a compressor inlet duct downstream of a filter. The filter avoids unnecessary deterioration of the flow path due to build up of deposits of particles present in the fluid, for example in the air. For example, air may be taken from the compressor inlet duct, downstream of the air filter, which may then be guided to the turbine casing using conduits.
Generally, the turbine can be a gas turbine. Furthermore, the component may be a turbine casing. The turbine casing may especially be in contact with at least one turbine guide vane. Moreover, the turbine casing can comprise a heat shield or a static shroud or it can be in contact with a heat shield or a static shroud.
Alternatively to a use of air from the compressor inlet duct, air may be taken directly from the enclosure surrounding the gas turbine. If this principle is used, a separate air filter placed at the inlet of the conduit may be needed to avoid unnecessary deterioration of the flow path due to build up of deposits of particles present in the air. In this case the air can be taken from the space which comprises parts of a fuel system for the gas turbine. Gas detectors can be used in the enclosures to prevent explosion from happening should there be a fuel leak.
Furthermore, the fluid can be ventilated, especially while it is guided to the component or to the inlet of the cooling system. This can be achieved by means of a ventilation flow inside the enclosure and/or by means of fans which can be arranged such that the entire volume is ventilated. Advantageously the fluid is ventilated with a frequency high enough to avoid rich pockets of fuel from being built up. Nevertheless particular attention should be paid when positioning the air inlet to the cooling system inside the enclosure. The inlet can be placed such that it is facing away from the fuel system and is facing the fresh air from the ventilation intake.
A further alternative is to feed the turbine stator cooling system from a separate, preferably filtered, feed through the enclosure wall.
Generally, after cooling the component the fluid may be guided to a cavity in a compressor casing which is in flow communication with a circumferential groove placed in the area of a first stage of the compressor. Advantageously, the pressure in the groove may be between 0.5 bar and 0.9 bar, preferably between 0.7 bar and 0.8 bar. The circumferential groove can be placed adjacent to a leading edge of a rotor blade or upstream of a leading edge of a rotor blade or at a front portion of a tip of a rotor blade.
Advantageously the fluid, for example the cooling air, can be guided through a sealed path in the turbine casing to perform the cooling. The principle used for the cooling may, for example, be convection or impingement. Should there be a need to enhance the cooling effect, e.g. increasing the pressure ratio over the cooling circuit, than an air ejector can be used where the driving fluid may be taken from the existing compressor bleed. Due to the anticipated high pressure level at the compressor bleed the use of a supersonic air ejector may be advantageous with regards to the compressor bleed air flow required.
The inventive turbine comprises a component, a conduit which is connected to the component such that a fluid can be guided away from the component, and a fluid discharge which is connected to the conduit. In the inventive turbine the fluid discharge is constructed such that it removes a fluid with a pressure below 1 bar. This means that a fluid with a sub atmospheric pressure is used to create a sufficient pressure drop to achieve the heat transfer coefficient required for cooling the component. The inventive method for cooling a component of a turbine can be performed by means of the inventive turbine. Generally, the inventive turbine has the same advantages as the inventive method.
Advantageously, the fluid discharge is constructed such that it removes a fluid with a pressure between 0.5 bar and 0.9 bar, preferably between 0.7 bar and 0.8 bar.
The fluid may be air. The turbine can be a gas turbine. Moreover, the component can be part of a stator of the turbine or at least part of a turbine casing.
The inventive turbine may further comprise a fluid supply. Preferably, the fluid supply and/or the conduit can comprise an inlet with a filter. This avoids unnecessary deterioration of the flow path due to build up of deposits of particles present in the fluid, for example in the air.
The fluid supply can be a compressor inlet duct. Furthermore, the fluid supply can be part of an enclosure surrounding the turbine or a space which comprises at least one part of a fuel system for a gas turbine. If the fluid supply is part of an enclosure surrounding the turbine, at least one gas detector can be placed in the enclosure. The gas detector prevents explosion from happening in case of a fuel leak.
Moreover, a fan and/or a ventilation element may be located inside the enclosure. Preferably the fan and/or the ventilation element may be constructed and located such that the entire volume of the fluid is ventilated with a frequency high enough to avoid rich pockets of fuel from being built up.
Furthermore, the enclosure may comprise a fluid supply with a filter. The filter avoids unnecessary deterioration of the flow path due to build up of deposits of particles present in the fluid, for example in the air.
Preferably the turbine can comprise a fuel system and a fluid supply with an inlet which is placed such that the inlet is facing away from the fuel system. The inlet can, for example, be placed such that it is facing the fresh air from a ventilation intake.
The turbine can comprise a compressor with a casing and a conduit may connect a cavity in the compressor casing with a circumferential groove for guiding the fluid away from the component. The circumferential groove can be placed in the area of a first stage of the compressor. Preferably the circumferential groove can be placed adjacent to a leading edge of a rotor blade or upstream of a leading edge of a rotor blade or at a front portion of a tip of a rotor blade.
Furthermore, the turbine may comprise an ejector. The ejector can be located between the compressor and the component. For example, the ejector can be a supersonic air ejector. By means of the ejector the cooling effect, e.g. the increase of the pressure ratio over the cooling circuit, can be enhanced.
Generally, the present invention offers several advantages, for example high effectiveness of the cooling, low complexity of the circuit and an improved overall turbine performance. The high effectiveness is due to the low temperature of the fluid, for example air, used and the optimized pressure ratio for the task.
The low complexity is due to the absence of a fluid cooler, for example an air cooler, to reach a low supply temperature. It is also a system which is mainly self controlling. The lowest pressure in the circuit, e.g. where the cooling air is discharged, is depending on the load of the turbine, for example of the gas turbine, or more specifically the compressor. The change in pressure with load will depend in part on whether the invention is applied to a constant speed single shaft gas turbine or a variable speed gas turbine.
One further advantage of the invention is that there is no risk of back flow at off design conditions, e.g. low loads, which requires conventional clearance control systems to change the air supply to a further downstream location in the compressor still having a positive drive pressure. A change of flow direction can otherwise, if the same air supply is connected to the bearings of the gas turbine, suck lubricant oil out of the bearings generating risks for fire and build up of carbon deposits in seals. If needed for circumventing pinch points (contact clearance) during hot restarts a valve may be used to shut off the air flow through the cooling circuit. When using an ejector as a pressure booster for the cooling air no extra moving parts including valves are required. If the cooling circuit is shut off the small flow of bleed air from the compressor will simply be discharged through the air intake for the mainstream flow in the ejector.
The overall performance for the gas turbine is improved due to the minimized tip clearance and no additional loss of mass flow and compressor work when not utilising the bled off air fully. The cooling air injected/sucked into the compressor has a higher temperature after cooling the component, for example the turbine casing, compared to the main flow in the compressor at the location where the air is discharged. Since the cooling air flow is anticipated to be only a small fraction of a percent of the total flow this negative impact on performance is more than compensated by advantages elsewhere.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features, properties and advantages of the present invention will be come clear from the following description of an embodiment in conjunction with the accompanying drawings. The described features are advantages alone and in combination with each other.
FIG. 1 schematically shows an inventive gas turbine where the cooling air is taken from the compressor inlet duct.
FIG. 2 schematically shows an inventive gas turbine where the cooling air is taken from the enclosure or through the enclosure wall.
FIG. 3 schematically shows an inventive gas turbine where the cooling air is taken from the enclosure and is pressure boosted by an existing compressor bleed.
FIG. 4 schematically shows part of an inventive gas turbine in a sectional view.
FIG. 5 schematically shows an ejector in a sectional view.
DETAILED DESCRIPTION OF INVENTION
An embodiment of the present invention will now be described with reference to FIGS. 1 to 5 . FIG. 1 schematically shows an inventive gas turbine. The gas turbine comprises a rotation axis with a rotor. The rotor comprises a shaft 107 . Along the rotor a suction portion with a casing 109 , a compressor 101 , a combustion portion 151 , a turbine 105 and an exhaust portion with a casing 190 are located.
The combustion portion 151 communicates with a hot gas flow channel which may have a circular cross section, for example. The turbine 105 comprises a number of turbine stages. Each turbine stage comprises rings of turbine blades. In flow direction of the hot gas in the hot gas flow channel a ring of turbine guide vanes 117 is followed by a ring of turbine rotor blades 115 . The turbine guide vanes 117 are connected to an inner casing of a stator. The turbine rotor blades 115 are connected to the rotor. The rotor is connected to a generator, for example.
During operation of the gas turbine air is sucked and compressed by means of the compressor 101 . The compressed air is led to the combustion portion 151 and is mixed with fuel. The mixture of air and fuel is then combusted. The resulting hot combustion gas flows through a hot gas flow channel to the turbine guide vanes 117 and the turbine rotor blades 115 and actuates the rotor.
The compressor 101 of the gas turbine comprises a compressor inlet duct 102 through which the air is led to the suction portion 109 . A conduit connects the compressor inlet duct 102 with the turbine casing. Through this conduit air with a pressure below 1 bar is guided to the turbine casing. The flow direction of this low pressure cooling air through the conduit is indicated in FIG. 1 by an arrow 103 .
Another conduit connects the turbine casing with the compressor casing. Through this conduit the cooling air is guided away from the turbine casing towards the compressor 101 . The cooling air is injected into the compressor 101 in the area of a first stage 140 of stator blades of the compressor 101 and/or in the area of a first stage 142 of rotor blades of the compressor 101 . The flow direction of the cooling air through this conduit back to the compressor is indicated by an arrow 104 . Preferably the compressor comprises a cavity with a circumferential groove which is placed in the area of the first stage 140 , 142 of the compressor 101 for guiding the cooling air away from the turbine casing back to the compressor 101 . The circumferential groove is placed adjacent to a leading edge of a compressor rotor blade 142 , 141 or upstream of a leading edge of a compressor rotor blade 142 , 141 or a front portion of a tip of a compressor rotor blade 142 , 141 .
At full load conditions only the first stage of the compressor will experience a pressure below atmospheric pressure. At low part loads more stages, for example also the second and third stage, may show subatmospheric pressure. However, the first stage will always show the lowest pressure in the compressor.
FIG. 2 schematically shows another variant of an inventive gas turbine where the cooling air is taken from the enclosure or through the enclosure wall of the turbine 105 . In contrast to FIG. 1 the cooling air with a pressure below 1 bar is taken from the enclosure or through the enclosure wall of the gas turbine. The flow direction of the cooling air from the enclosure or through the enclosure wall towards the turbine casing is indicated by an arrow 113 .
A further variant of an inventive gas turbine is schematically shown in FIG. 3 where the cooling air taken from the enclosure is pressure boosted by an existing compressor bleed. In contrast to FIGS. 1 and 2 the cooling air is pressure boosted by means of an ejector 122 before it is guided to the turbine casing. First, the cooling air is taken from the enclosure of the gas turbine and is guided to the ejector 122 . The flow direction of the cooling air to the ejector 122 is indicated by an arrow 120 . The cooling air is pressure boosted by means of air which is led through the conduit from the compressor 101 to the ejector 122 . The flow direction of the air through this conduit from the compressor 101 to the ejector 122 is indicated by an arrow 121 . The pressure boosted cooling air is then guided to the turbine casing to cool the turbine casing and is then guided back to the compressor casing as described in conjunction with FIGS. 1 and 2 . The flow direction of the pressure boosted cooling air to the turbine casing is indicted by an arrow 123 . The flow direction of the cooling air away from the turbine casing back to the compressor is indicated by an arrow 124 .
FIG. 4 schematically shows details of the cooling circuit in the turbine casing. The turbine casing 118 comprises an inlet 143 for cooling air and an outlet 144 for cooling air. The cooling air coming from the compressor inlet duct 102 or coming from the enclosure or through the enclosure wall 113 is guided through the inlet 143 to an inner wall 119 of the turbine 105 . A number of turbine guide vanes 117 are connected to the inner wall 119 . The flow direction of the cooling air through the inlet 143 is indicated by an arrow 123 . After cooling the inner wall 119 and the turbine casing 118 the cooling air is guided through the outlet 144 towards the compressor 101 . The flow direction of the cooling inside the turbine casing 118 is indicated by an arrow 125 . The flow direction of the cooling air through the outlet 144 is indicated by an arrow 124 .
FIG. 5 schematically shows the principle of an ejector 122 . The ejector 122 is schematically shown in a sectional view. The ejector 122 comprises in flow direction 130 , 131 a nozzle 132 a mixing unit 135 and a diffuser 136 . The nozzle 132 comprises a throat 133 and an exit 134 . A drive flow is guided through the nozzle 132 to the throat 133 and is then guided through the exit 134 towards the mixing unit 135 . The flow direction of the drive flow is indicated by an arrow 130 .
The nozzle 132 is surrounded by a circumferential flow channel 145 which comprises an inlet 146 for cooling air. The flow direction of the cooling air through the inlet 146 to the nozzle 132 is indicated by an arrow 147 .
In the mixing unit 135 the drive flow is mixed with the cooling air and the mixture is guided to the diffuser 136 . The flow direction of the drive flow and the cooling air in the mixing unit 135 and in the diffuser 136 is indicated by arrows 131 .
The diagram below the ejector 122 in FIG. 5 schematically shows the pressure in the nozzle 132 in the mixing unit 135 and in the diffuser 136 . The X-axis of the diagram shows the different locations, i.e. nozzle 132 , mixing unit 135 and diffuser 136 . The Y-axis shows the pressures in these regions. In the nozzle 132 the drive flow has a particular pressure P H . This pressure P H decreases when the drive flow passes the throat 133 and further decreases when the drive flow passes the exit 134 of the nozzle 132 . At the position of the exit 134 the pressure has its minimum value due to a pressure differential. This is indicated by an arrow 137 . At the Y-axis of the diagram the pressure of the cooling air which is injected through the inlet 146 is indicated by P L and the minimum of the pressure at the exit 134 is indicated as P S , which corresponds to the minimum pressure value.
In the mixing unit 135 the pressure of the mixture of the driving flow and the cooling air increases. The pressure further increases when the mixture passes the diffuser 136 due to the reduced flow velocity of the mixture in the diffuser 136 . The pressure of the mixture when it leaves the diffuser 136 is indicated by P D . The difference between the pressure P D and the initial pressure of the cooling air P L is indicated by an arrow 138 . | A method for cooling a component of a turbine is provided, wherein a fluid with a pressure below 1 bar is guided away from the component. Moreover, a turbine is described comprising a component, a conduit which is connected to the component so that a fluid can be guided away from the component, and a fluid discharge which is connected to the conduit. The fluid discharge is constructed so that it removes a fluid with a pressure below 1 bar. | 5 |
PRIORITY
The present application claims priority to U.S. Ser. No. Provisional Application No. 61/578,086 filed on Dec. 20, 2011, entitled, “Mixer/Flow Distributors” the entire disclosure of which is hereby incorporated by reference herein.
FIELD OF THE INVENTION
The invention relates to mixer/flow distributors and their use, e.g., in regenerative reactors. The invention encompasses a process and apparatus for controlling oxidation, e.g., for thermally regenerating a reactor, such as a regenerative, reverse-flow reactor.
BACKGROUND OF THE INVENTION
Combustion can be used for regenerating reactors utilized for cyclic, high temperature chemistry, e.g., regenerative reactors. Typically, regenerative reactor cycles are either symmetric (reaction chemistry is the same as regeneration chemistry) or asymmetric (reaction chemistry and regeneration chemistry are different).
One class of asymmetric regenerative reactors, e.g., those utilized for pyrolysis, comprises first and second zones, with each zone comprising at least one regenerative bed. The reactor is heated (or regenerated) in an exothermic oxidation step, e.g., by conducting fuel and oxidant to a mixing-distribution zone located between the first and second zones, mixing and distributing the fuel and oxidant in the mixing-distribution zone, combusting the fuel and oxidant, and then conducting the combustion products through the second zone and away from the reactor. During the pyrolysis step, a pyrolysis feed is conducted through the second zone and then through the first zone, thereby pyrolysing the pyrolysis feed and conveying heat from the second zone to the first zone. Some regenerative reactors deliver fuel and/or oxidant directly to the mixing-distribution zone without having those streams pass through the first or second zones. Prior art references disclose introducing fuel and/or oxidant via nozzles, distributors, or burners that penetrate the reactor system using means generally perpendicular to the reaction flow direction and usually through the reactor vessel side wall. For example, during the exothermic step in a conventional Wulff cracking furnace, air flows axially through the regenerative bodies, and fuel is introduced via nozzles that penetrate the side of the furnace, to combine with air (combusting and releasing heat) in an open zone between regenerative bodies.
One feature of a regenerative reactor is to execute reactions at high efficiency by recuperating product heat directly into feeds. Introducing fuel or oxidant radially via nozzles, distributors, or burners external to the reactor is disadvantageous because the regenerative reactor system is not utilized to preheat that reactant stream. In other words, bypassing some fraction of the fuel and/or oxidant around the regenerative reactor system reduces the reactor system's efficiency.
Attempts have been made to introduce fuel and/or oxidant to a location at or near the middle of the regenerative reactor via conduits that are positioned axially within one or more of the regenerative beds. For example, U.S. Pat. No. 4,240,805 discloses using pipes that are positioned axially within a regenerative bed to carry oxidant (air) to locations near the middle of the regenerative flow path. This conveys heat toward the reforming zone. More recently, U.S. Pat. No. 7,815,873 discloses providing fuel and oxidant, via substantially parallel flow paths within the first zone, to a mixer-distributor located in a mixing-distributing zone. The mixing-distributing zone is located between the first and second regenerative zones, and the mixer-distributor comprises convergence and divergence zones to improve the reactor's thermal efficiency.
Further improvements are desired.
SUMMARY OF THE INVENTION
In an embodiment, the invention relates to a regeneration method, comprising:
(a) conducting fuel through at least one first conduit and oxidant through at least one second conduit, the first and second conduits being located in a recuperation zone of a reactor system; (b) combining and reacting at least a portion of the fuel with at least a portion of the oxidant in a mixing-distributing zone to produce heat and a first reaction product, the mixing-distributing zone being located (i) in the reactor system and (ii) downstream of the recuperation zone and upstream of a reaction zone, the mixing-distributing zone comprising a mixer-distributor having an MD≦15.0%, a pressure drop ≦0.3 bar (absolute), and a combined fuel-oxidant flow rate ≧10.0 kg/hr; and (c) conducting the reaction product through the reaction zone and transferring at least a portion of the heat from the reaction product to the reaction zone.
In yet another embodiment, the invention relates to a hydrocarbon conversion process, comprising:
(A) providing fuel and oxidant to a reactor, the reactor comprising at least one mixer-distributor; (B) transferring the fuel and oxidant to the mixer-distributor in a fuel-oxidant flow-direction; (C) mixing and distributing the fuel-oxidant flow in the mixer-distributor and exothermically reacting at least a portion of the oxidant with at least a portion of the fuel sufficient to heat at least a portion of the reactor to a temperature ≧800° C., the mixer distributor comprising:
(i) at least one first baffle and a plurality of first orifices, the first baffle and plurality of first orifices being positioned at a first location in the mixer-distributor; (ii) at least one second baffle and at least one second orifice, the second baffle and second orifice being located at a second location in the mixer-distributor, wherein (a) the first location is upstream of the second location with respect to the fuel-oxidant flow, and (b) the first location has a greater number of orifices than the second location; and (iii) an inner boundary of the mixing-distributing zone, the inner boundary being either (a) connected to the first baffle's perimeter and the second baffle's perimeters or (b) sufficiently proximate to the first and second baffles' perimeters to substantially prevent the fuel-oxidant flow through the mixing-distributing zone except via the first and second orifices;
(D) providing a first mixture to the heated reactor in a direction that is substantially the reverse of the fuel-oxidant flow direction, the first mixture comprising alkane; and (E) exposing the first mixture to a temperature ≧800° C. in the heated reactor and abstracting sufficient heat from the reactor to convert at least a portion of the first mixture's alkane to unsaturated hydrocarbon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows one embodiment of the invention utilizing a regenerative, reverse-flow pyrolysis reactor.
FIG. 2 schematically shows the locations of selected fuel passages and oxidant passages within reactor 7 of FIG. 1 .
FIG. 2A schematically shows an end 9 of reactor 7 , the shaded region showing the approximate location of fuel channels 14 .
FIG. 3A schematically illustrates a mixer-distributor comprising five perforated plates.
FIGS. 3B and 3C schematically show the spacing and angular relationships among the perforations of plates 1 , 3 , 4 , and 5 .
FIG. 4 schematically shows the plate surface area and total perforation surface area for plates 1 - 5 .
FIG. 5 schematically shows swirling means located adjacent to plate 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is based in part on the observation that mixing and distribution effectiveness can be improved by utilizing a mixer-distributor comprising a plurality of orifices located within the mixing-distributing zone. In one embodiment, the mixer-distributor's orifices comprise a plurality of holes open to the flow of fuel and oxidant, the holes being located on one or more planes within or proximate to the mixing-distributing zone. For example, the holes can be (i) located on one or more plates within mixing-distributing zone, (ii) located on one or more protrusions of the mixing-distributing zone's boundary (e.g., toward a central portion of the zone), or (iii) a combination of arrangements (i) and (ii). The plates and/or protrusions can be, e.g., substantially parallel, and can be spaced apart with substantially equal inter-plate spacing within the mixing-distributing zone.
It has been found that utilizing mixer-distributors comprising an arrangement of orifices as specified below provides improved mixing and distribution compared to mixer-distributor utilizing convergence-divergence zones, e.g., those described in U.S. Pat. No. 7,815,873, particularly at an L:D ratio ≦3.0, e.g., ≦2.0, such as in the range of 0.5 to 1.5. The term “L:D ratio” has the same meaning as in U.S. Pat. No. 7,815,873, which is incorporated by reference herein in its entirety.
It has also been found that conventional mixer-distributors, e.g., those comprising convergence-divergence zones, are sensitive to (a) gas-flow variations and (b) axial misalignment between (i) the reactor components and (ii) the mixer-distributor components. It has been discovered that mixer-distributors comprising an arrangement of orifices (e.g., in the form of plurality of substantially-parallel perforated plates) are significantly less sensitive to such gas-flow variations and mixer-distributor misalignment. Utilizing the mixer-distributor in a reverse-flow regenerative pyrolysis reactor system results in a significant increase in efficiency over reactor systems utilizing conventional mixer-distributors. Since mixing and flow-distribution is improved, the regeneration step utilizes less fuel and oxidant than would a conventional mixer-distributor to achieve the same amount and uniformity of reactor heating. Moreover, when the fuel and pyrolysis feed are obtained from the same hydrocarbon source, less fuel usage during the regeneration step makes more of the hydrocarbon available for conversion to C 2 unsaturates, thereby increasing overall yield.
In an embodiment, the mixing-distributing zone is located between the first and second reactors of a regenerative reactor system, with each reactor comprising, e.g., at least one regenerative bed. The mixer-distributor, which comprises a plurality of orifices, is located within the mixing-distributing zone. The mixing-distribution zone can be of appropriate cross-sectional shape for convenient use in a regenerative reactor system, e.g., polygonal (triangular, rectangular, pentagonal, hexagonal, etc.), circular, elliptical, etc., including combinations thereof. The orifices can be, e.g., perforations in one or more baffle means, the baffle means comprising a plurality of plates and/or protrusions of the mixing-distributing zone's boundary. The baffle means substantially prevent the flow of reactants (e.g., fuel and/or oxidant) through the mixing-distributing zone except via the orifices. This can be accomplished, e.g., by locating the perimeter of the baffle means in proximity to the mixing-distributing zone's inside boundary in order to substantially prevent the flow of fuel and/or oxidant via flow-paths which substantially avoid at least some of the mixer-distributor's orifices. By substantially prevent, it is meant that less than 10% (by weight), e.g., <5%, of the flow of fuel and/or oxidant avoids at least some of the mixer-distributor's orifices.
One embodiment will now be described with respect to a mixing-distributing zone having a length L and cross-sectional area A, where (i) “length” is defined in a direction parallel to the average flow of fuel and oxidant traversing the mixing-distributing zone from upstream to downstream and “cross-sectional area” is defined with respect to a plane that is substantially perpendicular to L. The mixing-distributing zone 13 is located within a regenerative, reverse-flow reactor system, e.g., the reactor system illustrated in FIG. 1 . The mixing-distributing zone's cross-sectional area can be, e.g., (i) substantially constant over L and/or (ii) substantially the same as that of the first reactor 7 and/or second reactor 1 , as shown in FIG. 1 . Zones 16 and 7 each comprises at least one regenerative bed, where the term “regenerative bed” means a reactor bed comprising material that is effective in storing and transferring heat. In this embodiment, at least one mixer-distributor is located within the mixing-distributing zone, the mixer-distributor comprising at least two perforated plates. The length L of the mixing-distributing zone 13 is typically taken as the distance in between the regenerative beds of zones 16 and 7 , that is, the distance from the downstream end of the regenerative bed in zone 7 to the upstream end of the regenerative bed in zone 16 , with downstream being with respect to the flow of fuel and oxidant. Although the invention is described in terms of perforated plates located within such a mixing-distributing zone, the invention is not limited thereto, and this description is not meant to foreclose other embodiments within the broader scope of the invention, such as embodiments where the mixing-distributing zone has a different shape, where the mixing-distributing zone has an irregular cross-sectional area, where at least some of the orifices are not located on plates within the mixing-distributing zone, etc.
The invention is not limited to embodiments having one mixer-distributor. For example, in one embodiment first reactor 7 is a honeycomb in the form of an elongated rectangular body having upstream and downstream faces of substantially equal rectangular cross-sections. The honeycomb comprises four sections S 1 -S 4 joined side-to-side, the sections each being honeycombs in the form of an elongated rectangular body having upstream and downstream faces of substantially equal rectangular cross-sections. In this embodiment, each section can comprise fuel passages and oxidant passages. The use of multiple honeycomb sections (as in S 1 -S 4 ) facilitates the application to large-diameter reactor systems. In some embodiments, each section utilizes one mixer in region 13 to facilitate mixing of the first and second reactants that are flowing predominantly through the passages in that section. In those embodiments, there may be roughly the same number of mixers as there are sections. In large-diameter reactors, the number of sections may be very large, numbering in the dozens or even hundreds. For example, in one embodiment, the reactor system comprises (i) a first reactor comprising 100 sections and (ii) one mixer per section.
For the purpose of this description and the appended claims, the term “perforated plate” means a solid body having orifices open to the flow of gases, the solid body having a thickness (“T”), a cross-sectional area (“A”), effective plate diameter (“D p ”, with D p =2(A/π) 1/2 ), and a T/D p ratio ≦1.0, e.g., ≦0.5, such as ≦0.2. Plate thickness T is the average plate thickness proximate to a perforation (or the arithmetic mean of these values when the thickness proximate to one orifice differs from the thickness proximate to another). For example, supporting means that may be attached to a plate for positioning the plate in the mixing-distributing zone (e.g., rings and/or tabs for connecting a plate to the mixing-distributing zone's boundary) are excluded from the plate thickness. One or more of a plate's features (e.g., location of perforations) can be conveniently described in reference to a central axis. A plate's central axis is defined as a line that is substantially perpendicular to the plane of the plate that intercepts the plate's geometric center (“centroid”), where the term centroid means the average location (first moment) of all the points of the object. For example, the centroid of a circular plate of uniform density is the point at the center of the circle. Two or more plates can be positioned in approximately coaxial fashion, where the term “coaxial” means that the central axes of the plates are (i) in close proximity and (ii) substantially parallel. In this context, the term “close proximity” means the plates' central axes are separated by a distance that is ≦10% of the plate's effective diameter (or the effective diameter of the smaller plate when the plates are of unequal size), e.g., ≦5%. The term “substantially parallel” means that the difference in angle of interception to any of the planes of the plates is ≦10°, e.g., ≦5°. The central axis of a plurality of plates, called the common central axis, is the best fit (e.g., numerical average) of the plates' central axes.
In an embodiment, the mixer-distributor comprises two perforated plates. For example, the mixer can comprise:
(a) a first plate having (i) a cross-sectional area A p1 (ii) a thickness T p1 , and (iii) a plurality of orifices having a combined cross-sectional area A h1 , and (b) a second plate, the second plate having (i) a cross-sectional area A p2 , (ii) a thickness T p2 , and (iii) one substantially-centered orifice having a cross-sectional area A h2 .
Plate 2 can be located proximate to a plane (Plane 2 ) that is substantially orthogonal to the direction of flow and bisecting the mixing-distributing zone 13 , and plate 1 can be located proximate to a plane (Plane 1 ) that is (i) substantially parallel to Plane 2 and (ii) located upstream of Plane 2 with respect to the average flow of fuel and oxidant as these traverse the mixing-distributing zone. Planes 1 and 2 can be spaced apart to provide an L:D ratio (for the mixer-distributor of this embodiment) in the range of 0.1 to 10.0, e.g., in the range of 0.2 to 2.0, such as in the range of 0.5 to 1.5, L being (for this embodiment) measured between the downstream end of the regenerative bed in zone 7 to the upstream end of the regenerative bed in zone 1 along the central axis. Optionally, the plates are substantially coaxial, the ratio A p1 :A h1 is ≧2.0 and the ratio A p2 :A h2 is ≧1.5. A h2 is optionally in the range of 75.0% of A h1 to 125.0% of A h1 , e.g., 85.0 of A h1 to 115.0% of A h1 , such as 90.0% of A h1 to 110.0% of A h1 . While not wishing to be bound by any theory or model, it is believed that making A h1 and A h2 of substantially similar size leads to lower pressure drop across the mixer-distributor and lessens the variation in reactant (fuel and oxidant) flow velocities among the orifices. The total number of orifices (e.g., perforations) located on plate 1 is optionally in the range of 2 times to 8 times the number of orifices located on plate 2 , e.g., in the range of from 3 times to 6 times. For a plate having an effective diameter D p , the plate's thickness can be determined from the relationship T/D p ≦0.5, such as ≦0.2. Optionally, plate 2 has a thickness T p2 that is in the range of 75.0% of T p1 to 125.0% T p1 , e.g., in the range of 90.0% of T p1 to 110.0% of T p1 , such as in the range of 95.0% of T p1 to 105.0% of T p1 . Optionally, the downstream face of plate 1 is spaced apart from the upstream face of plate 2 by a distance S p1-p2 , wherein S p1-p2 is measured along the mixer-distributor's central axis and is in the range of 5% to 50% of plate 1 's D p , such as in the range of 5% and 20%. When plates 1 and 2 are of substantially equal perimeter, S p1-p2 can be in the range of 0.25S b to 5.0S b , where S b equals A h1 divided by the perimeter of plate 1 . The mixer-distributor is generally located coaxial with the mixing-distributing zone. When the mixer-distributor's effective length is less than that of the mixing-distributing zone, the mixer-distributor is optionally centered in the zone along the central axis. Optionally, A p2 is in the range of 75.0% of A p1 to 125% of A p1 , e.g., 85.0% of A p1 to 115% of A p1 , such as 90.0% of A p1 to 110.0% of A p1 . In an embodiment, plates 1 and 2 have substantially the same surface area and thickness, e.g., they are circular or polygonal plates of substantially equal diameter and thickness.
In the embodiment illustrated in FIGS. 3A-3C and FIG. 4 , the mixer-distributor comprises a plurality of perforated plates, e.g., at least two perforated plates. For example, the mixer-distributor can comprise:
(a) at least one first plate, the first plate having a cross-sectional area Ap 1 and having a plurality of orifices having a combined cross-sectional area A h1 , wherein A p1 :A h1 is ≧2.0; and (b) a second plate, the second plate having (i) fewer orifices than the first plate, (ii) a cross-sectional area A p2 is in the range of about 75.0%·A p1 to 125.0%·A p1 , and (iii) one substantially-centered orifice having a cross-sectional area A h2 , wherein A h2 is in the range of about 90%·A p1 to 110.0%·A p1 .
Optionally, the mixer distributor further comprises third, fourth, and/or fifth perforated plates. As shown in FIG. 3A , plate 3 is adjacent to the side of plate 2 that is opposite to plate 1 , plate 4 is located adjacent to the side of plate 3 that is opposite plate 2 , and plate 5 is adjacent to the side of plate 1 that is opposite plate 2 . Optionally, the plates comprising the mixer-distributor have one or more of the following features:
(i) at least one of the plates has a polygonal, elliptical, circular cross-section; (ii) at least two of the plates have a substantially equal cross-sectional area; (iii) the orifices through each of the plates (which orifices comprise the perforations) have a polygonal, elliptical, or circular cross-section or a combination thereof; (iv) at least two of the plates have substantially the same thickness; (v) at least one plate has a thickness that is not the same as those of the other plates; (vi) at least one plate has a substantially uniform thickness; (vii) at least one plate has a substantially non-uniform thickness, such as when one or more of the plates comprises embossed perforations, e.g., one or more orifices having a thickness that is not the same as that of the plate; (viii) the mixer-distributor comprises at least three plates of substantially equal spacing; (ix) the mixer-distributor comprises at least three plates of unequal spacing, such as when the spacing between plates 1 and 2 (denoted as S p1-p2 in FIG. 3A ) is not the same as the spacing between plates 2 and 3 (denoted as S p2-p3 ); or (x) a spacing between the last downstream plate of the mixer and the upstream end of the regenerative material in second reactor 1 denoted as S z1 that is approximately equal to the spacing between the first upstream plate and the downstream end of the regenerative material in first reactor 7 denoted as S z7 .
The mixer-distributor can further comprise additional mixing distribution elements, e.g., plates, swirling means, flow concentrators, flow expanders, etc., as described in U.S. Pat. No. 7,815,873. Optionally, the mixer-distributor includes means for decreasing (e.g., preventing) the flow of the fuel and/or oxidant in paths that avoid the plates' orifices. For example, the mixer-distributor can be located proximate to the inner wall of mixing-distributing zone 13 , to guide fuel and oxidant flow toward and through the mixture-distributor, and which substantially prevents the flow of these gases between zones 7 and 1 by other flow-paths.
One embodiment of a mixer-distributor will now be described in more detail, the mixer-distributor comprising perforated circular plates arranged as shown in FIG. 3A . Although the mixer-distributor is described in terms of this embodiment, the invention is not limited thereto, and this description is not meant to foreclose other embodiments, such as those having fewer plates, plates of non-circular cross-section area, unequal thickness, non-circular orifices, overlapping orifices, embossed orifices, etc.
In an embodiment, the first plate (“plate 1 ”) is a substantially circular plate having a cross-sectional area A p1 and a plurality of substantially circular orifices having a combined cross-sectional area A h1 , wherein A p1 :A h1 is ≧2.0. Optionally, the plate has one or more of the following properties: the plate has a cross-sectional area in the range of 500 mm 2 to 5.0×10 6 mm 2 , e.g., 2000 mm 2 to 5.0×10 4 mm 2 , such as 3000 mm 2 to 3.0×10 4 mm 2 ; the plate has a T/D p ≦0.3, such as in the range of 0.05 to 0.15; the plate has a substantially uniform thickness; each orifice has a cross-sectional area ≧0.01·A p1 , e.g., in the range of 0.01·A p2 to 0.2·A p1 ; the plate does not contain an orifice having a central axis that is less than 0.1 D p distant from the plate's central axis at the plane of the plate; the plate's diameter is in the range of 25 mm to 2,500 mm, e.g., 50 mm to 250 mm, such as 65.0 mm to 200.0 mm.
In an embodiment, the first plate comprises a plurality of non-overlapping, substantially circular orifices, with no orifice being located within 0.1 D p of the plate's central axis. Optionally, the number of orifices through plate 1 is equal to a factor “n” times the number of orifices through plate 2 , with n being in the range of from 2 to 20, such as in the range of from 3 to 6. In an embodiment, the number of orifices is equal to 6. Optionally, each orifice is of substantially equal area, as shown in the right hand side of FIG. 3B , and of substantially equal thickness. Optionally, the orifices are equally-spaced in a circular pattern, the circular pattern having a radius R 1 p1 , as shown in FIG. 3C . R 1 p1 is generally selected so that no orifice overlaps the plate's perimeter, and can be, e.g., in the range of 0.05·D p1 to 0.4·D p1 . The spacing angle α 1 can be determined from the number and diameter of the equally-spaced orifices. For example, α 1 can be in the range of about 40.0° to about 120.0° when plate 1 comprises a number of equally-spaced, non-overlapping orifices in the range of from three to nine.
The second plate (“plate 2 ”) is a substantially circular plate located adjacent to the first plate, as shown in FIG. 3A . In an embodiment, the second plate has (i) a cross-sectional area A p2 in the range of 75.0%·A p1 to 125.0%·A p1 , e.g., 90.0%·A p1 to 110%·A p1 , and (ii) one substantially-centered circular orifice having a cross-sectional area A h2 , wherein A p2 :A h2 is ≧1.5. In other words, plate 2 's central orifice can have a central axis that is separated (in the plane of the plate) by ≦0.1 D p , e.g., ≦0.05 D p , e.g., ≦0.01 D p , from the plate's central axis. Optionally, A h2 is in the range 75.0%·A h1 to 125% A h1 , e.g., 85.0%·A h1 to 115%·A h1 , such as 90.0%·A h2 to 110.0%·A h1 . Optionally, plate 2 's thickness and cross-sectional area are in the same ranges as those specified for plate 1 . Optionally, plate 2 has substantially the same thickness, thickness uniformity, and cross-sectional area as plate 1 . Optionally, the plate 2 contains one or more additional orifices. The additional orifices can have, e.g., a combined cross-sectional area ≦0.6·A h2 .
Generally, plate 1 has a greater number of orifices than plate 2 , with plate 2 having the fewest number of orifices among the mixer-distributor's plates (e.g., those of optional plates 3 , 4 , and 5 as shown in FIG. 3A ). In an embodiment, the third plate (“plate 3 ”) is a substantially circular plate located adjacent to plate 2 , as shown in FIG. 3A . Plate 3 has a cross-sectional area A p3 and a plurality of orifices having a combined cross-sectional area A h3 , wherein A p3 :A h3 is ≧2.0. Optionally, plate 3 's properties, e.g., thickness, thickness uniformity, cross-sectional area, orifice number/size/geometry, etc., are in the same ranges as those specified for plate 1 . Optionally, A p3 is in the range of 75.0%·A p1 to 125.0%·A p1 , e.g., 90.0%·A p1 to 110.0%·A p1 , such as in the range of 0.10·A p1 to [A p1 +(0.02·A p1 )]. In an embodiment, plate 3 comprises a plurality of non-overlapping orifices with no orifice overlapping a region that is within 0.1 D p of the plate's central axis. Optionally, the number of orifices through plate 3 is equal to a factor “m” times the number of orifices through plate 2 , with m being in the range of from 2 to 20, such as in the range of from 3 to 6. In an embodiment, plate 3 has six substantially circular orifices. Optionally, each orifice is of substantially equal cross-sectional area, as shown in the right hand side of FIG. 3B , and is of substantially equal thickness. Optionally, the orifices are equally-spaced in a circular pattern, the circular pattern having a radius R 1 p3 , as shown in FIG. 3C . R 1 p3 is generally selected so that no orifice overlaps the plate's perimeter, and can be, e.g., in the range of 0.5·D p3 to 0.4·D p3 . The spacing angle α 3 can be determined from the number and diameter of the equally-spaced orifices. For example, α 3 is approximately 60.0° when plate 3 comprises six equally-spaced, non-overlapping orifices. In an embodiment, plate 3 is substantially the same as plate 1 (e.g., with n=m).
When plates 1 and 3 each comprise a plurality of equally-spaced orifices, the orifices' patterns of plates 1 and 3 can be aligned within a relative rotational position. In such embodiment, each plate may have different rotational orientation, where the rotation is around the plate's central axis. Relative rotational position of one plate versus another is conveniently described in reference to a plane that includes the common central axis, and is bordered by the common central axis (exists on one side of that axis only). The intersection of this reference plane with each plate provides a common reference axis (“CRA”), shown as a horizontal line in FIG. 3B , from which angles of rotation can be measured. Relative rotational position of an orifice on a plate is defined as the angle (“δ”) between the reference axis and a radial line that links the centroid of the plate with the centroid of the orifice nearest to the reference axis. If a plate has orifices at substantially different radii, each set of orifices that have substantially similar radii may have their own δ. When angles require addition or subtraction, we follow the convention that positive angles from the reference axis are on the counter-clockwise side of the reference axis as viewed along the common central axis, observing from the side of plate 1 that is opposite from plate 2 (i.e., from “above” plate 5 as illustrated in FIG. 3A ). In an embodiment where plates 1 and 3 each have three to nine (e.g., six) circular orifices of substantially equal diameter, and wherein R 1 p1 =R 1 p3 =R 1 , the relative rotational position of plates 1 and 3 (δ 1 ) is in the range of −30.0° to 30.0° with respect to the (horizontally drawn) common reference axis as shown in FIG. 3B .
In an embodiment, the mixer-distributor can further comprise optional plate 4 . As shown in FIG. 3A , plate 4 is a circular plate located adjacent to plate 3 so that plate 3 is between plates 4 and 2 . In an embodiment, plate 4 has (i) a cross-sectional area A p4 , where A p4 is in the range of 75%·A p1 to 125.0%·A p1 , e.g., 90.0%·A p1 to 110.0%·A p1 (ii) a plurality of orifices having a combined cross-sectional area A h4 , wherein A p4 :A h4 is ≧2.0, and (iii) a number of orifices greater than that of plate 3 . Optionally, plate 4 's thickness and cross-sectional area are in the same ranges as those specified for plate 3 . Optionally, plate 4 has substantially the same thickness, thickness uniformity, and cross-sectional area as plate 2 . Optionally, plate 4 's orifices each have a cross-sectional area in the range of 0.01·A p4 to 0.2·A p4 . Optionally, the plate has an orifice having a cross-sectional area overlapping the plate's central axis. Optionally, the plate has an orifice having a center that is located substantially on the plate's symmetry axis.
In an embodiment, plate 4 is of substantially uniform thickness T 4 and comprises a plurality of non-overlapping circular orifices with one orifice being located substantially coaxially with the plate's central axis. Optionally, the number of orifices through plate 4 is equal to a factor “p” times the number of orifices through plate 3 , with p being in the range of from ≧2 or ≧3.0. In an embodiment, plate 4 has 19 circular orifices of substantially uniform thickness (substantially equal to that of the plate) and substantially equal cross-sectional area, as shown in the left hand side of FIG. 3B . With one orifice centered on the plate's symmetry axis, the remaining orifices can be, e.g., equally-spaced in first and second circular patterns, the first circular pattern having a radii R 1 p4 , and the second circular pattern having a radius R 2 p4 , as shown in FIG. 3C . R 1 p4 is generally selected so that no orifice overlaps the plate's central orifice and R 2 p4 is selected so that no orifice overlaps plate 4 's perimeter. R 1 p4 and R 2 p4 can each be, e.g., in the range of 0.05·D 4 to 0.4·D p4 . The spacing angles β 4 and γ 4 can be determined from the number and diameter of the equally-spaced orifices as shown in FIG. 3C . β 4 can be, e.g., in the range of about 45.0° to about 90.0° when four to eight (e.g., six) equally-spaced, non-overlapping orifices are equally-spaced at R 1 p4 . γ 4 can be, e.g., in the range of about 22.5° to about 45.0°, when eight to sixteen (e.g., twelve) equally-spaced, non-overlapping orifices are equally-spaced at R 2 p4 .
In an embodiment, the mixer-distributor can further comprise optional plate 5 . As shown in FIG. 3A , plate 5 can be a circular plate located adjacent to plate 1 so that plate 1 is between plates 5 and 2 . Plate 5 can have (i) a cross-sectional area A p5 , where A p5 is in the range of 0.10·A p1 to [A p1 +(0.02·A p1 )], (ii) a plurality of circular orifices having a combined cross-sectional area A h5 , wherein A p5 :A h5 is ≧2.0, and (iii) a number of orifices greater than that of plate 1 . Optionally, plate 5 's properties, e.g., thickness, thickness uniformity, cross-sectional area, orifice number/size/geometry, etc., are in the same ranges as those specified for plate 4 .
In an embodiment, plate 5 is of substantially uniform thickness T 5 and comprises a plurality of non-overlapping orifices with one orifice being located substantially coaxially with the plate's central axis. Optionally, the number of orifices through plate 5 is equal to a factor “q” times the number of orifices through plate 1 , with q being in the range of from ≧2.0 or ≧3.0, e.g., such as in the range of from 3 to 6. In an embodiment, plate 5 has 19 circular orifices of substantially uniform thickness (substantially equal to that of the plate) and substantially equal cross-sectional area, as shown in the left hand side of FIG. 3B . With one orifice centered on the plate's symmetry axis, the remaining orifices can be, e.g., equally-spaced in first and second circular patterns, the first circular pattern having a radii R 1 p5 , and the second circular pattern having a radius R 2 p5 , as shown in FIG. 3C . R 1 p5 is generally selected so that no orifice overlaps the plate's central orifice and R 2 p5 is selected so that no orifice overlaps plate 5 's perimeter. R 1 p5 and R 2 p5 can each be, e.g., in the range of 0.05·D p5 to 0.4·D p5 . The spacing angles β 5 and γ 5 can be determined from the number and diameter of the equally-spaced orifices as shown in FIG. 3C . β 5 can be, e.g., in the range of about 45.0° to about 90.0 when four to eight (e.g., six) equally-spaced, non-overlapping orifices are equally-spaced at R 1 p5 . γ 5 can be, e.g., in the range of about 22.5° to about 45.0°, when eight to sixteen (e.g., twelve) equally-spaced, non-overlapping orifices are equally-spaced at R 2 p5 .
In an embodiment where plates 4 and 5 each have two rings of orifices, the inner ring with six and the outer ring with 12 roughly evenly spaced orifices, the relative rotational position of the inner ring of 6 orifices on plates 4 and 5 (δ 2 ) is in the range of −30.0° to +30.0° with respect to the (horizontally drawn) common reference axis (CRA) as shown in FIG. 3B , and the relative rotational position of the outer ring of 12 orifices on plates 4 and 5 (δ 3 ) is in the range of −15.0° to +15.0° with respect to the (horizontally drawn) common reference axis (CRA) as shown in FIG. 3B . The two rings of orifices on plates 4 and 5 can have a relative rotational position with respect to each other (|δ 2 -δ 3 |) between 0.0° and 15.0°. In an embodiment, the two rings of orifices on plates 4 and 5 have a relative rotational position with respect to each other (|δ 2 -δ 3 |) between 12.0° and 15.0°. Plates 4 and 5 can have a relative rotational position with respect to plates 1 and 3 (|δ 1 -δ 2 |) in the range, e.g., of 0.0° to 30.0°. In one embodiment, the rotational position of plates 4 and 5 relative to plates 1 and 3 (|δ 1 -δ 2 |) is in the range of 0.0° and 5.0°. In one embodiment, the rotational position of plates 4 and 5 relative to plates 1 and 3 (|δ 1 -δ 2 |) is in the range of 25.0° and 30.0°. In one embodiment, the rotational position of plate 3 relative to plate 4 and of plate 5 relative to plate 1 are fixed as outlined above, but the relative rotational positions of the plate 3 - 4 pair and the plate 1 - 5 pair is not fixed at any specific value.
In an embodiment, the mixer-distributor further comprises optional swirling means. Such swirl means, when used, can provide, e.g., a swirl number in the range of from 0.1 to 3.0, e.g., 0.1 to 1.3, the swirl number can be determined using the methods described in Combustion Aerodynamics, Chapter 5, by J. M. Beer, Krieger Publishing, 1983. Although the mixer-distributor of the invention is less sensitive to misalignment between the bed of recuperator zone 7 and the mixer-distributor of zone 13 , it has been observed that this sensitivity can be further reduced when swirling means are located between plate 1 and plate 2 (plate 1 being upstream of plate 2 with respect to the average flow direction of the fourth mixture).
When swirling means are utilized, the fuel and oxidant mixing is aided by the radial flow of these gases into a chamber defined by swirl vanes B as shown in FIG. 5 . The swirl vanes direct the fuel and oxidant (and any reaction product) radially inward, while imparting a circumferential velocity. Swirling gases pass through the orifice of plate 2 , thereby increasing the amount of mixing.
Although shown in FIG. 5 as six radially-slanted fins, a different number of swirl vanes (B) can be used, and these vanes may be configured in other shapes effective for producing swirl, provided that the swirl created by the swirl generating devices (the swirl vanes in this embodiment) produce a swirl number ranging from about 0.1 to about 3.0, e.g., from about 0.1 to about 1.3, the swirl number being specified at the entrance to the orifice of plate 2 . Alternative swirl-generating passage shapes can be used, e.g., conventional swirl-generating passage shapes, though the invention is not limited thereto. For example, helical passages or spaces can be utilized between vanes.
An example of swirling means useful for the mixer-distributor is shown schematically in FIG. 5 . Swirling blocks shaped to achieve the designated swirl number are equally-spaced proximate to the upstream surface of plate 2 . The swirling blocks can have, e.g., a height h 1 , wherein h 1 ≦S p1-p2 , where S p1-p2 is the spacing between plates 1 and 2 , as shown in FIG. 3A . The minimum distance between opposed swirling blocks is D i , where D i is ≧1.0 times the minimum distance spanning plate 2 's central orifice. A baffle (e.g., a plate 6 ) can be located upstream of the swirling means and downstream of plate 1 , as shown in FIG. 5 . In an embodiment, the swirling blocks are equally spaced along a curve equidistant between D i and an outer diameter D o , with plate 6 being a circular plate having an outside diameter D o and a thickness h 2 . Optionally, plate 2 , the swirling blocks, and plate 6 are attached in face-to-face contact, one to the other in sequence, as shown in FIG. 5 .
In an embodiment, the mixer-distributor is configured to minimize its open volume while maintaining sufficient mixing to mix (i) ≧50.0 wt. % of the first reactant, e.g., ≧75.0 wt. %, such as ≧90.0 wt. % with (ii) ≧50.0 wt. %, e.g., ≧75.0 wt. %, such as ≧90.0 wt. % of the second reactant, the weight percents being based on the weight of the first or second reactant (as the case may be) conveyed to zone 13 . The term “open volume” means the total volume of the mixer-distributor, including optional plates 3 , 4 , and 5 and optional swirling means when these are used, less the volume of the material structure of the mixer-distributor. For example, the mixer-distributor can have a length L and an effective diameter D, wherein (i) the effective diameter D=2(A/π) 1/2 , and (ii) A is the mixer-distributor's cross-sectional area. In this embodiment, L and D are selected to achieve sufficient mixing and distribution of the fuel and oxidant within zone 13 while minimizing open volume. Optionally, L/D is in the range of 0.1 to 8.0, e.g., in the range of 0.2 to 2.0, such as in the range of 0.3 to 1.0. Optionally, the mixer-distributor has a total volume that is ≦20.0%, e.g., ≦15.0%, such as ≦10.0% of the combined volume of the recuperator zone 7 , reaction zone 1 , and mixing-distributing zone 13 .
For prior art mixer-distributors, such as those of U.S. Pat. No. 7,815,873, the total volume of the mixer-distributor is selected based on balancing (i) effectively mixing the fuel and oxidant in the mixing-distributing zone; (ii) uniformly distributing the flow of the combined fuel and oxidant across the cross-section represented by the ends of the (circular or polygonal) cylinder represented by the mixer-distributor; and (iii) providing a relatively low pressure-drop across the mixing zone. The mixer-distributor of the invention is an improvement, at least in part because the perforated plates comprising the mixer-distributor of the invention provide enhanced fuel-oxidant mixing and flow distribution of these gases without significantly increasing pressure drop—particularly at a relatively small mixer-distributor L/D, e.g., in the range of 0.2 to 2.0, such as in the range of 0.3 to 1.0. To achieve the same level of mixing, distribution, and pressure drop, prior art mixer-distributors would require a mixer-distributor length L that is ≧10.0%, e.g., ≧25.0% than the length L of the mixer-distributor of the invention of the same effective diameter D. The term “Mixing Effectiveness” (ME) is the amount (wt. %) of the fourth mixture's fuel component consumed via oxidation by the fourth mixture's oxidant component within and proximate to zone 13 , the weight percent being based on the weight of the fourth mixture's fuel component. Optionally, ME is ≧75.0 wt. %, e.g., ≧95.0 wt. %, such as ≧99.0 wt. %. Optionally, the mixer distributor has a pressure drop during mixing of the fuel and oxidant that is ≦0.3 bar (absolute), e.g., ≦0.1 bar, such as ≦0.05 bar. Optionally, the mixer distributor has a pressure drop during oxidation and pyrolysis stages that is ≦50%, such as ≦20%, e.g. ≦10% of the overall pressure drop in the reactor (zones 1 , 13 , and 7 ) during these stages.
For the mixer-distributor of the invention, the mixing-distributing zone's volume is primarily determined by the thicknesses of the perforated plates (specified above) and the inter-plate spacings. When the mixer comprises plates of approximately the same cross-section, cross-sectional area, thickness, perimeter (P) and total orifice surface area (A h ), the inter-plate spacings are generally in the range of 0.25S B to 5.0S B , where S B equals A h divided by P. Optionally, inter-plate spacing is in the range of 0.05·D p and 0.50·D p , such as in the range of 0.05·D p and 0.20·D p . Optionally, plate to bed spacings (S z1 , S z7 ) are between 100% and 300%, e.g., between 100% and 200% of the inter plate spacings. Optionally, L=T+I, where T is the total of the plate thicknesses (each plate thickness being as specified above) and I is the total spacing, which is the sum of the inter-plate and plate-to-bed spacings. Optionally, the total spacing is divided equally among the inter-plate and plate-to-bed spaces in the mixing-distribution zone, e.g., in a three-plate mixer, the spacing between plates 1 and 2 and between plates 2 and 3 and S z1 and S z7 are each equal to 0.25*I. Optionally, the plates of the mixer-distributor are approximately centered in zone 13 , e.g., the distance S z7 between the upstream plate of the mixer-distributor and the downstream end of the regenerative material in first reactor 7 is substantially the same as distance S z1 between the downstream plate of the mixer-distributor and the upstream end of the regenerative material in second reactor 1 .
Besides being effective for fuel-oxidant mixing, the mixer-distributor is effective for the substantially uniform distribution of gas flow in directions perpendicular to the average flow direction of fuel and oxidant in zone 13 . The term “substantially uniformly-distribution” refers to uniformity of axial gas velocity over the cross-sectional area that separates the mixer-distributor (zone 13 ) from zone 1 or zone 7 . The axial direction is the direction perpendicular to the plane that divides the mixing zone 13 from either zone 1 or zone 7 . Typically the axial direction is parallel to the common central axis, and in Cartesian coordinates is referred to herein as the “z” direction. Each element of cross-sectional area within the dividing plane can be evaluated for associated axial velocity, either by computational fluid dynamics or by experimental measurement. Substantially uniformly-distributed means that the flow Maldistribution value “MD” is ≦15.0%, e.g., ≦10.0%, such as ≦5.0%, wherein MD is equal to the (i) standard deviation of the axial velocity ( σ v z ) divided by (ii) the mean axial velocity in the plane defined by the mixer-distributor's cross-section proximate to the downstream end of the mixing-distributing zone (|<v z >|), expressed as a percent. σ v z is equal to the square root of the variance of v z , the variance and |<v z >| being determined by measuring axial velocity at least 100 points of approximately equal spacing; the points being located on a plane within the mixer-distributor's cross-section that is proximate to the downstream end of the mixing-distributing zone. Optionally, the mixer-distributor also provides for a uniform temperature distribution proximate to the downstream end of the mixing-distributing zone, as characterized by a Temperature Variability (“TV”), with TV≦60.0° C., e.g., in the range of from 1.0° C. to 60.0° C., such as in the range of from 10.0° C. to 50.0° C. TV is equal to the standard deviation of the gas temperature measured over the mixer-distributor's cross-sectional area in a plane proximate to the downstream end of the mixing-distributing zone. The standard deviation of the gas temperature is equal to the square root of the gas temperature's variance, the variance being determined by measuring temperature at least 100 points (locations) of approximately equal spacing; the points being located on a plane within the mixer-distributor's cross-section that is proximate to the downstream end of the mixing-distributing zone. The term “variance” is as defined in Experiments in Modern Physics, Chapter 10: “The Elements of the Theory of Statistics”, p. 446; Academic Press 1966.
It should be appreciated that the mixer-distributor can be substantially symmetric about the cross-section of plate 2 , e.g., functioning substantially similar for reverse flow operation of the first and second mixtures. Although the mixing function of the mixer-distributor does not play a process role in the reverse flow, the configuration of the mixer-distributor in the reverse flow direction benefits from the substantially unimpeded flow of the first and second mixtures (e.g., a low pressure drop across zone 13 ) while providing for relatively uniformly distributed first and second mixture as it exits the mixer-distributor zone 13 toward recuperator zone 7 .
Parameters such as (i) MD, (ii) TV, (iii) the amount of the fourth mixture's fuel component that is consumed via oxidation by the fourth mixture's oxidant component in the mixer zone, and (iv) the mixer-distributor pressure drop during operation depend at least in part on the mass flow rates of the fuel and oxidant. Although the single mixer-distributor, as described in FIGS. 3A-C and 4 can be used as the sole mixing element within the reverse-flow reactor, it can be desirable to utilize a plurality of such mixer-distributors operating in parallel in order to lessen the fraction of reactor-system volume handled by each of the mixer-distributors, particularly in very large reactor systems. Such a plurality of mixer-distributors is described in U.S. Pat. No. 7,815,873, for example. When extended sets of multiple-parallel segments (with respect to the average flow direction of the fourth mixture) are utilized, each of these segments can comprise, e.g., individual mixer-distributors such as those described above and illustrated in FIGS. 3A-C , 4 , and 5 . For example, individual mixer-distributors sections can be shaped with hexagonal external cross-sectional shape for ease of packing in large arrays.
The mixer-distributor is generally constructed or fabricated of a material able to withstand the high temperatures expected to be experienced in the reaction zone. In an embodiment, the mixer-distributor means is constructed from a material able to withstand temperatures ≧1.20×10 3 ° C., e.g., ≧1.60×10 3 ° C., such as ≧2.0×10 3 ° C. For example, one or more of plates 1 - 3 , optional plates 4 and 5 , optional swirling means, and optional baffle plate 6 are constructed ceramic material(s) such as one or more of silica, alumina, zirconia, silicon carbide, silicon nitride, yttria, etc.
Use in a Reactor System
In an embodiment, the mixer-distributor is utilized in a reverse-flow, regenerative bed reactor system. Such reactor systems can be used for operating (e.g., continuously or semi-continuously) a two-step asymmetric cycle reaction, e.g., a cycle comprising an oxidation (regeneration) step and an endothermic reaction step. Suitable reactor systems include, those described in U.S. Patent App. Pub. No. 2007/0191664, U.S. Pat. No. 7,491,250; U.S. Patent App. Ser. No. 61/349,464; and U.S. Patent App. Pub. Nos. 2007/0144940 and 2008/0142409, all of which are incorporated by reference herein in their entirety. An example of a representative reverse-flow, regenerative bed reactor system is depicted in FIG. 1 . The term “reactor” means equipment and combinations thereof for chemical conversion, including reactor combinations and systems such as disclosed in U.S. Pat. No. 7,943,808, which is incorporated by reference herein in its entirety. The reactor comprises three zones, a first (“recuperator”) zone 7 , a mixing-distributing zone 13 , and a second (“reaction”) zone 16 . Zones 16 and 7 each comprises at least one regenerative bed, where the term “regenerative bed” means a reactor bed comprising material that is effective in storing and transferring heat. In an embodiment, the regenerative beds comprise bedding or packing material, such as glass or ceramic beads or pheres, metal beads or spheres, ceramic (including, e.g., alumina, silica, yttria, zirconia, etc., and mixtures thereof) or metal honeycomb materials, ceramic tubes, extruded monoliths, catalysts, etc. The first and second reactor beds can be of the same shape and size, but this is not required. In this embodiment, zone 13 comprises the mixer-distributor of FIGS. 3A-C and 4 , including optional components such as plates 3 , 4 , and 5 ; swirling means; baffle plate 6 , etc.
In an embodiment, at least one of the first or second reactor beds comprises a honeycomb monolith. Honeycomb monoliths include, e.g., extruded porous structures such as those that are used for automotive catalytic converters, etc. The term “honeycomb” means a a solid body having multiple flow paths or passages located therein, the honeycomb passages having a passage length (T), passage cross-sectional area (A), an effective passage diameter (D psg , with D psg =2(A/π) 1/2 ), and a T/D psg ratio ≧1.0, such as ≧10.0. The analogous T/D psg for for the mixer-distributor's orifices is <1.0, this feature being useful for distinguishing the mixer-distributor's plates from the honeycombs of zones 16 and 7 . Although honeycombs can have a circular cross-section, this is not required, and the term is not limited to any particular monolithic structure, shape, or topology. In embodiments where a honeycomb monolith is used the honeycomb monolith is believed to enable low pressure loss transference while providing contact time and heat transfer.
The reactor system is heated for the endothermic, e.g., pyrolysis, step with at least a portion of the heat utilized by the endothermic being provided by the oxidation step. In the embodiment of FIG. 1 , the heating can occur in exothermic reaction region 2063 , which can be located, e.g., between a first point proximate to the downstream end 11 of first reactor 7 and a second point proximate to the downstream end 18 of second reactor 16 ; “downstream” in this case being with respect to the average flow of fuel and oxidant.
At least one mixer-distributor is located in zone 13 , e.g., the mixer-distributor of FIG. 5 . A first reactant, comprising, e.g., fuel, and a second reactant, comprising, e.g., an oxidant such as air, are generally conducted to a location proximate to the upstream side of plate 5 (“upstream” being with respect to the average flow direction of the first and second reactants in the reactor). The first and second reactants are distributed and mixed, e.g., as they traverse plate 5 's orifices, and the combined reactants together with any oxidation products are then conducted through the orifices of plates 1 - 4 , for further mixing, distribution, and reaction of the second reactant's components.
The oxidation step generally results in a high temperature zone in the reactor system's temperature profile, at least a portion of the high temperature zone being located in region 2063 . The temperature profile is illustrated schematically as a Gaussian-like shape in FIG. 1 .
The oxidation step thus includes the following features: (i) heating of zone 13 and the second reactor 16 by transferring at least a portion of the heat of combustion to the reactor system downstream of the end 11 of the first reactor 7 and (ii) by transferring at least a portion of the sensible heat recovered by the first and second reactants in an upstream region of the first reactor (upstream with respect to the flow of the first and second reactants) toward one or more of the downstream region of the first reactor, region 13 , or the second reactor in order to thermally regenerate the reactor system. Accordingly, at least a segment of each of the right-hand and left-hand edges of the temperature profile translate downstream from their starting locations at the beginning of the oxidation step, as shown in FIG. 1 by arrows 21 and 8 After the reactor system is heated, the flow-direction of gases traversing the reactor system is reversed for the pyrolysis step.
The Pyrolysis Step
At the start of the pyrolysis step, reaction zone 16 is at an elevated temperature and the recuperator zone 7 is at a lower temperature than the reaction zone 16 . A first mixture (the reactant feed, e.g., a pyrolysis feed) is introduced via a conduit 2046 , into a first end 18 of the reaction zone 16 .
In the embodiment of FIG. 1 , the pyrolysis region 2064 can be located, e.g., between a first point proximate to the upstream end 18 of the second reactor 16 and a second point proximate to the downstream end 9 of first reactor 7 , “upstream” and “downstream” being with respect to the average flow of the first mixture. It should be appreciated that the invention can be practiced without precisely defining (a) the boundaries of regions 2063 and 2064 . Although region 2063 (the exothermic reaction region) is at least partially coextensive with pyrolysis region 2064 , the upstream end of region 2063 (“upstream” with respect to the average flow of the fourth mixture) is generally proximate to the location where sufficient fuel and oxidant combine to produce an exothermic reaction. The downstream (with respect to the average flow of the first mixture) end of region 2063 is generally proximate to the downstream end of second reactor 16 as shown in FIG. 1 , though this is not required, and in at least one embodiment the downstream end of region 2063 is located further downstream, e.g., in conduit 2066 . In at least one of the embodiments represented by FIG. 1 , the upstream end of pyrolysis region 2064 is proximate to the upstream end 18 of the second reactor 16 . The downstream end of pyrolysis region 2064 can be, e.g., proximate to the downstream end 9 of the first reactor 7 . Optionally, a major amount (e.g., >50%) of the heat abstracted from the reactor system during the pyrolysis occurs in the portion of region 2064 that is coextensive with region 2063 .
The pyrolysis can be conducted, e.g., under high-severity pyrolysis conditions. The term “high-severity” with respect to the pyrolysis of a feed comprising hydrocarbon, e.g., the first mixture, means pyrolysis operating conditions resulting in the conversion to acetylene of ≧10.0 wt. % of the feed's hydrocarbon based on the total weight of hydrocarbon in the feed. The pyrolysis can be conducted under thermal pyrolysis conditions, e.g., high-severity thermal pyrolysis conditions, where the term “thermal pyrolysis” means <50.0% of the heat utilized by the pyrolysis is provided by (a) exothermically reacting the pyrolysis feed, e.g., by exothermically reacting an oxidant with hydrocarbon and/or hydrogen of the first mixture and/or (b) contacting the pyrolysis feed with the gaseous and/or liquid products of combustion to heat the pyrolysis feed. The term “thermal pyrolysis reactor” means a pyrolysis reactor wherein ≧50.0% of the heat utilized by the pyrolysis is provided by heat transfer from reactor components, e.g., solid surfaces associated with the reactor such as tubulars or bed materials; optionally ≧80.0% or ≧90.0% of the heat utilized by the pyrolysis is provided by such heat transfer.
In an embodiment, the first mixture is conducted to the pyrolysis stage 206 wherein it is exposed to a temperature ≧1.20×10 3 ° C. under thermal pyrolysis conditions, e.g., high-severity, thermal pyrolysis conditions, to convert at least a portion of the first mixture to the second mixture. At least a portion of the second mixture, e.g., a vapor-phase portion which comprises C 2 unsaturates, molecular hydrogen, and saturated hydrocarbon, is conducted away from the reactor system, e.g., to an optional upgrading stage. A portion of the second mixture's combustible non-volatile portion can remain in the stage 206 , e.g., as a deposit.
In an embodiment, the pyrolysis is conducted under high-severity thermal pyrolysis conditions, e.g., by exposing the first mixture to a temperature in the range of about 1.40×10 3 ° C. to about 2.30×10 3 ° C., e.g., in the range of about 1.45×10 3 ° C. to about 1.80×10 3 ° C. at a residence time ≦about 0.3 seconds, e.g., ≦0.05 seconds. Optionally, the residence time is ≦0.05 seconds, such as ≦0.02 seconds. Optionally, ≧25.0 wt. % (such as of the ≧50.0 wt. % or ≧75.0 wt. %) of the first mixture achieves a peak pyrolysis gas temperature ≧1.40×10 3 ° C., e.g., in the range of about 1.50×10 3 ° C. to about 1.675×10 3 ° C., based on the weight of the first mixture. The term “peak pyrolysis gas temperature” means the maximum temperature achieved by the bulk pyrolysis stream gases as they travel through the pyrolysis reactor (e.g., cracking region or radiant region). One skilled in the art will appreciate that temperatures immediately proximate to a partition may be higher, and may, in some infinitesimal boundary layer, actually approach the solid temperature. However, the pyrolysis temperature referred to herein should be considered a bulk gas temperature, which is a temperature that could be measured by a device (such as a thermocouple) that is not in contact with the solid material.
In an embodiment, the pyrolysis is conducted for a time duration (t 1 ) sufficient for exposing ≧50.0 wt. %, e.g., ≧75.0 wt. %, such as ≧90.0 wt. % of the first mixture (based on the weight of the first mixture) to pyrolysis conditions for a residence time ≦about 0.3 seconds, e.g., ≦0.05 seconds. In an embodiment, t 1 is ≦20.0 seconds, e.g., ≦10.0 seconds, such as ≦5.0 seconds. Optionally, t 1 is in the range of 0.1 seconds to 10.0 seconds.
In an embodiment, the pyrolysis step includes one or more of the following conditions: the first mixture achieves a peak pyrolysis gas temperature ≧1.40×10 3 ° C., e.g., in the range of 1.45×10 3 ° C. to 2.20×10 3 ° C., such as, 1.50×10 3 ° C. to 1.90×10 3 ° C., or 1.60×10 3 ° C. to 1.70×10 3 ° C.; a total pressure ≧1.0 bar (absolute), e.g., in the range of 1.0 bar to about 15 bar, such as in the range of 2.0 bar to 10.0 bar; a residence time (during high severity conditions) ≦0.1 seconds, e.g., ≦5.0×10 −2 seconds, such as ≦5.0×10 −3 seconds and/or a t 1 in the range of 0.1 seconds to 10.0 seconds.
Continuing with reference to FIG. 1 , the first mixture abstracts heat from the reactor system, resulting in the derivation of the second mixture from the first by pyrolysis. As this step proceeds, a shift in the temperature profile occurs, e.g., a shift in at least a segment of the right-hand edge of the temperature profile (the segment being schematically encompassed by a dashed boundary for the purpose of illustration), the direction of the shift being indicated by arrow 17 . The amount of this shift can be influenced by, e.g., the heat transfer properties of the reactor system. At least a portion of the second mixture, e.g., the portion in the vapor phase, is conducted from the downstream end 20 of the second reactor to the upstream end 11 of the first reactor 7 , and is conducted away from the first reactor via conduit 2065 proximate to the downstream end 9 , as shown. At the start of pyrolysis, the first reactor 7 has a temperature less than that of the second reactor 16 . As the second mixture traverses the first reactor 7 , the second mixture is quenched (e.g., cooled) to a temperature approaching that of the downstream end 9 of the first reactor. As the second mixture is quenched in the first reactor 7 , at least a segment of the left-hand edge of the temperature profile moves toward the downstream end 9 of the first reactor 7 as indicated by arrow 19 , the segment being schematically encompassed by a dashed boundary for the purpose of illustration. In at least one of the embodiments represented by FIG. 1 , the upstream end of pyrolysis region 2064 is proximate to the upstream end 18 of the second reactor 16 . The downstream end of pyrolysis region 2064 is proximate to the downstream end 9 of the first reactor 7 . Since the quenching heats the first reactor 7 , the oxidation step optionally includes cooling the first reactor, e.g., to shift at least a segment of the left-hand edge of the temperature profile away from end 9 of the first reactor 7 , as illustrated schematically by arrow 8 in FIG. 1 .
A first mixture useful in the pyrolysis step, and a second mixture that can be derived from the first mixture, will now be described in more detail.
First Mixture
In an embodiment, the first mixture comprises hydrocarbon and optionally further comprises molecular hydrogen and/or diluent. The type of hydrocarbon is not critical; e.g., the hydrocarbon can even compromise hydrocarbon non-volatiles, including those that are not in the gas phase at the temperature, pressure, and composition conditions subsisting at the inlet to the pyrolysis reactor.
In an embodiment, the hydrocarbon is derived from one or more source materials, e.g., natural gas, petroleum, etc. Examples of source materials comprising hydrocarbon include one or more of hydrocarbon derived from petroleum; syngas (a mixture comprising carbon monoxide and hydrogen); methane; methane-containing streams, such as coal bed methane, biogas, associated gas, natural gas, and mixtures or components thereof; synthetic crudes; shale oils; or hydrocarbon streams derived from plant or animal matter. Suitable hydrocarbon source materials include those described in U.S. Pat. Nos. 7,943,808 and 7,544,852, which are incorporated by reference herein in their entirety.
The first mixture can be derived from the source material(s) upstream of the pyrolysis, but this is not required. For example, in one embodiment hydrocarbon derived from a first source material and hydrogen derived from a second source material are conducted separately to the pyrolysis reactor, the hydrocarbon and hydrogen being combined to produce the first mixture proximate to (e.g., within) the pyrolysis reactor. Optionally, the hydrocarbon has (or is derived from one or more source materials having), e.g., a hydrogen content in the range of 6.0 wt. % to 25.0 wt. %, 8.0 wt. % to 20.0 wt. % (e.g., not natural gas), or 20.0 wt. % to 25.0 wt. % (e.g., natural gas).
Optionally, the first mixture further comprises diluent, e.g., ≧1.0 wt. % of diluent based on the weight of the first mixture. Suitable diluents (which can be a diluent mixture) include one or more of molecular hydrogen, oxygenate, such as water, nitrogen (N 2 ), hydrogen sulfide, C 4+ mercaptans, amines, mixtures of amines, non-hydrocarbon non-volatiles (whether combustible or not) including refractory inorganics, such as refractory oxygenates, inert gas (including inert gas mixtures), etc. In an embodiment, the first mixture comprises ≦10.0 wt. % diluent.
In an embodiment, the first mixture comprises a total amount of non-combustible non-volatiles (e.g., ash; ASTM D-189), from all sources, ≦2.0 parts per million weight (ppmw) based on the weight of the first mixture, e.g., ≦1.0 ppmw. Optionally, the first mixture comprises a total amount of combustible non-volatiles (e.g., tar, asphaltenes, ASTM D-6560) in the first mixture, from all sources, ≦5 wt. % based on the weight of the first of the hydrocarbon in the first mixture, e.g., ≦1.0 wt. %, such as ≦100.0 ppmw or ≦10.0 ppmw, provided the presence of the combustible non-volatiles does not result in ≧2.0 ppmw (e.g., ≧1.0 ppmw) based on the weight of the second mixture.
In an embodiment, the first mixture has one or more of the following properties: (i) at least 15.0 wt. % of the molecular hydrogen in the first mixture (based on the total weight of molecular hydrogen in the first mixture) is molecular hydrogen derived from the second mixture or one or more products thereof. In another embodiment, the first mixture comprises ≧50.0 ppm sulfur based on the weight of the first mixture.
In an embodiment, the first mixture has the following composition: (a) the first mixture comprises (i) ≧10.0 wt. % of hydrocarbon, e.g., ≧25.0 wt. % hydrocarbon and (ii) ≧1.0 wt. % molecular hydrogen, e.g., ≧15.0 wt. % molecular hydrogen, the weight percents being based on the weight of the first mixture and/or (b) the first mixture comprises (i) ≧0.10 mole % of hydrocarbon, e.g., in the range of 0.10 mole % to 90.0 mole % and (ii) ≧0.01 mole % of molecular hydrogen, e.g., in the range of 0.01 mole % to 90.0 mole %, the mole percents being per mole of the first mixture.
Second Mixture
In an embodiment, the second mixture comprises ≧1.0 wt. % of unsaturates and ≧1.0 wt. % of combustible non-volatiles, based on the weight of the second mixture. Optionally, the second mixture further comprises one or more of hydrogen, methane, ethane, or diluent, and optionally further comprises benzene, paraffin (iso-, cyclo-, and/or normal) having ≧3 carbon atoms, etc.
In an embodiment, a third mixture is derived from the second mixture in one or more upgrading/treatment stages, e.g., by separating from the second mixture one or more of hydrogen, methane, and/or combustible non-volatiles. In another embodiment, the third mixture comprises, consists essentially of, or consists of the second mixture, e.g., that part of the second mixture which is in the vapor phase at the downstream end of a regenerative, reverse-flow pyrolysis reactor.
Producing the second mixture from the first mixture by pyrolysis is an endothermic reaction, which withdraws heat from the pyrolysis reactor system. When the reactor system is cycled continuously or semi-continuously, at least a portion of the heat utilized by the pyrolysis steps is replaced by heat produced during the intervening oxidation steps, with one cycle of the reactor system comprising an oxidation step and a pyrolysis step. The oxidation (regeneration) step will now be described in more detail with reference to FIGS. 1 and 2 .
The Oxidation Step
Regeneration entails transferring heat from (i) the mixing-distributing zone 13 and optionally (ii) from recuperator zone 7 to the reaction zone 16 , to thermally regenerate the reactor system for a pyrolysis step. A fourth mixture (the regeneration gas, e.g., the combustion gas) is produced proximate to zone 13 by mixing and distributing the first and second reactants, e.g., fuel and oxidant. The first reactant (comprising fuel) is conducted to recuperator zone 7 via conduit 305 . The second reactant (comprising oxidant) is conducted to recuperator zone 7 via conduit 3051 . Optionally, first distribution means (D 1 ) can be utilized for conducting the first reactant into fuel passages 14 and/or second distributor means (e.g., plenum 206 B) can be utilized for conducting the second reactant into oxidant passages 15 , the fuel passages and oxidant passages being located within recuperator zone 7 . Since the fuel and oxidant passages are substantially independent flow paths (e.g., there is little or no fluid communication, one with the other) mixing of the first and second reactants generally does not occur until zone 13 , where the first and second reactants combine to produce the fourth mixture. A fifth mixture, derived from at least in part from the oxidation of at least a portion of the fourth mixture's fuel component, is conducted away from the reactor system via plenum 206 A and conduit 2066 .
The first and second reactants exit recuperator zone 7 , and combine in zone 13 to produce the fourth mixture. By keeping these reactants substantially separated upstream of zone 13 , upstream with respect to the average flow of the first and second reactants, the heat (i) conveyed from the recuperator zone toward the regenerator zone and (ii) released during the exothermic reaction is directed towards regions of the reactor system that are beneficial for the pyrolysis. The term “substantially separated”, means that ≦50.0 wt. %, e.g., ≦25.0 wt. %, of the first reactant's fuel component is consumed by reaction with the second reactant's oxidant component upstream of zone 13 , based on the weight of the first reactant's fuel component conveyed to distributor (D 1 ). In this manner, the majority of the heat release from the reaction of the fourth mixture's fuel and oxidant components will not take place until the gases have exited from the recuperator zone 7 into mixing-distributing zone 13 . Optionally, passages 14 and 15 of recuperator zone 7 are oriented substantially parallel to the direction of the average flow of fuel and oxidant. Such passages are provided, for example, by regenerative beds comprised of extruded honeycomb monoliths, packing, stacked layers of corrugated materials, etc. When the recuperator zone 7 includes a packed bed or foam monolith materials (not shown), these bed materials should be configured to keep the first and second reactants substantially separated. Radial dispersion and the amount of first-reactant-second reactant mixing can be measured and/or calculated as described in U.S. Pat. No. 7,815,873.
FIG. 2 schematically shows another view of the reactor system and its flow distributors. Distributor D 1 (utilized to direct fuel into passages 14 ) has a plurality of apertures (shown as small arrows in FIGS. 1 and 2 ) aligned with passages 14 . Plenum 206 B provides for the flow of oxidant into passages 15 . The apertures of D 1 can be aligned with, but are not sealed to, the openings of channel 15 . By not “sealing” D 1 's apertures to passages 14 , passages 14 and 15 may be utilized during the reverse flow or reaction cycle, increasing the overall efficiency of the system. This “open” distributor (D 1 ) can also be utilized in embodiment comprising multiple pyrolysis reactor systems, e.g., those where the reactor/recuperator beds move (e.g., rotate) in and out of a gas stream. FIG. 2A schematically shows an end view of reactor 7 , with the shaded regions representing the approximate locations of distributor D 1 (utilized to direct fuel into passages 14 ).
During the oxidation step, the first and second reactants transit the recuperator zone 7 , abstracting at least a portion of the heat, stored in the recuperator zone from previous pyrolysis steps. The heated reactants are then introduced into zone 13 as shown in FIGS. 1 and 2 . The mixer-distributor means produces the fourth mixtures by combining the first and second reactants emerging from recuperator zone 7 , and then distributes the fourth mixture, particularly the fourth mixture's fuel and oxidant components to achieve a more uniform oxidation over the reactor system's cross-section upstream of reaction zone 16 . The fourth mixture's oxidant component reacts with (i) the fourth mixture's fuel component and (ii) combustible non-volatiles located in the reactor system to produce a fifth mixture, which can further comprise unreacted fourth mixture, if any.
In this embodiment, the total duration of an oxidation step t 2 is greater than or equal to the time needed for the second reactor to abstract sufficient heat from the oxidation to accomplish the pyrolysis step. In other words, the oxidation step is conducted for a time duration greater than or equal to a time sufficient to displace the peak of the temperature profile toward the second reactor sufficient to heat the pyrolysis region 2064 for exposing the first mixture to a temperature ≧1.20×10 3 ° C. during the pyrolysis step. The value of t 2 depends on factors such as the geometry of the reactors utilized in stage 206 , the heat transfer characteristics of the reactors and the materials from which the reactors are made, and the amount of heat needed by the pyrolysis step. Optionally, the t 2 is in the range of 0.1 seconds to 10.0 seconds. In an embodiment, t 2 is greater than or equal to the time needed to heat the pyrolysis region 2063 to a temperature sufficient for exposing ≧50.0 wt. % of the first mixture, e.g., ≧75.0 wt. %, such as ≧90.0 wt. % to a temperature ≧1.20×10 3 ° C. during the pyrolysis step; the weight percents being based on the weight of the first mixture. In an embodiment, t 2 is ≦20.0 seconds, e.g., ≦10.0 seconds, such as ≦5.0 seconds.
It is understood that flow control means (e.g., one or more of valves, rotating reactor beds, check valves, louvers, flow restrictors, timing systems, etc.) can be used to control gas flow, actuation, timing, and to alternate physical beds between the flow systems for the first, second, fourth, and fifth mixtures, and the optional purge gas when used between one or more of the steps. Suitable spargers, distributors, etc., are disclosed in U.S. Pat. No. 7,815,873; which is incorporated by reference herein in its entirety. Although the invention is compatible with the use of conventional spargers, distributors, plenums, etc., in stage 206 , the invention is not limited thereto. The fourth and fifth mixture will now be described in more detail.
Fourth Mixture
The fourth mixture comprises first and second reactants. The first reactant can comprise, e.g., ≧10.0 wt. % fuel based on the weight of the first reactant, such as ≧50.0 wt. % fuel. The second reactant can comprise, e.g., ≧10.0 wt. % oxidant based on the weight of the second reactant, such as ≧20.0 wt. % oxidant. The fuel can be derived from the same source materials utilized for deriving the first mixture. Optionally, the fuel has substantially the same composition as the first mixture.
The fuel and oxidant can be the same as those disclosed in U.S. Pat. No. 7,943,808. Optionally, the fuel is derived from, comprises, consists essentially of, or consists of one or more of hydrogen, CO, methane, methane containing streams such as coal bed methane, biogas, associated gas, natural gas, and mixtures or components thereof, etc. Exothermically reacting the first reactant's fuel component and the second reactant's oxidant component provides at least a portion of the heat utilized by the pyrolysis, e.g., ≧50%, such as ≧75%, or ≧95% of the heat utilized by the pyrolysis. Additional heat, when needed, can be provided to the regenerative, reverse-flow pyrolysis reactor by, e.g., a burner or furnace, e.g., a furnace external to the reactor but in thermal communication therewith. The first and second reactants mix within the regenerative, reverse-flow pyrolysis reactor to produce the fourth mixture, the fuel and oxidant then reacting, e.g., by an oxidation reaction such as combustion, as the fourth mixture traverses at least a portion of the pyrolysis reactor. The first reactant comprises fuel, e.g., molecular hydrogen, synthesis gas (mixtures of CO and H 2 ), or hydrocarbon, such as ≧10.0 wt. % hydrocarbon (including mixtures thereof), or ≧50.0 wt. % hydrocarbon, or ≧90.0 wt. % hydrocarbon based on the weight of the first reactant. The second reactant comprises oxidant, e.g., molecular oxygen.
The amount of oxidant in the second reactant and the relative amounts of first and second reactants utilized to produce the fourth mixture can be specified in terms of the amount of oxidant in the second reactant needed for oxidizing combustible non-volatiles in the reactor system (“X”) and the amount needed for the substantially stoichiometric oxidation of the first reactant's fuel component (“Y”). In an embodiment, the total amount of oxidant in the fourth mixture is Z(X+Y), wherein Z is in the range of 0.8 to 10.0, e.g., in the range of 1.0 to 3.0, and the amounts X and Y are on a molar basis. When Z>1.0, the excess oxidant can be utilized, e.g., for moderating the reaction temperature during the oxidation step as disclosed in U.S. Pat. No. 7,943,808, and/or for conveying heat within the reactor system.
The fourth mixture is generally produced in the mixing-distribution zone located downstream of the first reactor's channels. Although the fourth mixture is defined as the combination of first reactant and second reactant, the combined stream generally includes species resulting from the oxidation of combustible non-volatiles located in the first reactor's passages. Optionally, the combined stream further comprises species resulting from reaction of the first and second reactants in one or more of the first reactor's channels, or locations upstream thereof, as a result of commingling of the first and second reactants. Generally, the amount of commingling is small, as disclosed in U.S. Pat. No. 7,943,808. It can be beneficial for the amount of oxidant in the fourth mixture to exceed that needed to oxidize substantially all of the fourth mixture's fuel component, e.g., for (i) oxidizing combustible non-volatiles located in regions of the reactor system downstream of the first reactor's channels, (ii) moderating the temperature during the oxidation of the fourth mixture's fuel component, and/or (iii) transferring heat within regions of the reactor system downstream of the mixing-distribution zone. The desired amount of excess oxygen can be provided by increasing the relative amount of oxidant in the second reactant and/or by increasing the relative amount of second reactant in the fourth mixture.
Optionally, the fourth mixture further comprises diluent, e.g., ≧1.0 wt. % of diluent based on the weight of the fourth mixture. Suitable diluents (which can be a diluent mixture) include one or more of, e.g., oxygenate (water, carbon dioxide, etc.), non-combustible species such as molecular nitrogen (N 2 ), and fuel impurities such as hydrogen sulfide. In an embodiment, the fourth mixture comprises ≦96.0 wt. % diluent, e.g., in the range of 50.0 wt. % to 95.0 wt. % diluent, based on the weight of the fourth mixture. In an embodiment, diluent is provided to the fourth mixture as a component of the second reactant. For example, the second reactant can comprise 60.0 mole % to 95.0 mole % diluent and 5.0 mole % to 30.0 mole % oxidant per mole of the second reactant, such as when the second reactant is air. Optionally, the second reactant has a mass ratio of diluent to oxidant in the range of 0.5 to 20.0, e.g., in the range of 4.0 to 12.0. It can be beneficial for the second reactant (and fourth mixture) to further comprise diluent, e.g., for (i) moderating the temperature during the oxidation of the fourth mixture's fuel component and/or transferring heat within the reactor system.
In an embodiment, the first reactant comprises ≧90.0 wt. % molecular hydrogen based on the weight of the first reactant and the second reactant comprises ≧90.0 wt. % air based on the weight of the second reactant. When the second reactor comprises ≧90.0 wt. % air based on the weight of the second reactant, a fourth mixture produced from these can comprise, e.g., ≧1.0 wt. % molecular oxygen, e.g., in the range of 5.0 wt. % to 25.0 wt. %, such as 7.0 wt. % to 15.0 wt. %, ≧0.1 wt. % fuel, e.g., in the range of 0.2 wt. % to 5.0 wt. %, the weight percents being based on the weight of the fourth mixture, with the balance of the fourth mixture being molecular nitrogen diluent, e.g., ≧50.0 wt. % diluent, such as in the range of 60.0 wt. % to 94.50 wt. % diluent based on the weight of the fourth mixture.
In an embodiment, the mass flow rate of the fourth mixture during the oxidation step is ≧1.0 times the flow rate of the first mixture during the pyrolysis step, e.g., in the range of 1.0 to 6.0 times the flow rate of the first mixture during the pyrolysis step.
Fifth Mixture
The fifth mixture comprises (i) products derived from the exothermic reaction of the fourth mixture's fuel and oxidant with each other and with the combustible non-volatiles within the reactor, optionally (ii) diluent, when diluent is present in the fourth mixture, and/or (iii) unreacted fuel and oxidant. When the exothermic reaction of the fuel and oxidant involves hydrocarbon combustion, or when a diluent is present in the fourth mixture (such as N 2 or H 2 S), the fifth mixture can comprise carbon dioxide, and can further comprise sulfur oxides, nitrogen oxides, etc.
EXAMPLES
Example 1
A regenerative, reverse-flow pyrolysis reactor is provided with a mixer-distributor of the invention. The reactor is cylindrically-symmetric and has the dimensions specified in the following table, with reference to FIGS. 3A-3C and FIG. 4 . The mixer-distributor has five circular plates of substantially the same diameter and thickness, these values also being specified in table 1. The plates' orifices are circular holes with number and arrangement as shown in FIG. 4 , and having the specified diameter and spacings.
TABLE 1
Dimension
Value
Bed Diameter
mm
95.3
Total Reactor Length
mm
609
Recuperator Bed (first
mm
209
reactor) Length
Pyrolysis Bed (second
mm
314
reactor) Length
Mixer Region Length
mm
86.4
Plate-to-Plate Spacing
mm
9.53
Plate 5-to-Bed Spacing
mm
10.8
Plate 4-to-Bed Spacing
mm
10.8
Plate Thickness
mm
5.41
Plate 4, 5 Hole Size
mm
12.9
Plate 1, 3 Hole Size
mm
19.6
Plate 2 Hole Size
mm
52.1
δ 2
deg
−15
δ 1
deg
15
Plate 4, 5 R1
mm
20.1
Plate 4, 5 R2
mm
40.0
Plate 1, 3 R1
mm
29.2
During an oxidation step, a fourth mixture was produced downstream of the reactor's recuperator zone, the fourth mixture comprising 1.2 wt. % molecular hydrogen (fuel), 12.7 wt. % molecular oxygen (oxidant), and 86.1 wt. % nitrogen (diluent) based on the weight of the fourth mixture. Fuel rate is 2.96×10 −4 Kg/s and oxidant rate is 0.024 Kg/s, at a feed pressure of 1.172 bar (absolute; 2.3 psig). The mixer-distributor mixes the first and second reactants to produce the fourth mixtures and distributes the fourth mixture to provide a relatively uniform gas flow through the second reactor, which is in the form of a honeycomb monolith. Plates 3 and 4 are used to redistribute the flow uniformly over the honeycomb monolith. Reducing hole overlap between plates 1 and 2 is observed to improve mixing of the fuel and oxidant. The mixer-distributor has a pressure drop of 0.8 bar, and MD of 5.7%, a TV of 70%, and an ME of 98.3 wt. %.
Example 2
A regenerative, reverse-flow reactor is provided, the reactor being the same as that of Example 1 except that a mixer distributor of U.S. Pat. No. 7,815,873, FIG. 6, was substituted for the mixer-distributor of the example. A combustion step was operated using the same feed and conditions as specified in Example 1. The mixer distributor has an MD equal to about 9.2%.
Discussion
Utilizing the mixer-distributor of the invention (Example 1) provides improved mixing-distribution performance over the mixer of the prior art (Example 2), indicating that the distribution of the fourth mixture is improved, leading to a more efficient oxidation step. In particular, the mixer-distributor of Example 1 has (i) a significantly reduced MD and (ii) pressure drop, TV, and ME values that are the same as or better than those of the mixer-distributor of Example 2. | The invention relates mixer/flow distributors and their use, e.g., in regenerative reactors. The invention encompasses a process and apparatus for controlling oxidation, e.g., for thermally regenerating a reactor, such as a regenerative, reverse-flow reactor. | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to agricultural harvesting equipment, and more particularly to an improved wheat harvesting combine.
Combines have for many years been used to harvest wheat. They may be either of the self-propelled type in which the propulsion unit is a part of the combine, or may be designed to be pulled by a tractor or other vehicle. In any event, combines typically include a sickle which has a multiplicity of reciprocating cutting teeth, and a header which defines a trough and a rotary shaft or auger which collects the cut wheat and feeds it to a central or laterally offset feeder. The feeder then feeds the wheat rearwardly through a threshing/separating system which separates the grain from the rest of the plant, and the grain is accumulated in a grain tank.
Pulled combines are typically of cantilevered construction with the feeder housing being positioned at one lateral end of the header. This is desirable, if not necessary, because the pulling vehicle should be disposed to one side of the combine so that the wheat which is being harvested is not matted down by the wheels of such vehicle. This cantilevered construction normally limits the length of the header and therefore the width of swathe which is being cut. Self-propelled combines, which centrally support the header, permit wider swathes to be cut but are far more expensive than pulled combines because an entire propulsion system, including an operation station, must be included.
Another important design consideration with combines is the extent to which the header follows undulations in the terrain which is being traversed. Some combines are designed exclusively for use on relatively flat terrain. Other combines, commonly know as hillside combines, are designed to follow substantial changes in the terrain. Such combines, which are typically self-propelled, are normally provided with a so-called circle which is mounted adjacent the feeder housing to permit relative rotation between the feeder housing and the header. Because the feeder housing is, with such self-propelled combines, centrally located rather than at one lateral end or the other of the header, upward movement of either end results in downward movement at the other end. This is undesirable because it results in uneven cutting.
Some types of combines, such as belt pick up types, include a wheel adjacent each end of the header. This is possible with a pick up combine because it is merely picking up the wheat which has been cut. With direct-cut headers which simultaneously cut and pick up the wheat, such wheels would not be permissible because one of the wheels would be rolling over wheat which has not yet been cut.
There have been many prior attempts to design header support systems which permit the length of the header to be increased. One such design is presented in U.S. Pat. No. 4,359,854 to Witzel. This patent discloses an outrigger-type support having a plurality of wheels behind the header of a pulled combine. Another Witzel patent, U.S. Pat. No. 4,329,833, discloses a self-propelled combine in which the feeder housing is centrally disposed on the header, and a plurality of outrigger-type wheeled supports are provided on each side of the propulsion unit. In both Witzel patents the header is permitted to swivel upwardly and downwardly along a horizontal, longitudinal axis as the header passes over undulations in the contour of the ground. Both headers are also mounted to swivel about a vertical axis so that they may be swung out of the way for roadway travel. However, the means by which the header is mounted to the outrigger-type supports it is not adequately disclosed and does not appear to permit the vertical movement which would normally take place as the header is pivoting. The combines disclosed in the Witzel patents are also relatively complicated, resulting in substantial initial and operating costs.
Yet another drawback of the combine disclosed in U.S. Pat. No. 4,359,854 is that a driven chute must be disposed between the header and the feeder to convey wheat therebetween. This presents an obstruction in the flow of wheat and requires additional energy input.
It is therefore an object of the present invention to overcome the drawbacks and limitations of the prior art proposals. More specifically, the invention has as its objects the following: (1) to provide a pulled combine having a header which is as wide as those of the self-propelled type, thereby dramatically increasing the rate at which wheat can be harvested; (2) to develop a combine which is suitable to operate on either flat or hilly terrain; (3) the provision of a pulled combine which has sufficient structural integrity that it may be used with rough terrain without maintenance problems; (4) to provide a combine which permits the header to be pivoted with respect to the feeder housing without adverse stress occurring in the components thereof; (5) to provide a combine in which wheat is permitted to flow directly from the header into the feeder housing without requiring the use of any intermediate drive means; and (6) to develop a hillside, pulled combine which is easily adjustable to different cutting heights without requiring complex drive cylinder arrangements, cables, or the like.
SUMMARY OF THE INVENTION
The present invention achieves the above objects by providing a combine of the type having a laterally extending header with proximal and distal ends, and a wheeled feeder/separator assembly extending rearwardly from the header. The improvement comprises circle means mounted to a rearward facing portion of the inner header end for facilitating pivoting of the header along a longitudinal axis extending through the center of the circle means, a laterally extending frame member pivotally mounted to the feeder/separator assembly along a frame member pivot axis, and a header support wheel disposed laterally outwardly or distally from the frame member pivot axis for supporting the weight of the header. The frame member pivot axis normally extends at a rearwardly converging angle with respect to the longitudinal axis. The invention normally also includes vertical pivot means defining a substantially vertical pivot axis disposed adjacent an outer or distal end of the circle means to permit the header to pivot along a vertical axis as the combine passes over undulations in the terrain which cause the frame member to pivot upwardly and downwardly with respect to the feeder/separator assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the present invention;
FIG. 2 is an exploded, perspective view showing the auger, the feeder assembly, and some of the components of the circle of the embodiment of FIG. 1;
FIG. 3 is a top plan view of the embodiment of FIG. 1; and
FIG. 4 is a fragmentary perspective view of the outrigger wheel, the remote end of the header, and associated structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
One form which the invention may take is depicted in FIGS. 1-4 and is identified generally with the numeral 10. The depicted combine 10 is of the pulled, direct-cut type and is conventional in design in many respects. The novel features are associated with the support assembly 12 for header 14. Header 14 is convention except that it is longer than conventional headers for pull-type combines. This increased length feature is shown in FIG. 3 with the length x being the normal header length of a pulled combine, which is typically no more than about 18 feet. The length y is shown as the increased length which may be added with the present invention, so that x+y may be as much as 30 feet or more.
Header 14 includes a conventional rotatable reel 16, a reciprocating sickle 18, and a rotating auger 20 disposed within a trough 22 to rotate on an auger axis 15a. As with all pulled combines, a drive shaft 24 is provided which extends rearwardly from the pulling vehicle (not shown), and is mounted to a hitch 26 and a hitch frame assembly 28. Driving power from the pulling vehicle is thus provided to auger 20, the feeder assembly 32, the thresher (not shown), and the separator 36, all of which are of well known design. The feeder assembly, thresher and separator will sometimes be referred to herein as the feeder/separator assembly. Disposed above separator 36 is a grain tank 44 with an unloader tube 46 extending therefrom.
The unique aspects of combine 10 will now be discussed. As mentioned above, the novelty of this design centers around support assembly 12. This assembly permits header 14 to be longer than previously possible with pulled combines. Support assembly 12 cooperates with a circle 48 which allows header 14 to pivot along a longitudinal circle axis 50 as header 14 undulates with changes in the terrain. Circle 48 is of conventional design and is commonly used in International Harvester's 1470 series self-propelled hillside combines. The use of a circle with the present type of pulled combine is, however, novel.
A vertical pivot joint 52 is provided adjacent a distal end of circle 48. This joint is necessary in the depicted embodiment for purposes which will become evident as this description continues.
Support assembly 12 includes a first frame member 54 and a second frame member 56, both of which extend outwardly or distally from the housing of separator 36 toward an outrigger wheel 58. First and second frame members 54 and 56 intersect at an outrigger frame post 60 which extends upwardly to provide an appropriate mounting for header 14. A header mounting arm 62 extends obliquely from the upper end of outrigger frame post 60, to adjacent the lower portion of header 14, and is provided with a first and a second universal joints 64 and 66. First universal joint 64 of header mounting arm 62 may be positioned in any one of three vertical positions depending upon which of three positioning holes 63 is used to pin the joint to frame post 60. A header mounting chain 68, sometimes referred to herein as post/header connection means, also normally extends between this distal end of header 14 and first universal joint 64, in order to provide additional stability to the header. In the depicted embodiment, header mounting chain 68 is provided with a turnbuckle 70 which can adjust the tension of the chain. In some applications, header 14 may be sufficiently rigid that header mounting chain 68 may be deleted.
A header mounting arm hydraulic cylinder 72 extends between a point below outrigger frame post 60 and header mounting arm 62 to permit the height of header 14 to be varied. The operation of this cylinder is coordinated with the operation of a similar cylinder, to be described below, which is disposed at the opposite or proximal end of header 14.
Outrigger wheel 58 is normally somewhat lighter than drive wheels 30, but is typically the same diameter, and is provided with a suitable axle, bearings, and the like. The axis of rotation of outrigger wheel 58 extends parallel to header 14 and is identified in FIG. 3 with the numeral 74.
The proximal ends of first and second frame members 54 and 56 mount to the housing of separator 36 at a pair of pivot joints 76 and 78. These pivot joints 76 and 78 are aligned along a pivot joint axis 80 which extends at an angle which is rearwardly converging on longitudinal pivot axis 50.
Circle 48 and feeder assembly 32 will now be described. FIG. 2 shows feeder assembly 32 in a position in which the assembly has been pivoted open along vertical pivot joint 52 to an extent far greater than would be possible during normal operation of combine 10, in order to show the appropriate structure. FIG. 2 also shows the adjacent end of auger 20 in an opened or exploded view in order to permit a discussion of that structure.
Following the path of the wheat through the apparatus, the rotation of auger 20 and its vanes 84 causes wheat to collect in a space 82 below the auger. The continuing rotation of auger 20 feeds the wheat into the feed assembly 32. Normally, feed assembly 32 is engaged by header 14 by a feeder assembly lip 86 which fits under, and is engaged by, an engagement edge 88 extending along the upper edge of header 14. During use, a pair of latches 87 (only one of which shows in FIG. 2) engage a corresponding pair of grommets 85 to hold the assembly together.
The wheat is then engaged by a conventional feeder beater 90. Circle 48 is, in the depicted embodiment, positioned immediately downstream of feeder beater 90 and is designed to permit relative rotation along pivot point 95 between a forward portion 91 of feeder assembly 32 and a rearward portion 93 thereof, vertical pivot joint 52 being mounted between such portions. To permit relative rotation between such portions, first and second circle members 92 and 94 are provided with a circle roller 96 which is mounted to circle member 92 but which rolls along second circle member 94 as in conventional designs.
Extending rearwardly from circle assembly 48 is a vertical thrust absorbing rail 98 which cooperates with an idler roller 100 to absorb downward thrusts on forward portion 91 or upward thrusts upon rearward portion 93 of feeder assembly 32. Because pivoting along vertical pivot joint 52 normally does not exceed 5 degrees, idler roller 100 is in contact at all times with vertical thrust rail 98.
To prevent leakage of wheat from feeder assembly 32, a first and a second seal plate 102 and 104 extend rearwardly from the forward portion 91, and which are engaged by complementing guide plates 106. Each guide plate 106 is provided with an adjacent but spaced seal bolt 108. Referring to FIG. 2, guide plates 106 appear in the foreground of the rearward portion 93, each guide plate being aligned with a seal plate slot 110. An upper seal plate slot is disposed behind vertical thrust absorbing tail 98, and this slot is aligned with the upper foreground seal bolt which is identified with the numeral 106 because it does not include a separate guide plate. The other seal bolts 108, which appear only in the background of FIG. 2, are spaced from guide plates 106 so that first and second seal plates 102 and 104 can fit between the seal bolts and the guide plates at the seal plate slots. Again, because the opening of feeder assembly 32 is normally not more than about 5 degrees, the guide plate/seal bolt assembly always engages the seal plates to ensure alignment thereof and to prevent leakage of wheat therefrom.
The lower portion of feeder assembly 32 is sealed by a belt-type seal 112 which is comprised of flexible belting and which complements an upwardly sloping floor 114 disposed below a cutter roll 116 in the rearward portion 93 of feeder assembly 32. Thus, as the wheat passes through feeder beater 90, it is directed across belt seal 112 and onto sloping floor 114 where it comes into contact with cutter roll 116. Because of the sliding but sealed fit between belt seal 112 and sloping floor 114, there is no leakage of wheat even if the pivoting along vertical pivot joint 52 is as much as 5 degrees.
The limited pivoting is not visible from the exterior of circle 48, but is shown diagrammatically in FIG. 3 at the remote end of header 14 with pivoted auger axis line 15b.
The rearward portion 93 is provided with a frame 118 which ensures the structural integrity of this portion of the feeder assembly. A forward and downwardly extending lip 120 covers most of the gap between the forward and rearward portions of feeder assembly 32.
FIG. 2 also shows a feeder assembly hydraulic cylinder 122 which extends between rearward portion 93 and the housing of separator 36 to control the pivoting between these two members. A conventional pivot connection is provided between feeder assembly 32 and the housing separator 36 but is not depicted and will not be described. Such pivoting takes place along a transversely extending axis 124 which is parallel to the axis 74 of rotation of outrigger wheel 58. Feeder assembly hydraulic cylinder 122 is hydraulically in series with header mounting arm hydraulic cylinder 72 so that the two ends of header 14 will be maintained at the same level at all times regardless of loading differentials between the two ends of header 14.
OPERATION OF THE DEPICTED EMBODIMENT
The operation of the depicted embodiment will now be described. As mentioned above, the actual harvesting operation is conventional with the exception of the capabilities which combine 10 has in moving over uneven terrain. Therefore, this discussion will center upon the operation of the various components as the combine moves over such terrain.
As combine 10 is being pulled and wheat harvesting operations are taking place, header 14 is permitted to pivot along longitudinally extending circle axis 50 because rotation between the first and second circle members 92 and 94 is permitted. This rotation will have no effect upon the wheat which is being directed from auger 20 through feeder assembly 32 and into separator 36 because of the various seals disposed within and adjacent to the feeder assembly. The rotational displacement of header 14 is controlled by the pivoting along pivot axis 80 of first and second frame member pivot joints 76 and 78. Pivot joint axis 80 does not coincide with circle axis 50 so as support assembly 12 pivots upwardly and downwardly, the distal end of the support assembly moves toward separator 36 at a faster rate than does the distal end of header 14. This causes angulation in header mounting arm 62 (looking at the arm in plan such as in FIG. 3) which tends to draw the distal end of header 14 slightly rearwardly. Such movement is permitted by vertical pivot joint 52. The pivoted position is shown by pivoted auger axis line 15b in FIG. 3.
The extent of pivoting is reduced by the angulation between pivot joint axis 80 and longitudinal circle axis 50. In fact, it may be possible to eliminate vertical pivot joint 52 altogether, with the angulation between axes 50 and 80 such that upward or downward pivoting of support assembly 12 causes the distal end of the support assembly to move forwardly at the same rate that angulation (in plan) is developing in header mounting arm 62. This embodiment has not been depicted but would be identical to combine 10 except for the deletion of vertical pivot joint 52 and the structure associated with circle 48 which facilitates such pivoting movement.
In addition to providing the pivot capability described above, combine 10 also permits the height of header 14 to be adjusted through the use of header mounting arm hydraulic cylinder 72 and feeder assembly hydraulic cylinder 122. To raise or lower header 14, these cylinders are either extended or retracted through a common hydraulic line so that the header will always extend parallel to the ground.
The invention thus provides a combine which is versatile in that it is suitable for use on hilly terrain, and has far greater harvesting capabilities than prior art pulled combines because of the wide swathe which can be cut. The swathe is comparable to that provided by self-propelled combines, at substantially less cost. The combine is quite simple and therefore is inexpensive to construct and maintain.
In an alternate embodiment of the invention which has not been depicted, the pivot joint axis 80 is precisely parallel to circle axis 50. However, this is not the preferred embodiment because the degree of pivoting along vertical pivot joint 52 will be more exaggerated than with combine 10.
Other changes and modifications to the preferred embodiment described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is, therefore, intended that such changes and modifications be covered by the following claims. | The present invention provides a combine of the type having a laterally extending header with proximal and distal ends, and a wheel/feeder separator assembly extending rearwardly from the header. The invention includes the following components: a circle mounted to the header adjacent a rearward facing portion of the proximal end for facilitating pivoting of the header along a longitudinal axis extending through the center of the circle; a frame member pivotally mounted to and extending laterally outwardly from the feeder/separator assembly to support the distal header end, the frame member defining a frame member pivot axis extending at a rearwardly converging angle with respect to the longitudinal axis; and a header support wheel rotatably mounted to the frame member and disposed laterally outwardly from the frame member pivot axis for supporting weight from the header. | 0 |
TECHNICAL FIELD
This invention relates to improved polyester fibers, and more particularly to spinning such fibers from modified polymers that combine polyethylene oxide and tetraethyl silicate additives with poly(ethylene terephthalate) to give commercial quality polyester manufacturing (i.e. spinning) processes and fibers having both significantly enhanced dye rates, that retain surprisingly good color stability to light and wash cycles, and good pilling performance.
BACKGROUND OF INVENTION
Polyester apparel fibers are for the most part produced from a standard homopolymer polyethylene terephthalate base using either dimethyl terephthalate/diethylene glycol or terephthalic acid/diethylene glycol as starting materials. The commercial need to minimize polymer discontinuities during the polymer spinning operation has mostly required that the polymer have a sufficientdegree of polymerization (18 to 24 LRV) to provide a spinnable melt. Polymer viscosities between 800 and 1800 poise have generally been employed, because spinning discontinuities have been more numerous at lower viscosity, een below 1000 poise. Additives such as the branching agents described by Mead and Reese in U.S. Pat. No. 3,335,211 and by Vaginay in U.S. Pat. No. 3,576,773 can be added to the lower chain length materials in order to raise polymer viscosity and allow commercial spinning performance. "By trifunctional or tetrafunctional branching agent" herein is meant trifunctional and tetra functional branching agents of the type disclosed by Mead and Reese and by Vaginay.
Fibers made in the above manners generally have at least one and sometimes two undesirable properties. For instance, fibers produced with high LRV polymer give knit and woven fabrics and garments that form undesirable "pills" from surface abrasion during normal wear and require high energy superatmospheric and/or enviromentally undesirable chemical additives to the dye systems to effect the coloration desired and necessary for commerce. Fibers and fabrics produced from reduced chain length polymers by the incorporation of melt viscosity enhancing additives that may give reduced "pill" fabrics and garments, still require the use of the high energy dye or chemical systems to achieve coloration.
Historically, polymer modifications (e.g. polyethylene oxides, adipates, glutarates, etc.) have been used to enhance the dye rate and styling versatility in carpet and rug fibers of high dpf (typically 6 and above dpf, denier per filament) and allow easy atmospheric dyeing. Dye enhancing polymer modifications have been practically limited to less sensitive non-textile end uses because the modifiers depress polymer viscosity and can lead to excessive spinning discontinuities that render spinning processes non-commercial and fabrics non-saleable because of excessive defects. The normal route to correcting spinning performance has been to increase the degree of polymerization(LRV). This has had the unwanted effect of increasing fiber strength and subsequently fabric pilling.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided a novel combination of polymer modifier and tetraethyl silicate (TES) that provides polymers of reduced molecular weight to give surprisingly high, commercial quality, spinning without excessive spinning discontinuities and defects. The resulting spun and drawn fibers provide fabrics with significantly enhanced dye rates, good light and wash dye stability, good pilling characteristics and without fiber defects that are normally associated with polymer modification and poor spinning performance. The polymer modifier is polyethylene oxide (PEO) of molecular weight in the range 200-2000. Spinning viscosity is maintained at greater than 800 poise by adjusting the tetraethyl silicate level in the range 0.05 to 3 mole percent of the final polymer.
Accordingly, there are provided textile fibers of about 0.5 to 2 denier per filament, consisting essentially of poly(ethylene terephthalate) polymer of relative viscosity (LRV) in the range about 9 to 17, modified to provide a Relative Dye Rate (RDR) of at least 150 by containing about 1.5 to about 5% by weight of polyethylene oxide of molecular weight in the range about 200 to about 2000, and modified to provide spinning continuity by having been polymerized with presence of a trifunctional or tetrafunctional viscosity builder in amount about 0.05 to 0.3 mole percent.
This novel combination in a polyester fiber of low dpf, of polymer modification, relative viscosity and tetraethyl silicate to control polymer molecular weight and melt viscosity, provides textile fibers and fabrics that dye faster and with much lower energy than conventional PET. Surprisingly, lightfastness, washfastness and staining properties of the resulting dyed fabrics are excellent. Likewise, the novel combination provides fabrics with good pilling performance.
According to another aspect of this invention, textile fibers of this invention may be made by melt spinning and drawing PET filaments of the correct polymer composition to give the desired dye enhancement and with commercially acceptable spinning vicosity, as shown in the Examples.
The polymer preferably includes a delusterant. Optical brighteners in most cases are advantageous since polymer modifiers tend to cause some discoloration of the polymer. Cross-sections are generally but not limited to round. Fibers are generally cut to staple lengths dependent on the contemplated end use, e.g. 5 to 75 mm. Mixed deniers may be used.
It will be understood that both terms "filament" and "fiber" are used generically herein. While the primary application discussed is staple, it is believed that continuous filament applications in the form of yarn or tow would provide similar dye, and pilling advantages when converted into knit or woven fabrics.
DETAILED DESCRIPTION
The use of tetraethyl silicate in polyester fibers has been described in Mead and Reese U.S. Pat. No. 3,335,211. Mead and Reese do not teach the particular benefits that I have found of tetraethyl silicate with regards to modified polymers that depress polymer melt viscosity. As indicated herein, an essential element of this invention is the selection of a specific combination of polymer modification, polymer viscosity as measured by both LRV and poise, and mole percent tetraethyl silicate that allow commercial quality spinning performance and provide textile fibers of suitably low dpf with significantly enhanced dye rates. Fibers produced in this manner show surprisingly good combinations of properties, including good pilling performance, and both good dye lightfastness and washfastness stability.
Polyethylene terephthalate containing polyethylene glycol has already been disclosed in the art, e.g. by Snyder in U.S. Pat. No. 2,744,087 and by DeMartino in U.S. Pat. No. 4,666,454, the disclosures of which are hereby incorporated herein by reference. Similarly, the disclosures of Vail U.S. Pat. No. 3,816,486, and Hancock et.al. U.S. Pat. No. 4,704,329 are hereby incorporated herein by reference to disclose the various processing techniques for preparing drawn annealed and drawn relaxed fibers, and various polymers, compositions and cross-sections of filaments that may be produced according to invention.
The addition of PEO is used to increase the dyeability and the commercial value of the fiber. A molecular weight of 600 was used because it was convenient, but may vary from about 200 to about 2000.
As indicated above, each of the elements of the present invention, namely, the selected polyethylene terephthalate polymer, PEO modifier, tetraethyl silicate melt viscosity enhancer and the apparel deniers have been used separately for various textile applications but have not, so far as I know, been used in the present combination for this purpose.
The invention is further illustrated in the following Examples. The PEO was of molecular weight 600. The T107 and T40A fibers used for comparative purposes were prior art "pill resistant" fibers that are presently commercially available from Du Pont, and are of homopolymer PET, without PEO. The relative viscosity of the polymer was measured essentially as described in Hancock et. al. U.S. Pat. No. 4,704,329, col. 9, lines 6-11, but on a solution obtained by dissolving 0.40 grams of fiber in 5.0 ml of solvent. The relative dye rate (RDR) was measured by subjecting the samples and referenced control samples to common dye conditions, in an agitated, temperature controlled dye apparatus using normal Merpol and Avitone surfactants at 1.0 g/L each, a 4.15 pH buffer to control solution acidity and Blue GLF dye at 0.037 g/g of fiber. No carrier was employed. After a 1 deg C per minute rise from 60C the fibers were dyed for 40 min at 95C. Pads were rinsed and measured for Reflectance on a Hunter Model D25D2M Colorimeter. Reflectances were converted to K/S values for each specimen via the equation:
K/S=(1-(R/100)) 2/(2R/100)
and the Relative Dye Rate (RDR) was calculated by the equation:
RDR=(K/S test)/(K/S control)×100
Colorfastness to light was measured on dyed knit fabric by subjecting the specimens to Xenon-Arc light as prescribed in AATCC Test Method 16E-1982. The samples after being subjected to the light source for 40 hours were evaluated for color loss by reference to the Gray Scale for Color Change. Washfastness and Staining were determined on a different portion of the same dyed fabric by procedures described in AATCC Test Method 61-1985 and specifically in the IIA Test for commercial and home launderings. As with the Lightfastness Test, the Washfastness specimens were graded with reference to the Gray Scale for Color Change. On this scale a grade of 5 indicates negligible or no change. A grade of 4 indicates a color change equivalent to Gray Scale Step 4, a grade of 3 indicates equivalence to a Gray Scale Step 3, and so forth; the severity of the change being greatest at Gray Scale Step 1. Staining was assessed by rating the transfer of dye to a #10 multifiber fabric composed of Dacron®, nylon, Orlon®, Wool and acetate. The multifiber fabrics were pinned to the sample specimens during the IIA Wast Test. The staining was rated in a manner similar to that used for Lightfastness and Washfastness, but against the AATCC Chromatic Transference Scale. Again, the grades ranged from 5 to 1 with a 5 grade indicating no or negligible staining.
EXAMPLES
Example 1
A series of fiber items were produced with conventional unmodified PET (Item #1) and modified PET (Items #2 and #3) according to the invention. All were delustered with 0.10 weight percent Ti02. Item #2 was modified with 2% PEO, and Item #3 with 4.3 weight % PEO. All fibers used a specified combination of tetraethyl silicate and LRV to provide polymer with sufficient viscosity for good spinning.The polymers were melt spun at 282°-283° C. and 80 pounds per hour through a spinneret with 900 round capillaries. The spinning unit was fitted with polymer rheological equipment and polymer melt viscosity was measured for each item. The filaments were collected at 1800 yards per minute on bobbins using a commercial winding device. Bobbins of each item were combined in a creel and drawn on a test apparatus having (A) the capability of drawing in 1 or 2 stages in saturated liquid sprays, crimping and hot air relaxing, or (B) the capability of drawing in 1 or 2 stages in saturated liquid sprays and annealing in saturated steam as described in U.S. Pat. No. 4,639,347, crimping and hot air drying. The fibers were tested for tensile properties, relative dye rate and flex life properties. Flex life is an indicator of fabric pilling. The results are shown in Table 1.
TABLE 1__________________________________________________________________________ Item Number 1 2 3 CONTROL INVENTION INVENTION__________________________________________________________________________Polymer LRV 11.2 12.2 14.6PEO 600, wt. % None 2 4.3Polymer Viscosity 1080 963 871Mole % TES 0.21 0.21 0.21 1A 1B 2A 2B 3A 3BDraw Process Relax Anneal Relax Anneal Relax AnnealTotal Draw Ratio 3.13 3.07 3.17 3.48 3.17 3.53Anneal psig -- 150 -- 150 -- 150Dryer Temp C. 120 75 120 76 120 75Denier/Filament 1.33 1.28 1.33 1.14 1.34 1.16Tenacity 3.7 4.0 3.7 4.7 3.6 3.7Elongation % 34 22 40 14 44 19Relative Dye Rate 104 123 156 189 290 416Flex Life 789 604 763 1079 1010 1452__________________________________________________________________________
Example 2
The items in Table 1 were cut to 11/2" fiber length and blended with 50% combed cotton and processed on commercial textile machinery, ring spun to 28/1 cc yarns, and knit into 22 cut jersey fabrics on a commercial machine. At the same time and on the same equipment, yarn samples from commercially available "pill resistant" 1.5-T107 and 1.2-T40A fibers were prepared. The knit fabrics were atmospherically dyed and subjected to the standard Random Tumble Pill Test, essentially as described in ASTM D3512, with ratings at the intervals indicated herein. The Flex Life data in Table 1 predicts and RTPT data in Table 2 demonstrates pill performance comparable to the current commercially available pill resistant fibers.
Some of the fabrics were also subjected to standard Lightfastness, Washfastness and Staining tests. For this procedure the fabrics were prescoured, dyed without any carrier in an Ahiba dye apparatus at 212F for 60 minutes with 0.50% Intrasil Red FTS dyestuff, and post scoured. The samples were then evaluated for Lightfastness, Washfastness and Staining by the AATCC Methods referenced above. The data of Table 2 demonstrates dye stability properties comparable to commercially acceptable fabrics. This is very surprising in view of the extensive polymer modification by the PEO (and tetraethyl silicate).
TABLE 2__________________________________________________________________________ CONTROLS INVENTION PRIOR ARTItem Number 1A 1B 2A 2B 3A 3B T-40A T-107__________________________________________________________________________Modified Polymer No No Yes Yes Yes Yes No NoPolymer LRV 11.2 11.2 12.2 12.2 14.6 14.6 14.0 11.5PEO, wt. % 0.0 0.0 2.0 2.0 4.3 4.3 0.0 0.0Mole % TES 0.21 0.21 0.21 0.21 0.21 0.21 0.10 0.16Pill Rating@ 15 min. 3.0 -- 3.5 3.8 3.8 3.2 3.5 3.3@ 30 min. 1.5 -- 1.5 1.3 2.3 1.5 1.5 1.8@ 60 min. 1.5 -- 1.7 1.0 1.3 1.2 1.2 1.3Lightfastness -- -- 4-3 -- -- 4-3 -- 3-2Washfastness -- -- 4 -- -- 5 -- 5-4Staining -- -- 3 -- -- 4-3 -- 3-2__________________________________________________________________________
Example 3
The invention was further demonstrated for a range of 1.0 to 1.5 dpf textile products on commercial equipment. Similarly to Example 1, polymer was modified with 2.0 to 2.2 weight percent 600 MW PEO, and polymerized to 15.9 LRV in the presence of 0.11 mole % tetraethyl silicate additive. Polymer viscosity was measured for each item by the use of suitable rheology equipment and is given in Table 3. Spinning performance of all items was commercially acceptable. Indeed, spinning interruptions were very few, and were comparable to those experienced during spinning of control fibers from polymer without any PEO, as can be seen from Table 3. Spun supplies of between 840 and 953 spinning ends were 2 stage draw and annealed per the teaching of U.S. Pat. No. 4,639,347, crimped and dried to give fibers with enhanced dye rate properties, as compared with control fibers prepared from polymer without any PEO, as shown in Table 3.
TABLE 3__________________________________________________________________________ RELAXED ANNEALEDITEM 4 5 6 CONTROL CONTROL__________________________________________________________________________Polymer LRV 15.9 15.9 15.9 11.4 14.0Weight Percent PEO 2.0 2.2 2.2 None NoneMole Percent TES 0.11 0.11 0.11 0.16 0.10Polymer Temperature, C. 281 281 281 279 280Polymer Viscosity, Poise 1040 1020 1012 842 1089Spinning Interruptions, 0.15 0.06 0.00 0.04 0.14per 1000 poundsDeniser per Filament 1.12 1.27 1.44 1.50 1.17Tenacity 5.1 5.3 5.1 3.8 4.8Elongation % 23.1 22.5 22.6 33.2 22.5Dry Heat Shrinkage 5.1 5.3 8.5 6.5 5.5RDR vs Anealed Control 2.11X 2.19X 2.15X 0.92X --__________________________________________________________________________
Example 4
One and one-half inch cut fibers from items 5 and 6 of Table 3 and from commercially available "pill resistant" 1.5-T107 and 1.2-T40A were each draw blended to a 50/50 ratio with combed cotton, processed on commercial textile equipment, and then ring spun to 1 cc yarns on commercial textile equipment. The yarns of each item were knit to 22 cut jersey fabric on a commercial knitting machine, dyed and subjected to the Random Tumble Pill Test. The test indicates pill performance comparable to these commercially available "pill resistant" fibers.
______________________________________Item 5 6 T107 T40A______________________________________Pill Rating (of fabrics of yarns of 50/50blends with cotton)@ 15 min. 3.8 3.0 3.8 3.5@ 30 min. 2.2 2.5 2.7 2.2@ 60 min. 1.7 2.0 2.0 1.5______________________________________ | Polyester filaments of 0.5-2 denier per filament from ethylene terephthalate polymers modified both by polyethylene oxide and by tetraethyl silicate to give polymers of commercial spinning viscosities, and textile fibers and fabrics having greatly improved dye rates, good color stability to standard lightfastness and wash cycles and good pilling, when compared to unmodified polyester and polyester/cotton blend fabrics. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to an internal combustion engine with at least one combustion chamber for burning a fuel in timed explosions accompanied by formation of a combustion gas, wherein the combustion chamber is connected with at least one expansion chamber which is separate from the combustion chamber and which has a piston for converting energy of the combustion gas into mechanical energy or work. Further, the invention is directed to a method for operating an internal combustion engine of this type.
2. Description of the Related Art
An engine of the kind mentioned above is known from EP 957 250 A2. The advantage of an engine of this type with separate combustion chamber and expansion chamber is that the conditions for the combustion of the fuel and for the expansion of the combustion gas formed during combustion can be predetermined independently from one another, so that a high degree of efficiency can be achieved. A further improvement in efficiency compared with conventional two-stroke, four-stroke or diesel engines is achieved in this known engine in that, for each explosion stroke, the combustion chamber is filled with a constant, optimal charge of combustible mixture. To control the power output of the engine, the charging of the combustion chamber is not changed; rather, idle strokes are also inserted between working strokes in which the combustible mixture is ignited in the combustion chamber. There is no ignition of the mixture in these idle strokes; the mixture remains unburned in the combustion chamber. In order to make it possible to transmit the drive output of an engine controlled in this manner to a drive shaft, for example, of a wheel in a motor vehicle, relatively complicated steps are necessary in EP 957 250 A2. In an embodiment example, the piston of the expansion chamber is connected with a connecting rod which drives the drive shaft via an automatic transmission which is controlled in accordance with the required output and the required torque. In this regard, there is considerable expenditure on control and, moreover, lateral forces are exerted on the piston by the crankshaft, so that oil lubrication of the piston is required. In another embodiment example in EP 957 250 A2, the piston of the expansion chamber advantageously remains in an idle stroke at its top dead center. A hydraulic transmission device which, again, is relatively complicated is necessary for transmitting the drive output.
OBJECT AND SUMMARY OF THE INVENTION
It is the primary object of the invention to enable simplified transmission of the output of the piston of the expansion chamber to a drive shaft in an internal combustion engine of the type mentioned in the beginning, wherein idle strokes or stroke pauses in which the piston of the expansion chamber remains in its top dead center can be inserted in addition to working strokes in order to control the engine (preferably with constant loading of the combustion chamber) such that efficiency is optimized. This highly complex problem is solved according to the invention in a surprisingly simple manner in that a drive shaft can be driven by the piston of the expansion chamber via a cam drive or cam gear unit having a cam disk and associated thrust member, wherein the thrust member can be lifted from the cam disk for implementing irregular engine cycles independent from a continuous rotation of the cam disk, including a pausing of the piston of the expansion chamber at its top dead center.
Cam gear units have a cam disk with a correspondingly shaped circumferential contour and (as driving or driven element) a thrust member contacting the cam disk. A cam gear unit of this kind enables a simple separation of the piston of the expansion chamber from the drive shaft during an idle stroke or stroke pause when a running face of a cam disk is provided for the thrust member only on one side and the thrust member remains raised from the cam disk during the idle stroke or stroke pause. The thrust member is advantageously formed by the free end of the piston rod which, for this purpose, is advantageously constructed as a roller tappet acting on a cam disk arranged at the drive shaft. The use of a cam disk also makes it possible to operate the internal combustion engine without oil lubrication for the piston (as will be explained in more detail).
For internal combustion engines which do not belong to the generic type because they do not have an expansion chamber that is separate from a combustion chamber but, rather, have a work piston that is arranged directly in the combustion chamber, the use of special cam gear units has already been suggested in particular, for example, in U.S. Pat. No. 5,813,372. However, this cam gear unit is used for other purposes and not to make it possible to add idle strokes between two explosion strokes; idle strokes of this type cannot be carried out at all in this kind of engine. Further, in these internal combustion engines, the thrust members of the cam gear units are positively guided because of the cam disks acting on both sides of the thrust members and it is not possible to raise the thrust member from the cam disk. Since a separate compression stroke must be carried out in these engines, this positive guiding of the thrust rod is required.
In a preferred embodiment example of the invention, a precompressor device which is separated from the combustion chamber is provided for precompression of air to be introduced into the combustion chamber. Using separate precompressor devices in this way in timed internal combustion engines is already known, for example, from DE 32 14 516 A1. In a particularly preferred embodiment example, the piston rod of the piston of the precompressor device is connected with the piston of the expansion chamber by a shared piston rod.
Further, at least one injection nozzle opening into the expansion chamber is advantageously provided for injecting a coolant liquid to introduce an implosion stroke following the explosion stroke. The energy inherent in the combustion gas can be better exploited by an implosion stroke of this kind so that a further increase in efficiency is achieved. The energy guided off in the implosion stroke is advantageously utilized for precompression by transmission to the precompressor device.
Further advantages and details of the invention are explained in the following with reference to an embodiment example of the invention shown in the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic top view of an internal combustion engine according to the invention;
FIG. 2 shows a section along line A—A of FIG. 1;
FIG. 3 shows a partial section along line B—B of FIG. 1;
FIG. 4 shows a partial section along line C—C of FIG. 1;
FIG. 5 shows a schematic view of a cam disk of the cam gear unit; and
FIG. 6 shows a schematic view of an embodiment form in which a plurality of units, each with an expansion chamber and a connecting rod, act on a shared cam disk.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment example of an internal combustion engine according to the invention which is shown schematically has combustion chambers 1 , 1 ′ which are connected, via controllable internal combustion chamber outlet valves 2 , 2 ′, with an expansion chamber 3 which is formed by the cylinder space of a piston-cylinder unit 5 having a piston 4 . An internal combustion engine according to the invention can also have a plurality of expansion chambers which are connected with one or more combustion chambers.
The combustion chambers 1 , 1 ′ are surrounded by thermal insulation 6 in order to prevent heat radiation from the walls 7 of the combustion chambers 1 , 1 ′ as far as possible. Therefore, in continuous operation of the internal combustion engine the walls 7 of the combustion chambers 1 , 1 ′ are heated to very high temperatures above 700° C. The thermal insulation of the combustion chambers could also be carried out in that the combustion chambers themselves are made from a thermally insulating material of corresponding thickness, for example, a ceramic. The fuel is injected directly into the combustion chambers 1 , 1 ′. For this purpose, double nozzles 8 , 8 ′ are provided and are used not only to inject fuel but also serve to inject water. The spray characteristic of the double nozzles 8 , 8 ′ is such that the fuel fans out so that the walls 7 of the combustion chambers 1 , 1 are wetted by fuel as well as possible and over the greatest possible area when fuel is injected. An electromagnetic switching valve 9 is provided for controlling the fuel injection, and a pressure accumulator 10 for fuel in the form of an air vessel which is acted upon by a fuel pump 11 which, in turn, conveys fuel from a tank 12 is connected to this electromagnetic switching valve 9 . The reference switching time for the electromagnetic switching valve 9 is in the range of one millisecond. Such electromagnetic switching valves are known in motor vehicles (for example, K-Jettronic or Common Rail).
Spark plugs 13 , 13 ′ are provided for cold-starting the internal combustion engine. As soon as the walls 7 of the combustion chambers 1 , 1 ′ are sufficiently heated and autoignition of the injected fuel occurs (at temperatures over approximately 600° C.), the spark plugs 13 , 13 ′ are no longer fired. Because of its autoignition, the fuel is finely atomized by the injection nozzles at high pressure and introduced into the combustion chamber only at the moment of ignition. When the individual fuel droplets impinge, they ignite at the burner walls with flame centers around each individual droplet.
Because of the flame center occurring around each individual droplet as a result of the multiple surface ignitions, there is a pronounced knock of the engine, i.e., the combustion proceeds with extreme turbulence and at high speed. In contrast to conventional internal combustion engines in which this effect is extremely undesirable (prevention through antiknock agent and limited compression ratios), this type of combustion is very advantageous in the engine according to the invention since, in particular, the turbulence of the combustion with supersonic gas eddies leads to an intensive mixing of the mixture during burnup. This already makes possible air factors of lambda 1.05 for approximately CO-free and HC-free burnup, wherein values far below the exhaust gas value of an Otto engine with catalytic converter can be achieved. Due to the fact that the gas transfer caused by pressure is faster than the flame speed during bumup, the combustion chamber outlet valve 2 remains closed until complete combustion of the mixture because otherwise unburned mixture reaches the work chamber 3 and no longer ignites therein.
In order to minimize thermal losses in the piston-cylinder unit 5 also as far as possible, the insulation 6 also extends over the cylinder head 14 . In addition, the piston 4 is provided with insulation 15 . Only the cylinder wall 16 is not thermally insulated in order to prevent excessive thermal loading of the piston seal 17 . This piston seal 17 is made of plastic, preferably graphite-Teflon, which is resistant to continuous temperatures up to approximately 250° C. This seal 17 is water-lubricated and one or more coolant water spray nozzles which are arranged in the piston rod 18 and whose function will be described more exactly in the following cause an additional cooling and a lubrication of the piston seal 17 .
In order to reduce NOx emission of the internal combustion engine, water is injected into the combustion chambers 1 , 1 ′ along with the fuel during the explosion stroke. This water injection is likewise carried out via double nozzles 8 , 8 ′. For this purpose, each of the double nozzles 8 , 8 ′ has a central inner nozzle for injecting the fuel and an outer nozzle which surrounds this inner nozzle annularly for injection of water. The nozzle opening of the inner fuel nozzle and the nozzle opening of the water nozzle are closed in pressureless state and only open when these nozzles are acted upon by a high pressure such as is known in conventional diesel nozzles. At its circumferential wall, the outer water nozzle has a water inlet and a water outlet located opposite to the latter, wherein coolant water flows through this water nozzle also in the closed state of its nozzle opening, so that the inner fuel nozzle is also cooled and no fuel can evaporate when the walls 7 of the combustion chambers 1 , 1 ′ are hot but no explosion stroke is carried out and the engine is at rest. The flow of water through the outer water nozzle of the double nozzle 8 , 8 ′ is caused by the pump 19 which pumps water from a storage vessel 20 . An electromagnetic valve 21 is provided in the return of the outer water nozzle of the double nozzle 8 , 8 ′. As soon as this is closed, a pressure builds up in the outer water nozzle of the double nozzle 8 , 8 ′ and water is injected into the combustion chamber 1 , 1 ′. When the valve 21 is open, the water flows back to the storage vessel 20 via the spray head 22 and the air intake head 23 whose function will be described in more detail in the following.
The piston 4 of the expansion chamber 3 is connected with a precompressor device which is formed by a piston-cylinder unit 25 . The piston 24 of this piston-cylinder unit and the piston 4 of the expansion chamber 3 have a shared piston rod 18 . During a downward movement of the piston 4 which is transmitted via the piston rod 18 to a downward movement of the piston 24 , air is sucked into the cylinder space of the piston-cylinder unit 25 via the check valve 26 . The quantity of air sucked in before reaching the bottom dead center of the piston 4 can be changed by means of the throttle 27 which is adjustable via the actuating motor 28 . In a subsequent upward movement of piston 4 and piston 24 of the precompressor unit, which piston 24 is connected to piston 4 , the sucked in air is pressed into the combustion chambers 1 , 1 ′ via the check valves and is precompressed therein.
The energy of the hot combustion gas which is formed in the combustion chambers 1 , 1 ′ and which drives the piston 4 in the expansion chamber 3 is converted into mechanical energy of the drive shaft 32 by means of a cam gear unit 31 which can be driven by the piston 4 . The thrust member 30 of the cam gear unit is formed by the free end of the piston rod 18 of the piston 4 which, in the present embodiment example, forms the shared piston rod of the piston 4 of the expansion chamber and of the piston 24 of the precompressor unit. The thrust member 30 is constructed as a roller tappet, wherein a wheel or a roller 33 is rotatably mounted via a ball bearing at the free end of the piston rod 18 . The thrust member 30 acts on a cam disk 31 arranged at the drive shaft 32 and the piston rod 18 is mounted outside the piston-cylinder unit 5 in a rolling bearing 34 which also receives the lateral forces exerted on the thrust member 30 . Accordingly, no important lateral forces are exerted on the upper part of the piston rod 18 and on the pistons 4 and 24 arranged at the latter, and simple O-shaped plastic seals 35 , 17 , 37 are sufficient for additional supporting and sealing of these parts. Oil lubrication of these parts is not required.
In the shown embodiment example, the cam disk 31 has two symmetrically formed cams 38 along its circumference. The part of the cam disk 31 contacting the roller 33 during the downward movement of the piston 4 forms a first running surface 39 of the cam disk 31 . Further, a second running surface 40 is preferably provided at the cam disk 31 from which the piston 4 can be restored to its top dead center. However, as will be described below, the force exerted on the piston 4 and piston 24 , respectively, via the second running surface 40 and thrust member 30 is reinforced in the present embodiment example of the invention by the force acting on the piston 4 in the implosion stroke and can even be replaced by it.
A work cycle of the embodiment example of an internal combustion engine according to the invention will be described more exactly in the following:
In continuous operation of the internal combustion engine, during which the walls 7 of the combustion chambers 1 , 1 ′ have a high temperature, as was described, the ignition of the fuel injected into the combustion chambers 1 , 1 ′ which are charged with fresh air is carried out by autoignition at the walls 7 . The spark plugs 13 , 13 ′ are utilized for ignition only in the startup phase. The injection and ignition of the fuel is carried out at a point in time shortly before the first running surface 39 reaches the roller 33 . During the next millisecond, the combustion spreads in the combustion chambers 1 , 1 ′ and is essentially concluded when the tip of the cam 38 or the start of the running surface 39 reaches the roller 33 . The time period required for complete combustion depends, among other things, on the utilized fuel, the precompression of the fresh air in the combustion chambers 1 , 1 ′ and the burner shape and is, for example, about 3 milliseconds. Accordingly, in order to determine the correct injection and ignition times, the speed and the angular position of the shaft 32 must be determined by suitable sensors. Before the internal combustion engine is started, the cam disk 31 is brought into a position by the electric motor 41 so that the roller 33 contacts precisely the start of the first running surface 39 in order to ensure the correct rotating direction of the drive shaft 32 when starting. After the start of the internal combustion engine, the electric motor 41 acts as a generator for supplying energy to the electric components of the vehicle and for charging the vehicle battery.
In addition to injecting water into the combustion chambers 1 , 1 ′ during the explosion stroke together with the fuel for reducing NOx emissions, as was already mentioned, additional water is preferably sprayed into the combustion chambers 1 , 1 ′ after complete burnup of the water-fuel mixture at about 1500° C. for further reduction of the temperature of the combustion gas. Accordingly, the temperature of the hot combustion gas is additionally reduced to below 1000° C., preferably to below 900° C.; however, the required temperature of the walls 7 of the combustion chambers 1 , 1 ′ is retained for autoignition of the fuel. Therefore, no change in exergy occurs in the hot combustion gas. But after the expansion, described below, of the gas-vapor mixture in the expansion chamber 3 accompanied by performance of mechanical work, this gas-vapor mixture only has temperatures of less than 300° C. Accordingly, all seals can be formed of maintenance-free plastic and maintenance-intensive stop seals can be dispensed with.
When the roller 33 contacts the start of the running surface 39 and the combustion in the combustion chambers 1 , 1 ′ is essentially completely terminated, the combustion chamber outlet valves 2 , 2 ′ are opened and the hot combustion gas which is under pressure flows into the expansion chamber 3 and propels the piston 4 downward. The piston performs work against the drive shaft 32 via the cam gear 30 , 31 . By suitable selection of the quantity of injected fuel and precompressed fresh air and with corresponding dimensioning of the combustion chambers 1 , 1 ′ in relation to the expansion chamber 3 , the combustion gas has expanded to roughly atmospheric pressure when the piston 4 has reached the bottom dead center UT. The volume of the expansion chamber 3 is essentially greater than, preferably more than twenty-times greater than, the total volume of combustion chambers 1 , 1 ′ communicating with the expansion chamber 3 .
The hot combustion gas preferably flows out of the combustion chambers 1 , 1 ′ into the expansion chamber 3 so as to be throttled. For this purpose, the combustion chamber outlet valves 2 , 2 ′ are opened gradually rather than suddenly with maximum speed. The line cross sections between the combustion chambers 1 , 1 ′ and the expansion chamber 3 can also be relatively small. The advantage in the hot combustion gases flowing out in a throttled manner is the reduced pressure peaks acting on the piston 4 and all parts connected therewith. Since the throttling constitutes a rubbing of the gas, this results in heating of the gas. This increase in the temperature of the expansion gas leads to an increase in its volume and pressure. However, this gas has not yet performed work in the internal combustion engine according to the invention when flowing out of the combustion chambers 1 , 1 ′, so that the exergy of the gas is not changed by this throttling effect, i.e., no losses occur.
The explosion stroke is accordingly terminated and an implosion stroke is subsequently introduced in the present embodiment example of the invention, during which implosion stroke the combustion chambers 1 , 1 ′ are scavenged and refilled and precompression is carried out. For this purpose, the cooling water injection nozzles 42 (a plurality of injection nozzles arranged annularly along the circumference of the piston rod 18 or an individual annular injection nozzle) are triggered by the actuation of the electromagnetic valve 43 . The cooling water injection nozzles 42 are fed from a pressure accumulator 45 in the form of an air vessel which is acted upon by a pump 44 . The pump 44 draws its water from the storage vessel 20 which was already mentioned. The coolant water is sprayed in under high pressure, wherein the spray water jet is fanned out in the circumferential direction of the cylinder wall 16 and is oriented upward at an acute angle relative to the piston 4 . Excess coolant water encountering the cylinder wall 16 can accordingly exit in the circumferentially extending water collecting groove 47 . Due to the fact that coolant liquid is sprayed in, the temperature of the hot explosion gas is reduced suddenly and an underpressure or negative pressure is built up, wherein the pressure in the expansion chamber is approximately 0.2 bar at the start of the implosion stroke. Because of this negative pressure, the piston 4 is pulled upward in the direction of the top dead center OT. The force exerted on it is transmitted via the piston rod 35 to the piston 24 of the precompressor device. The piston 24 moving upward presses the fresh air stored in the cylinder space of the piston-cylinder unit 25 into the combustion chambers 1 , 1 ′ via the check valves 29 , 29 ′, so that the combustion gas is initially purged from the latter and is replaced by fresh air. At the conclusion of the charge exchange, which is also assisted by the negative pressure in the expansion chamber 3 , the combustion chamber outlet valves 2 , 2 ′ are closed and increased pressure is subsequently built up in the combustion chambers 1 , 1 ′. This pressure preferably ranges between 5 bar and 15 bar and is particularly preferably between 7 bar and 11 bar.
The spraying in of coolant liquid via the injection nozzles 42 is carried out only in the first phase of the upward movement of the piston 4 and is stopped before the injected coolant liquid would impinge on the hot cylinder head 14 . The injected coolant liquid also serves to cool the cylinder wall 16 and to lubricate the piston seal 36 .
A spring 48 which pretensions the piston 24 in the direction of its top dead center and is tensioned during the explosion stroke can be provided to reinforce the force exerted on the piston 24 of the precompressor unit by the implosion of the hot combustion gas. The quantity of fresh air with which the piston-cylinder unit 25 is charged during the explosion stroke and which is subsequently pressed into the combustion chambers 1 , 1 ′ is controlled by the choke 27 . In this embodiment example, in which the piston 24 is pretensioned via the spring 48 , the thrust member 30 is normally lifted from the respective second running surface 40 at the cam disk 31 during the implosion stroke. Corresponding to the movement of the piston 4 from the top dead center to the bottom dead center which is faster in the explosion stroke than in the implosion stroke because of the negative pressure from the bottom dead center to the top dead center, the first running surface 39 of the cam disk 31 extends over about 40° to 70° of the circumference of the cam disk, while the second running surface 40 extends over about 110° to 140°. This second running surface 40 is provided here only as a safety device in case no cooling liquid is injected for triggering an implosion stroke due to a fault. The return speed of the piston 24 is measured electronically to regulate the throttle 27 . It must be ensured that piston 24 or piston 4 has been braked precisely to a speed of zero up to the top dead center and, on the other hand, that piston 24 or piston 4 has just reached the top dead center. If an air cushion remained in the cylinder space of the piston-cylinder unit 25 , this would exert a downwardly directed force on this piston 24 immediately at the conclusion of the upward movement of the piston 24 , i.e., in some cases before the opening of the combustion chamber outlet valves 2 , 2 ′ in the subsequent explosion stroke.
In order to minimize the time for damaging heat losses due to convection, the first running surface 39 , 39 ′ is constructed more steeply than the second running surface 40 , 40 ′.
Alternatively, however, the spring 48 can also be dispensed with. In this case, the upward movement of the piston 24 is reinforced by the cam disk 31 according to the standard. A cam disk 31 ′ constructed in a manner corresponding to FIG. 5 is preferred for this purpose. In this case, two cams, each with a first and second running surface 39 ′, 40 ′, are provided. The first running surface 39 ′ again has an angular range of approximately 40° to 70° of the circumference of the cam disk, while the angular range of the second running surface 40 ′ is somewhere between 50° and 80°. The piston 4 or piston 24 is accordingly guided back in a positive or compulsory manner from the bottom dead center UT to the top dead center OT, wherein this process is still, as before, reinforced by the force exerted on the piston 4 by means of the implosion. In order to prevent the connecting rod 30 from lifting off the running surface 40 ′ at low rotational speeds also (for example, at speeds below 30 km/h in motor vehicles), the injection of the coolant water is carried out in a throttled manner at these slow rotational speeds, so that the negative pressure forming in the implosion stroke is built up more gradually. The precompression pressure selected in this case is high enough to brake the return of the piston 24 also at the maximum speed of the engine to the top dead center to zero. Accordingly, there is no longer a need for electronic measurement of the return speed or the associated regulating element in the form of the choke 27 . In the cam disk in FIG. 5, there is a larger area 49 with constant radius between the successive running surfaces 40 ′ and 39 ′ in which the pistons 4 and 24 are at their top dead centers, so that the ignition time for the combustion chambers 1 , 1 ′ receives a certain tolerance period and, in particular, a sufficient period of time is provided for complete adiabatic burnup of the mixture in the combustion chambers 1 , 1 ′. The pause at the top dead center OT can be adjusted over the length of the area 49 depending on the combustion velocity of the utilized fuel.
In principle, it would be conceivable and possible to omit entirely an injection of coolant water for triggering an implosion stroke, wherein pistons 4 and 24 are displaced from their bottom dead center to the top dead center exclusively by the force exerted on the thrust member 30 via the running surface 40 , 40 ′ of the cam disk 31 , 31 ′. Naturally, a certain reduction in efficiency of the internal combustion engine is accordingly taken into account.
On its path from the bottom dead center to the top dead center, the piston 4 of the expansion chamber 3 further compresses the combustion gas which is located in the expansion chamber 3 and which is initially under negative pressure in case coolant liquid is sprayed in. During the movement of the piston 4 from its bottom dead center to the top dead center, the ring 51 of the expansion chamber outlet valve is displaced upward. For this purpose, a plurality of restoring springs 52 acting upward on the ring 51 are provided at the top of the cylinder head 41 along the circumference of the ring 51 (see FIG. 4 ). These restoring springs 52 pull the ring 51 into its upper position in which an annular outlet channel 53 is released when the tappets 55 arranged in the hydraulic cylinders 54 are not under pressure load by the hydraulic liquid. A plurality of hydraulic cylinders 54 are likewise arranged on the top side of the cylinder head 14 along the circumference of the ring 51 . O-rings 56 , 57 which run alongside the ring 51 are used to seal the ring 51 . The seal 67 is provided for sealing the outlet channel 53 in the bottom position of the ring 51 . The ring 51 has a wedge-shaped taper at its lower edge to increase the sealing pressure.
When the ring 51 is displaced into its upper position releasing the outlet channel 53 , the expansion chamber outlet valve 50 is still closed by the O-ring 58 which surrounds the outlet channel 53 on the outer side and forms a check valve. When the pressure in the expansion chamber 3 has increased above atmospheric pressure during the upward movement of the piston 4 in the direction of the top dead center, the O-ring 59 releases the outlet channel 53 and the cooled combustion gas, together with the coolant liquid contained therein, is pressed out in the exhaust pipe line 59 . The exhaust gas-steam mixture is pressed into the spray head 22 through which it is sprayed into the air intake funnel 23 . In so doing, the exhaust gas-steam mixture is mixed with surrounding air by a factor of 1:10 to 1:25 and is suddenly cooled to about 30° C. The cooled water precipitates in the precipitator 60 . The fresh air is sucked in by means of a suction fan 61 arranged downstream. The exhaust gas-cooling air mixture is separated via an exhaust 62 , while the precipitated coolant water is returned to the storage vessel 20 .
When the piston 4 has reached its top dead center, a working stroke of the internal combustion engine is concluded and the combustion chambers 1 , 1 ′ are filled with precompressed fresh air. Depending on the instantaneous output requirement, the next working stroke of the internal combustion engine can either be initiated (by injection of fuel into the combustion chambers 1 , 1 ′) in that the combustion has concluded at a time at which the thrust member 30 has just reached the next first running surface 39 , 39 ′ or a stroke pause of varying length can be inserted. During this stroke pause, the piston 4 of the expansion chamber remains at its top dead center and the thrust element 30 is lifted from the cam disk 31 , while the cams 38 of the cam disk move past the thrust element 30 freely below the latter. The next working stroke of the internal combustion engine is introduced by injecting fuel into the combustion chambers 1 , 1 ′ at a time when the thrust element 30 is located exactly at the start of a first running surface 39 , 39 ′ of the cam disk 31 at the conclusion of combustion when the combustion chamber outlet valves 2 , 2 ′ are opened.
After the internal combustion engine has been stationary for a longer period of time, the above-atmospheric pressure of the fresh air located in the combustion chambers 1 , 1 ′ has evaporated (due to persistent leakage in the valves). In this case, before starting the engine, a precompression of fresh air in the combustion chambers 1 , 1 ′ is carried out by the pump 64 driven by the motor 63 via lines with check valves 66 , 66 ′. Further, the motor 41 brings the cam disk 31 into the correct position in which the roller 33 is located at the start of a first running surface 39 , 39 ′. Subsequently, fuel is injected into the combustion chambers and the mixture is ignited by the spark plugs 13 , 13 ′.
Instead of an individual unit 65 comprising the combustion chambers 1 , 1 ′, expansion chamber 3 with piston 4 , precompressor device and thrust element 30 , it is also possible to provide two or more units of this kind which are controlled in a corresponding relationship to one another and act on the same cam disk or on a plurality of cam disks 31 . For vibration-free running, units of this type are advantageously provided in pairs so as to work in opposite directions. Gas movements and mass movements accordingly cancel each other out. FIG. 6 shows a schematic view of an embodiment example in which four such units 65 act on an individual cam disk.
In the embodiment example shown in the drawing, the cam disk 31 has two cams 38 . In principle, it would also be conceivable and possible to provide one cam 38 or more than two cams 38 of this kind.
In the shown embodiment example, the piston rod 18 is oriented at right angles to the drive shaft 32 , In principle, it would also be conceivable and possible to provide the piston rod 18 and drive shaft 32 with a parallel orientation and to provide the drive shaft 32 with a cam disk which is formed for a thrust element acting in axial direction of the drive shaft 32 .
While the foregoing description and drawings represent the present invention, it will be obvious to those skilled in the art that various changes may be made without departing from the true spirit and scope of the present invention.
REFERENCE NUMBERS
1 , 1 ′ combustion chamber
2 , 2 ′ combustion chamber outlet valve
3 expansion chamber
4 piston
5 piston-cylinder unit
6 thermal insulation
7 wall
8 , 8 ′ double nozzle
9 switching valve
10 pressure accumulator
11 fuel pump
12 tank
— 13 ′ spark plug
14 cylinder head
15 insulation
16 cylinder wall
17 piston seal
18 piston rod
19 pump
20 storage vessel
21 valve
22 spray head
23 air intake funnel
24 piston
25 piston-cylinder unit
26 check valve
27 throttle
28 actuating motor
29 , 29 ′ check valve
30 thrust member
31 cam disk
32 drive shaft
33 roller
34 rolling bearing
35 plastic seal
37 plastic seal
38 cam
39 , 39 ′ first running surface
40 , 40 ′ second running surface
41 electric motor
42 coolant water injection nozzle
43 valve
44 pump
45 pressure accumulator
47 water collecting groove
48 spring
49 area
50 expansion chamber outlet valve
51 ring
52 restoring spring
53 outlet channel
54 hydraulic cylinder
55 tappet
56 O-ring
57 O-ring
58 O-ring
59 exhaust line
60 precipitator
61 suction fan
62 exhaust
63 motor
64 pump
65 unit
66 , 66 ′ check valve
67 seal | The internal combustion engine comprises at least one combustion chamber for burning a fuel in timed explosions accompanied by formation of a combustion gas, at least one expansion chamber which is connected with the combustion chamber and separate from the combustion chamber and which has a piston for converting energy of the combustion gas into mechanical energy or work, and a cam gear unit by which a drive shaft can be driven by the piston and which has a cam disk and associated thrust member, wherein the thrust member can be lifted from the cam disk for carrying out irregular engine cycles independent from a continuous rotation of the cam disk, including a pausing of the piston of the expansion chamber at its top dead center. | 5 |
TECHNICAL FIELD
[0001] This invention relates to a folding closure, such as a folding door or window, having a plurality of hinged panels, all of which are of substantially the same width. In particular, the invention is directed to a folding door or window comprising at least three hinged panels of equal width, of which at least two panels are joined by offset hinges.
BACKGROUND OF THE INVENTION
[0002] Folding doors and windows are a popular building choice, due to their ability to provide clear unimpeded openings in a wall. A typical folding door or window comprises a plurality of hinged panels suspended from one or more carriages which travel along an overhead track. A carriage and a hinge may be combined to form a carrier hinge in which the hinge pin serves to suspend the hinge (and affixed panels) from the carriage, as shown in U.S. Pat. No. 6,618,900.
[0003] The panels may open by folding, in concertina fashion, to one side of the opening. Alternatively, particularly for wide openings, the panels may be formed as two hinged sets which fold to opposite sides of the opening. In both cases, the panels fold open to an orientation in which they are juxtaposed parallel to each other, 90° to the plane of the opening, to minimise the width of the opening they occupy.
[0004] A plan view of a conventional folding door or window 10 is shown schematically in FIG. 1 . The illustrated closure comprises an end or jamb panel “A” which is adjacent the jamb 15 and hinged thereto by a single-leaf hinge 11 , a leading panel “B” which is furthest from the jamb, and a pair of intermediate panels “C”, “D” which are hinged to the jamb and leading panels, respectively, typically by upper and lower butt hinges 12 edge-fixed to those panels. The two intermediate panels C, D are also hinged together by upper and lower edge-fixed butt hinges (not shown), the upper hinge being suspended from a carriage 13 . The distal end of the leading panel B is suspended from the track by a single-leaf carrier hinge 14 .
[0005] To ensure that the proximal end face of the jamb panel A closes sufficiently close to the jamb face 15 to provide adequate weatherproofing, the jamb panel A is hinged to the jamb 15 by upper and lower offset hinges 11 each having a single angled leaf, i.e. the mounting face of each hinge leaf is offset from its hinge axis. Similarly, to ensure that the distal end face of the leading panel B closes sufficiently close to the opposite jamb, or an opposing leading panel, to provide adequate weatherproofing, the leading panel B is hinged to the carriage 14 by at least an upper offset hinge having a single angled leaf.
[0006] Consequently, as can be seen in FIG. 1 , the jamb and leading panels A, B have a width “W” which is greater than the width of the intermediate panels C, D by an amount “w”, being the hinge offset. An inherent disadvantage of such folding doors and windows is that the panels must be manufactured in two different sizes. This adds significantly to manufacturing and inventory costs. Furthermore, errors may occur in installation due to the wrong sized panel being mounted in the wrong position.
[0007] U.S. Pat. No. 4,295,514 discloses a bifold door assembly comprising two door panels of equal width. The panels are joined by hinges having knuckles offset from the panel edges, to permit the door panels to be opened to an obtuse position, i.e. greater than 90°. However, while this may be an advantage for a small two panel bifold cupboard door, it is not applicable to most large doors and windows having three or more panels as the jambs of such doors and windows do not normally permit the panels to open to an obtuse orientation, nor is it usually desired to fold the panels open to an obtuse orientation.
[0008] Moreover, the hinge arrangement of the '514 patent is unsuitable for conventional folding closures of three or more hinged panels for several reasons. First, as can be seen from FIG. 5 of the '514 patent, the panels cannot be arranged parallel to each other and at 90° to the plane of the opening. If the end panel is folded against a jamb at 90° to the plane of the opening, the adjacent panel will be angled obliquely, which not only occupies more of the opening space, but also detracts from the aesthetic appearance of the folded panels.
[0009] Secondly, if a third panel were to be added to the embodiment shown in FIG. 5 of the '514, say for a wider opening, the axis of the hinge connection of that third panel to its adjacent panel would not follow the guide track, and hence a carrier hinge could not be used.
[0010] Thirdly, the hinge arrangement of the '514 patent is designed for bifold doors having pivots and guides within the perimeter or plan section of the door, unlike many suspended folding doors in which the hinge axis (or axes) of each panel is (or are) located outside the plan section of the panel.
[0011] It is an aim of this invention to provide an improved folding closure with panels of equal width, which overcomes or ameliorates one or more of the disadvantages or problems described above.
SUMMARY OF THE INVENTION
[0012] In one broad form, this invention provides a folding closure comprising an overhead track, and at least three hinged upright panels of substantially equal width suspended from the track. The panels are adapted to be folded about their hinged connections from (a) a closed configuration whereat they are aligned substantially in a plane to (b) an open configuration whereat they are juxtaposed in substantially parallel planes orthogonal to the plane. At least one pair of adjacent panels of the closure are hinged together by at least one offset hinge.
[0013] Where the context permits, the term “offset hinge” as used herein is intended to mean a hinge having one or more leaves each adapted to be fixed to a respective panel, the plane of the fixing face of each leaf being offset from the hinge axis.
[0014] The closure is typically a door or window, but could be a screen, shutter, partition or the like. The term “panel” as used herein is intended to include any generally planar component of a folding door, window, screen, partition or the like, whether glazed or unglazed. The invention has particular application to an external folding door or window of a building, but is not limited thereto, as it can also be applied to internal partitions.
[0015] Normally, a first or end panel of the closure is hinged to a jamb member by at least another (single leaf) offset hinge. The use of the offset hinge between at least a pair of adjacent panels compensates for the offset introduced by the end panel, and enables panels of equal width to be used in the folding closure.
[0016] Preferably, each offset hinge which is connected between a pair of adjacent panels is a double-leaf non-mortise offset hinge in which one leaf fits within the other. Each such offset hinge is suitably edge-fixed to the pair of adjacent panels, i.e. fixed to opposed end faces of the panels by screws or other fasteners. However, the offset hinge may alternatively be face-fixed to the pair of adjacent panels, i.e. fixed to a side of each panel.
[0017] Typically, the pair of adjacent panels are hinged together by two offset hinges located respectively near the top and bottom of the panels. A third offset hinge may be connected to the pair of adjacent panels between the two offset hinges. The third offset hinge may be provided with a handle.
[0018] Normally, each of the panels is mounted for pivoting about an axis or axes outside the respective panel.
[0019] Preferably, the folding closure includes at least one carriage adapted to travel along the track. A pair of adjacent panels of the folding closure can be joined by a hinge which is connected to the carriage and suspended therefrom. (This may be the pair of adjacent panels connected by the offset hinge(s), or another pair).
[0020] In another form, the invention provides a method of forming a folding closure, comprising the steps of: suspending at least three hinged panels of substantially equal width from a track, such that the hinged panels can be folded from (a) a closed configuration whereat they are aligned substantially in a plane to (b) an open configuration whereat they are juxtaposed in substantially parallel planes orthogonal to the plane; and joining at least one pair of adjacent panels of the closure by at least one offset hinge.
[0021] In yet another form, the invention provides a folding closure for an opening in a building, comprising at least three hinged panels of equal width, the panels being adapted to be folded about their hinged connections from (a) a closed configuration whereat they are aligned substantially in a plane to (b) an open configuration whereat they are juxtaposed in substantially parallel planes orthogonal to the plane, and wherein at least one pair of adjacent panels are hinged together by at least one offset hinge.
[0022] In order that the invention may be more readily understood and put into practice, preferred embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
[0024] FIG. 1 is a plan view of a prior art folding closure.
[0025] FIG. 2 is a plan view of a folding closure according to one embodiment of the invention.
[0026] FIG. 3 is a plan view of the folding closure of FIG. 2 with top mount and carriages removed to show the hinges.
[0027] FIG. 4 is a perspective view of the folding closure of FIG. 2 (when open).
[0028] FIG. 5 is a perspective view of an offset hinge in one configuration.
[0029] FIG. 6 is a perspective view of the offset hinge of FIG. 5 in another configuration.
[0030] FIG. 7 is a perspective view of an offset hinge with handle attached.
[0031] FIG. 8 is a plan view of a folding closure (when open) according to a second embodiment of the invention.
[0032] FIG. 9 is a plan view of the folding closure FIG. 8 , with carriage omitted.
[0033] FIG. 10 is a plan view of the folding closure of FIG. 8 , when closed.
[0034] FIG. 11 is a plan view of the folding closure of FIG. 10 with carriage omitted.
[0035] FIG. 12 is a plan view of a folding closure according to a third embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
[0037] As shown in FIGS. 2 to 4 , a folding closure 20 , which may be a folding door or window, comprises four hinged panels 21 - 24 . A jamb panel 21 is hinged to a jamb (not shown) by top and bottom single-leaf offset hinges 25 , as is known in the art. A leading panel 22 is suspended from a carriage 27 by a single-leaf offset hinge 26 , again as is known in the art. Two intermediate panels 23 , 24 are hinged together at one end thereof by top and bottom edge-fixed butt hinges 28 , the upper hinge being suspended from a carriage 29 , as is known in the art. It is to be noted that the hinge axes of hinges 25 , 26 , 28 are aligned with the centreline 19 of the track (not shown) on which the carriages 26 , 29 travel. Thus the carriages 26 , 29 can form part of respective carrier hinges.
[0038] At its other end, intermediate panel 23 is hinged to the jamb panel 21 by top and bottom double-leaf offset hinges 30 . Similarly, at its other end, intermediate panel 24 is hinged to the leading panel 22 by top and bottom double-leaf offset hinges 31 .
[0039] The construction of the offset hinges 30 , 31 is shown in more detail in FIGS. 5 and 6 . FIG. 5 shows the hinge with its hinge leaves at 180° (which is the configuration of the hinge when the panels are folded to an open position as shown in FIGS. 2-4 ). FIG. 6 illustrates the hinge with its hinge leaves at 0° (which is the configuration of the hinge when the panels have been extended to a closed position). At this configuration, the leaves interfold into the thickness of a single leaf, i.e. the hinge is a non-mortise hinge.
[0040] As shown in FIGS. 5 and 6 , each hinge 30 , 31 has a pair of interfolding or interfitting leaves 32 , 33 adapted to be screwed to an edge face of a respective one of a pair of adjacent panels. Each leaf 32 , 33 has a knuckle portion 32 A, 33 A, respectively with a bore through it. A hinge pin (not shown) is located within the aligned bores, and defines a hinge axis A about which the hinge leaves 32 , 33 can pivot.
[0041] However, unlike the known regular butt hinges 12 used between adjacent panels on conventional folding closures as shown in FIG. 1 , the hinge leaves 32 , 33 are substantially offset from the hinge axis A. That is, the hinge axis A is offset or spaced from the plane defined by the face of each hinge leaf 32 , 33 which is fixed to the panel.
[0042] The total offset distance, i.e. the transverse spacing between the fixing faces of the hinge leaves when they are at 180°, is selected to counter the offset of the single-leaf offset hinges used on the jamb and leading panels. In this manner, all panels 21 - 24 can be made of the same width and still have their carriages aligned on the track, as can be seen clearly in FIG. 3 . Consequently, manufacturing can be standardised and inventory can be reduced, thereby reducing overall costs of manufacture.
[0043] For tall panels, such as door panels, intermediate offset dual-leaf hinges 34 may be fixed to adjacent panels between the top and bottom hinges, as shown in FIG. 4 . The construction of each intermediate offset hinge 34 is shown in more detail in FIG. 7 . The intermediate hinge 34 is of similar construction to the top and bottom offset hinges 30 , 31 , but is provided with a handle 35 to facilitate folding of the panels from their flat (closed) configuration.
[0044] The advantages of the invention can also be obtained by using different positioning of the offset hinges. FIGS. 8-11 illustrate another embodiment of the invention. In this three-panel embodiment, a folding closure 40 comprises a jamb panel 41 , a leading panel 42 and an intermediate panel 43 . The jamb panel 41 is connected to the jamb 44 by a single leaf offset hinge 45 . The jamb panel 41 is also hinged to the intermediate panel 43 by top and bottom regular (flat leaf) butt hinges 46 , each having a leaf edge-mounted to the respective panel. For tall panels, such as in a folding door, an intermediate hinge with a handle 47 may also be provided.
[0045] The intermediate panel 43 is also hinged to the leading panel 42 , but by top and bottom dual-leaf offset hinges 48 , the top hinge 48 being suspended from a carriage 49 . In this embodiment, the leaf of hinge 48 which is fixed to the intermediate panel 43 should have the same amount of offset as that of hinge 45 . This enables all of the panels 41 - 43 of the embodiment of FIGS. 8-11 to be of the same width, yet the axis of hinge 48 still aligns with the track line 50 , enabling the hinge 48 , and carriage 49 to be combined as a carrier hinge.
[0046] The principal advantage of the invention, i.e. a folding closure with panels of equal width, can also be achieved by replacing each hinge 48 with a regular butt hinge, and each hinge 46 with an offset hinge having the appropriate amount of offset. That is, the jamb panel 41 and the intermediate panel 43 can be hinged together using top and bottom offset hinges, while the intermediate panel 43 and the leading panel 42 can be hinged together using top and bottom flat leaf butt hinges.
[0047] In another variation, hinges 46 and 48 of the embodiment of FIGS. 8-11 can be replaced by two offset hinges, each of appropriate offset, so that the axis of hinge 48 remains aligned with track line 50 .
[0048] In yet another embodiment, a folding closure with panels of equal width can be obtained by replacing each hinge 30 of the embodiment of FIGS. 2-4 with a regular butt hinge, and fixing offset hinges between panels 23 and 24 , and between 24 and 22 , as shown applied to a five panel closure in FIG. 12 . In this case however, the offset hinges will have twice the amount of offset of the offset hinges of FIGS. 2-4 .
[0049] The foregoing embodiments are illustrative only of the principles of the invention, and various modifications and changes will readily occur to those skilled in the art. For example, although the illustrated embodiments use edge-fixed hinges, the invention can also utilise face-fixed offset hinges.
[0050] In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | A folding closure ( 20 ), such as a bifold door or window, comprises at least three hinged panels ( 21, 21, 23, 24 ) suspended from the track. The panels can be folded about their hinged connections, from a closed configuration whereat they are aligned substantially in a plane, to an open configuration whereat they are juxtaposed in substantially parallel planes orthogonal to the plane. An end panel ( 21 ) is hinged to a jamb by an offset hinge ( 25 ). At least one pair of adjacent panels ( 21, 23 and/or 22, 24 ) are hinged together by at least one offset hinge ( 30, 31 ), to compensate for the offset of the end panel ( 21 ), and thereby permit all the panels to be of substantially equal width. | 4 |
BACKGROUND OF THE INVENTION
(1). Field of the Invention
The present invention relates to a thermochemical reactor for a cooling and/or heating apparatus including at least one reagent unit capable of absorbing, by chemical combination, a gas flow coming from a tank and of desorbing this gas flow by reverse chemical reaction, under the action of a rise in temperature, so that it reintegrates into said tank, said reagent unit being arranged in a container connected to said tank through a pipe, and having walls, at least some of which include diffuser means permitting to distribute the gas flow in one direction or in the other one between the reagent unit and the tank, said reagent unit being of the type capable of expanding during the absorption of the gas flow and of retracting during the desorption of the gas flow and being connected to heating means.
The invention also relates to a cooling and/or heating apparatus including such a thermochemical reactor as well as an isothermal device provided, in turn, with said cooling and/or heating apparatus.
The present invention more specifically relates to the field of the production of cold and/or heat from thermochemical systems.
(2). Description of the Prior Art
In a known way, such systems are based on heat transfers resulting from a chemical reaction between a gas, such as ammonia, and reactive salts, such as calcium chlorides, contained respectively in two tanks separated by a valve. When the latter opens, a chemical reaction occurs, during which the gas vaporizes, in order to join the salts. This evaporation is heat-consuming and therefore generates a production of cold at the level of the tank containing the gas. Furthermore, the chemical reaction between the gas and the salts is exothermic and causes heat to be released at the level of the salt tank.
After complete evaporation of the gas, or when the salts are saturated, the chemical reaction stops as well as the production of cold and heat. It is then possible to regenerate the system, simply by heating the reactive salts, which causes the separation of the salts and the gas which then returns to its original tank where it is again condensed. After regeneration of the reactive salts, a new cooling and/or heating cycle can be performed.
The progressive implementation of these thermochemical systems in an industrial environment has at the same time required the development of suitable apparatuses, having means capable of optimizing, improving and controlling the evolution of the thermochemical reactions, and designed by means of reliable materials capable of withstanding high stresses, namely pressure and temperature stresses.
In this context, many work related to the development of the reactor, i.e. the unit formed by the reactive salts, the envelope in which they are contained and the various means the latter is provided with, with a view to providing a solution in which the reagent is not only capable of absorbing and desorbing a maximum quantity of gas without being carried along by this gas, but also capable of undergoing volume changes in said envelope, without deteriorating same or losing its reactive qualities, even bursting.
Presently, several documents are known, which are dedicated to the description of innovations made in this field.
Thus, FR 2 455 713 for example refers to a thermochemical reactor, which can be formed of several reactive bodies made self-supporting by a binder and contained in a flexible envelope having several envelope elements. Passages provided for between adjacent envelope elements define channels allowing the gas flow to circulate between the various reactive bodies. The reactor also includes distribution structures which communicate with the circulation channels and are designed so as to be adapted to the dimensional changes of an envelope element. These distribution structures can include telescopic elements which can be pushed into each other in order to cause changes in length of said distribution structures.
Such a thermochemical reactor has the disadvantage of a complex structure characterized by a great brittleness.
U.S. Pat. No. 2,649,700 describes a thermochemical reactor including several annular-shaped elementary reagent units confined between an inner wall and a peripheral wall. Porous screens separating the elementary units from each other distribute the gas flow between the lower and higher surfaces of the latter and an inlet and outlet conduit. The elementary units are made out of sintered metal and are thus dimensionally stable, namely as regards the above-mentioned pressure and temperature stresses.
Practice has shown that this embodiment has many disadvantages. Indeed, the metallic nature of the units highly limits the quantity of gas that can be absorbed and is in addition characterized by poor retention of the absorbing particles. This obliges to cause the gas flow to pass too fast through screens acting as filters, which complicate the structure of the unit and make it heavy.
From EP 0 206 875 is also known a reagent unit formed by a mixture of chloride and an foamed carbon derivative, capable of absorbing high quantities of gas per volume of unit, and solving the problem of mass transfer. This solid reagent unit has however a low mechanical strength that tends to quickly be deformed under the action of pressure gradients and volume changes it undergoes, so that its gas retention capability gradually tends to decrease during the cooling-regeneration cycles. Finally, the surfaces of the reagent for the mass exchanges can be deformed so much that they become completely ineffective.
In the solution provided by U.S. Pat. No. 2,384,460, the reactive material is confined between containment walls, in a limited volume, and through same pass perforated gas conduits filled with glass wool aimed at retaining said reactive material. Because of the close confinement, the reactive material maintains the same volume and the same shape, not only during the saturation phase, but also during the successive absorption-desorption cycles.
A quite similar thermochemical reactor device is also provided in EP 0 692 086, which describes namely a thermochemical reactor including a solid reagent unit confined in a container, between containment walls, some of which are pervious to mass exchanges. The characteristic of this reactor is defined by the reagent unit used being likely to undergo changes in volume depending on the quantity of gas absorbed, while the containment walls are capable of ensuring the stability in shape of the unit against the tendency to said changes in volume. Thus, in this document is provided to enclose a solid reagent unit in a container with strictly adapted dimensions, so that this reagent unit maintains its dimensions during the various absorption-desorption cycles, maintains its initial mechanical strength, and avoids its swelling, even its deterioration through bursting.
It could be observed that confining the reagent inside a limited space, as described in particular in the last two documents, although made necessary in order to avoid the deterioration of the system, in particular in order to avoid bursting of the reagent unit, represents an obstacle to an optimal evolution of the expected thermochemical reactions. Indeed, impeding the swelling of the reagent considerably reduces the maximum quantity of gas which can be successively absorbed and desorbed, which has in particular a repercussion on the time of autonomy of the system.
Another known similar device is described in the document FR 2 723 438 and tries to cope with the separation of the solid reagent from the walls of the enclosure, this separation resulting into a loss of the power of the reaction through a drop in the thermal-transfer coefficient. To this end, a fluid is introduced between the reagent and the walls of the enclosure, said fluid bringing about the thermal connection between the reagent and the enclosure. In addition, a fluid-confining device is added inside the enclosure in order to limit the displacement of said fluid and to prevent it from accumulating on top of the reagent.
This device has nevertheless the disadvantage of being of a complex embodiment, using additional means for implementing a fluid and for confining same.
SUMMARY OF THE INVENTION
The object of this invention is thus to provide a new thermochemical reactor, in which the swelling of reagent is not prevented, but nevertheless controlled so that its absorption-desorption capacities are fully used without fearing its deterioration through bursting.
To this end, the invention provides a thermochemical reactor for a cooling and/or heating apparatus comprising at least one reagent unit capable of absorbing, by chemical combination, a gas flow coming from a tank and of desorbing this gas flow by reverse chemical reaction, under the action of a rise in temperature, so that it reintegrates into said tank, said reagent unit being arranged in a container connected to said tank through a pipe, and having walls, at least some of which include diffuser means permitting to distribute the gas flow in one direction or in the other one between the reagent unit and the tank, said reagent unit being of the type capable of expanding during the absorption of the gas flow and of retracting during the desorption of the gas flow and being connected to heating means, wherein at least some of said walls consist of movable walls, capable of following the longitudinal movement performed by the reagent unit during its expansion or its retraction inside said container, so as to enable the successive deformation phenomena by expansion and restoring to the initial shape by retraction of said reagent unit.
According to a preferred embodiment, in the invention said container is also defined by a tube, each end of which is extended by a half-sphere, the diameter of which is such that it substantially allows inserting without backlash the reagent unit, which has, in turn, a cylindrical shape and is sandwiched between two discs capable of sliding longitudinally, should the case arise, towards each half-sphere under the action of the expansion of the reagent unit, or, should the case arise, towards the central zone of the tube under the action of the retraction of the reagent unit.
Furthermore, according to an advantageous feature, the present invention also provides that the diffuser means enabling the distribution of the gas flow in one direction or in the other one between the reagent unit and the tank are defined by a set of several walls imbricated into each other, delimiting centrally a channel, each made out of materials capable of permitting the passing through of the gas flow, said set being capable of being inserted through openings provided for this purpose in said reagent unit and said movable walls, and said set communicating at the level of one of its ends with the pipe connecting the container to the tank.
According to an embodiment of the invention, the thermochemical reactor is provided with heating means defined by a set of heating collars or ribbons positioned outside the container in which the reagent unit is arranged.
On the other hand, this document also refers to a cooling and/or heating apparatus including a thermochemical reactor according to the invention, connected to a gas-fluid tank by means of a pipe provided with a valve, as well as to an isothermal device provided with such a cooling and/or heating apparatus.
The present invention also relates to the features which will become clear during the following description, and which should be considered separately or according to all their possible combinations.
This description relating to exemplary embodiments, given by way of an indication and in a non-restrictive way, will permit to better understand how the invention can be carried out, with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 represents a schematic perspective and exploded view of an embodiment of a thermochemical reactor according to the present invention,
FIG. 2 represents a schematic perspective view of a cooling and/or heating apparatus according to the invention,
FIGS. 3 and 4 represent schematic longitudinal cross-sectional views of a thermochemical reactor according to the invention, before and after the absorption of gas, respectively,
FIG. 5 represents a schematic perspective view of a device provided with the cooling and/or heating apparatus of FIG. 2 ,
FIG. 6 represents a schematic cross-sectional view of the thermochemical reactor of FIGS. 3 and 4 , along the line VI-VI of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The thermochemical reactor 1 that can be seen in FIG. 1 , relating to a particular embodiment of the invention, is comprised of a solid reagent unit 2 , in the form of at least four cylindrical wafers inserted into a container 3 defined by a tube, which is preferably made out of stainless steel and has a diameter adapted to guarantee a close contact between its inner walls 30 and the outer surface 20 of the reagent unit 2 after their assembling. Furthermore, as can be seen in FIG. 3 , the reagent unit 2 is slid into the tube defining the container 3 in a centered way, while providing some clearance 32 at each end 34 , 35 of said tube.
Each end 34 , 35 of the tube defining the container 3 is furthermore closed thanks to closing means 31 having the shape of a half-sphere or a cap (only one of which is schematically shown in FIG. 1 ), which is fixed through welding, during the manufacture of the reactor 1 .
The container 3 is connected by means of a pipe 4 provided with a valve 40 , and a check and/or non-return valve 41 , to a tank 5 , visible in FIG. 2 , aimed at containing a gas under pressure, for example ammonia.
Preferably, the nature of the reagent unit 2 used in a thermochemical reactor according to the invention is based on the association of two components, namely Expanded Natural Graphite (GNE), which remains inert during the thermochemical reaction, and a reactive salt, such as alkaline, alkaline-earth, or metal salts. It could be shown that such a structure, including GNE, allowed improving the thermochemical performances of the method.
In the exemplary embodiment represented in FIG. 1 , the reagent unit 2 is perforated with three openings, not shown, of which one central opening and two openings located on both sides of the latter, aimed at allowing the passing through of diffuser means 7 for enabling the distribution of the gas flow, in one direction or the other one, between the reagent unit 2 and the tank 5 , and of a sleeve 6 for accommodating heating means such as a heating resistor, respectively.
One can observe, in this respect, that according to another embodiment, a thermochemical reactor according to the invention could also be provided with heating means defined not by a heating resistor inserted into the reagent unit 2 , but by a set of heating collars or ribbons positioned outside said container 3 .
The sheath 6 of the heating resistor is conventionally in the form of a stainless steel tube, which passes through the container 3 , and is fixed at the level of its two ends to the bottoms of the closing means 31 in the form of half-spheres, while the diffuser means 7 , the structure of which, which represents another specificity of this invention, is in the form of an assembly of several pervious walls.
Thus, these diffuser means 7 are more specifically defined by a set of several walls imbricated into each other, delimiting a channel centrally, each made out of materials capable of allowing the passing through of the gas flow, said unit being capable of being inserted through openings as mentioned above, provided for this purpose in said reagent unit 2 . Said set of walls communicates at the level of one of its ends with the pipe 4 connecting the container 3 to the tank 5 and conveying the gas flow between these two elements.
In fact, the unit forming the diffuser means 7 includes namely an inner wall defined by a profile bar with a triangular cross-section manufactured after folding a perforated sheet at two points, for example of the R2T4 type, as well as a median wall formed by a stainless steel fabric, the size the meshes of which is preferably between 10 microns and 100 microns, wound around the perforated sheet. Finally, the unit also includes an outer wall, defined by a porous tube of stretched metal, the pore size of which is preferably between 100 microns and 800 microns.
On the other hand, according to the invention, this set of several walls including diffuser means 7 has a length substantially identical to that of the tube forming the container 3 , so that each of its ends enters into contact with the bottom of each half-sphere of the closing means 31 .
In a known way, the diffuser means 7 play an essential role for the evolution and reproducibility over time of the thermochemical reaction. The structure given to the diffuser means 7 within the framework of this invention has, for this purpose, multiple advantages. Indeed, the perforated sheet prevents the diffusion openings provided for in the reagent unit 2 from clogging, while the stainless-steel fabric is used as a filter capable of retaining in the reagent unit 2 possible grains of salts sucked into the circuit at the opening of the valve 40 . In addition, the stretched metal tube prevents the tensions due to the expansion of the reagent unit 2 from passing through the stainless-steel fabric, through the holes in the perforated sheet.
Because of such a structure of the thermochemical reactor 1 , the material forming the reagent unit 2 is thus radially confined between the inner wall 30 of the container 3 , the wall of sheath 6 and the outer wall of the set of walls including the diffuser means 7 .
Advantageously, according to the invention, the reagent unit 2 is furthermore sandwiched between two discs 8 provided with openings 80 , 81 , 82 for the passing through of the sheath 6 and the diffuser means 7 , respectively, these openings 80 , 81 , 82 being located in front of the openings provided for the same reasons in the reagent unit 2 .
According to the invention, these discs 8 advantageously define movable walls capable of sliding longitudinally and following the movement of the reagent unit 2 , should the case arise, towards the closing means 31 , along the clearance 32 , under the action of an expansion of the reagent unit 2 during the production of cold, or towards the central zone 33 of the container 3 under the action of a retraction of the reagent unit 2 during its regeneration.
According to a preferred embodiment, the discs 8 are applied against one of the lower 21 or upper 22 faces, respectively, of the reagent unit, which they are made integral with through adequate means for making integral.
Conventionally, at the opening of the valve 40 , the gas maintained under pressure in liquid state within the tank 5 evaporates and is diffused through the diffuser means 7 towards the salts of the reagent unit 2 , which fix same, while being capable, according to the invention, of expanding longitudinally, as can be seen when referring to FIGS. 3 and 4 . The evaporation of the gas causes the production of cold at the level of the tank 5 , whereas the exothermic reaction between the gas and the salts simultaneously leads to a release of heat at the level of the container 3 . When the salts of the reagent unit 2 are fully saturated, the heating resistor is connected to the mains, in order to cause a supply of heat and the desorption of the gas, which flows back, through the check valve 41 , to the tank 5 , where it re-condenses, while the reagent unit 2 retracts to adopt its initial volume.
Permitting the reagent unit 2 to breathe and expand longitudinally along the clearances 32 advantageously allows avoiding the problems of deterioration of the reactor feared with the traditional devices, in particular because this allows avoiding the high pressure stresses the diffuser means 7 , which traditionally also act as containment walls, are subjected to.
On the other hand, according to another feature of the invention, the discs 8 have a diameter substantially identical to the inner diameter of the tube defining the container 3 , and are thus capable, each, of abutting against the inner wall of said tube at the level of each closing means 31 , because of the narrowing of the diameter of the tube at this location, in order to stop the movement performed by the reagent unit 2 during its expansion and to prevent it from entering into contact with the bottom of each closing means 31 .
Thus, the presence of the discs 8 advantageously prevents the ends of the diffuser means 7 from being clogged during the expansion of the reagent unit 2 .
The invention also relates to a cooling and/or heating apparatus 10 , such as for example the one schematically shown in FIG. 2 , which includes two thermochemical reactors 1 having the features previously described, each of them being connected to a gas-fluid tank 5 by means of a pipe 4 provided, in turn, with a valve 40 and a check valve 41 .
When referring to FIG. 5 , such a cooling and/or heating apparatus 10 can be adapted onto an isothermal device 100 having a box 101 aimed at receiving the products to be maintained at temperature and towards the inside of which said tank 5 producing the cold is oriented. | A thermochemical reactor ( 1 ) for a cooling and/or heating includes at least one reagent unit ( 2 ) which, using chemical combination, can absorb a gas stream originating from a tank and which, using the reverse chemical reaction, can desorb the gas stream due to a rise in temperature. The reagent unit ( 2 ) is disposed in a container ( 3 ) that has walls, at least some of which are equipped with diffusers ( 7 ) for distributing the gas stream. In addition, the reagent unit ( 2 ), which can be heated, is of the type that can expand during absorption of the gas stream and retract during desorption of the gas stream. Moreover, at least some of the walls are mobile walls, which can accompany the longitudinal movement of the reagent unit ( 2 ), to enable successive deformation phenomena. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a process for the preparation of a hydrocarbon mixture, in which one or more oxygen-containing organic compounds are contacted with one or more zinc halides at elevated temperature.
Processes for the conversion of organic oxygenates to hydrocarbons using molten zinc halides are known, and described, for example, in U.S. Pat. No. 2,492,984 and U.S. Pat. No. 3,969,427.
A similar process to that according to the present invention is known from U.S. Pat. Nos. 4,059,646 and 4,059,647. Both patent specifications describe a process for the preparation of triptane, in which methanol, dimethyl ether or mixtures thereof are contacted with zinc bromide and zinc iodide, respectively, at a temperature of 210°-245° C. and 180°-240° C., respectively.
According to the examples in said patent specifications, relatively large quantities of zinc halide are used in relation to the quantity of methanol to be converted.
It has now been found that the quantity of zinc halide required for the process can be drastically reduced, while the reaction time is found to be short and a valuable hydrocarbon mixture is obtained, if the process is carried out in the presence of a high boiling compound which has a melting point which is lower than the temperature at which the process is carried out and a vapor pressure at said temperature which is at most 0.05 of the pressure of the oxygen-containing organic compound(s), and in which the oxygen-containing organic compound(s) and zinc halide are soluble.
SUMMARY OF THE INVENTION
The invention therefore relates to a process for the preparation of a hydrocarbon mixture, in which one or more oxygen-containing organic compounds are contacted with one or more zinc halides at elevated temperature, characterized in that the process is carried out in the presence of a high-boiling compound which has a melting point which is lower than the temperature at which the process is carried out and a vapor pressure at said temperature which is at most 0.05 of the pressure of the oxygen-containing organic compound(s), and in which the oxygen-containing organic compound(s) and zinc halide are soluble.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Oxygen-containing organic compounds which can be used in the process according to the invention are preferably lower aliphatic compounds, e.g., aliphatic alcohols (particularly methanol), ethers (particularly dimethyl ether), ketones (particularly acetone), carboxylic esters and/or aldehydes, for example acetaldehyde, carboxylic acids, for example acetic acid, polyhydric alcohols and carboxylic anhydrides. The oxygen-containing compounds may have up to about 8 preferably up to about 4 carbon atoms in one or more portions attached to the oxygen atom.
The starting materials containing the above-mentioned oxygen-containing compounds may of course be obtained from any usual source. Methanol derived from synthesis gas obtained from coal and methanol prepared from natural gas, for example, are extremely suitable.
At the temperature at which the process is carried out the high-boiling compound preferably has a vapor pressure in the range from 10 -3 to 0.5 bar. In the case of a vapor pressure below 10 -3 bar there is a great chance that the compound is in the solid phase under the reaction conditions. A vapor pressure in excess of 0.5 bar implies that the compound evaporates excessively under the reaction conditions. The high-boiling compounds which are suitable include the alcohols having 10 to 23 carbon atoms, such as dodecanol, heptadecanol, nonadecanol and pentadecanol, and further the ethers having 14-24 carbon atoms, such as didodecyl ether, tetradecyl tetracosanyl ether, dinonyl ether and dipentadecyl ether. Other high-boiling solvents having a boiling point above 210° C., which are liquid under the reaction conditions of the process are suitably employed according to the invention.
Of the alcohols heptadecanol is most preferred. Of the ethers most preference is given to didodecyl ether. The conversion of oxygen-containing organic compound(s) into hydrocarbons is found to be highest in the use of heptadecanol or didodecyl ether.
Good results are obtained if the quantity of high-boiling compound in relation to the quantity of zinc halide is 5-25% by weight.
Exemplary zinc halides include zinc chloride, zinc bromide and zinc iodide.
Zinc iodide is preferably used on account of its great activity as zinc halide. It has been established experimentally that
a. a high-boiling compound must be used to which applies that the solubility therein of zinc halide at 100° C. is preferably at least 1 mol/liter. The process will prove to be economically unattractive if the solubility is less than 1 mol/1.
b. The pressure at which the process is carried out is preferably in the range from 1 to 80 bar, at which pressure the organic oxygen compound to be converted must be present in the vapor phase. Operation of the process at pressures higher than 80 bar and below 1 bar is economically disadvantageous.
c. The temperature at which the process is carried out is preferably in the range from 170° to 250° C. At temperatures below 170° C. the conversion reaction proceeds too slowly.
Temperatures above 250° C. may adversely affect the conversion process because undesired side-reactions such as cracking and carbonization reactions may take place, with the result that the yield of the desired hydrocarbon mixture is affected unfavorably.
The process according to the invention can also advantageously be carried out with zinc halide on a carrier, for example silica or alumina or combinations thereof. The process according to the invention can be carried out batchwise or continuously.
Irrespective of the chosen process, a good degree of mixing or contact between the zinc halide and the organic oxygen compound(s) is important to obtain good results. It is possible to use any reaction system in which a high degree of mixing or contact between said compound(s) and zinc halide is obtained. Use can be made, for example, of systems having fixed beds or slurry reactors. The contact times are not of special importance and experts may vary these times to obtain optimum results which are also dependent on, for example, the volumes of the reactants, reactor type, temperature, etc. When use is made, for example, of a reactor with fixed bed and continuous flow of the reactants, contact times of about 0.5 to 180 minutes and even longer periods can be used. In batchwise operation the contact times may be considerably longer.
The invention will be further illustrated with reference to the following examples to which the invention is not limited, however.
EXAMPLE I
Quantities of 10.4 g of zinc iodide, 2.1 g (2.6 ml) of methanol and 0.2 g (0.25 ml) of heptadecanol were charged to a 200 ml autoclave, whereupon the autoclave was sealed airtight. The mixture was stirred and heated at 205° C. for 1 hour. The pressure rose to 13 bar. The reactor was subsequently cooled to room temperature. Gaseous product was discharged into a gasometer. Liquid product was distilled over at 160° C. from the reactor to a cooled collecting vessel, initially at atmospheric pressure, while nitrogen was blown through in order to promote the distillation (30 minutes), subsequently at reduced pressure (30 minutes at 20 mm Hg, then 15 minutes at 2 mm (Hg). The heptadecanol remained behind on the zinc iodide.
The liquid product in the cooled collecting vessel consisted of two layers, an aqueous layer and a layer of hydrocarbon oil. The bottom layer consisted mainly of water and less than 0.88 g of methanol was present. The layer of hydrocarbon oil, which had a weight of 0.53 g, had the following analysis:
______________________________________ % by weight______________________________________2-methyl propane 0.72n-butane 1.232,2-dimethyl propane 0.64n-pentane 1.902,2-dimentyl butane 0.022,3-dimethyl butane 1.352-methyl pentane 0.363-methyl pentane 0.28n-hexane 0.142,2,3-trimethyl butene-1 5.722,4-dimethyl pentane 0.372,2,3-trimethyl butane 17.82,3-dimethyl pentane 0.722-methyl hexane 0.183-methyl hexane 0.21n-heptane 0.64butenes 0.42pentenes 2.27hexenes 0.52heptenes 1.12octenes 1.402,2,4-trimethyl pentane 0.312,2,3,3,-tetramethyl butane 0.462,5-dimethyl hexane 0.312,2-dimethyl hexane 0.332,2,3-trimethyl pentane 11.833,3-dimethyl hexane 0.812,3,4-trimethyl pentane 0.692,3,3-trimethyl pentane 1.413,4-dimethyl hexane 0.25n-octane 0.16higher boiling than n-octane 43.65Total 100______________________________________
EXAMPLE II
In this experiment use was made of a catalyst consisting of ZnI 2 /heptadecanol on a carrier of silica spheres having an average diameter of 15 nm and pores with an average diameter of 2.5 nm. This catalyst was prepared as follows:
100 g of ZnI 2 was dissolved in 60 ml of methanol, to which 5 g of heptadecanol was subsequently added. To this solution 100 g of silica in the above-mentioned form was added so that the silica was impregnated with the solution. The catalyst material was subsequently dried at 120° C.
For the experiment 20.3 g of said catalyst and 2.1 g (2.6 ml) of methanol were charged to a 200 ml autoclave, whereupon the autoclave was sealed airtight. The mixture was stirred and heated at 205° C. for 1 hour. The pressure rose to 15 bar. The reactor was subsequently cooled to room temperature.
Gaseous product was discharged into a gasometer. Liquid product was distilled over at 160° C. from the reactor to a cooled collecting vessel, initially at atmospheric pressure, while nitrogen was blown through as in Example I (30 minutes), subsequently at reduced pressure (30 minutes at 20 mm HG, subsequently 15 minutes at 2 mm Hg). The heptadecanol remained behind on the zinc iodide.
The liquid product in the cooled collecting vessel consisted of two layers, an aqueous layer and a layer of hydrocarbon oil. The bottom layer consisted mainly of water and less than 0.3 g of methanol was present. The layer of hydrocarbon oil, which had a weight of 0.8 g, had the following analysis:
______________________________________ % by weight______________________________________2-methyl propane 1.18n-butane 0.872,2-dimethyl propane 0.822-methyl butane 1.06n-pentane 2.162,2-dimethyl butane 0.032,3-dimethyl butane 0.642-methyl pentane 0.213-methyl pentane 0.16n-hexane 0.162,2,3-trimethyl butene-1 4.562,4-dimethyl propane --2,2,3-trimethyl butane 8.072,3-dimethyl pentane 0.322-methyl hexane 0.203-methyl hexane 0.15n-heptane 0.52butenes 0.52pentenes 2.16hexenes 0.41heptenes 1.03octenes 0.952,2,4-trimethyl pentane 0.142,2,3,3-tetramethyl butane 0.382,5-dimethyl hexane 0.132,2-dimethyl hexane 0.262,2,3-trimethyl pentane 23.13,3-dimethyl hexane 0.372,3,4-trimethyl pentane 0.342,3,3-trimethyl pentane 0.993,4-dimethyl hexane 0.11n-octane --higher boiling than n-octane 48.1Total 100______________________________________
EXAMPLE III
Quantities of 10.4 g of zinc iodide and 0.2 g (0.25 ml) of heptadecanol were charged to a 200-ml autoclave and subsequently 1.51 g of dimethyl ether was supplied to the autoclave at a pressure of 5 bar at room temperature.
The mixture was stirred and heated at 205° C. for 1.5 hours. The pressure rose to 12 bar. The reaction product was worked up in the same manner as in Example I.
A layer of hydrocarbon oil having a weight of 0.92 g was formed, which layer was not analyzed further.
EXAMPLE IV
Quantities of 10.4 g of zinc iodide, 2.1 g (2.6 ml) of acetone and 0.2 g (0.25 ml) of heptadecanol were charged to an autoclave under nitrogen, whereupon the autoclave was sealed airtight.
The pressure rose to 9 bar and the mixture was stirred and heated at about 180° C. for 1 hour. The reactor was subsequently cooled to room temperature. Gaseous product was discharged into a gasometer. Liquid product was distilled over at 160° C. from the reactor to a cooled collecting vessel, initially a atmospheric pressure, while nitrogen was blown through as in Example I (30 minutes), and subsequently at reduced pressure (30 minutes at 20 mm Hg and subsequently 15 minutes at 2 mm Hg). The material remaining in the autoclave was removed by washing with water.
The quantity of gaseous product was small and consisted mainly of isoparaffins. The liquid product present in the cooled collecting vessel consisted of two layers, an aqueous layer and a layer of hydrocarbon oil. The layer of hydrocarbon oil, which was not analyzed, had a weight of 0.8 g.
EXAMPLE V
In order to demonstrate the effect of the high-boiling compound on the degree of conversion of the oxygen-containing compound(s) a comparative experiment was carried out which differs from the experiment of Example I only in the fact that no high-boiling compound was used.
After the product had been processed, it was found that no detectable quantity of hydrocarbon oil had formed. | Method for the production of hydrocarbon comprises contacting as feed low molecular weight oxygenated organic compounds with a zinc halide in the presence of certain high-boiling, low vapor pressure compounds having good solvency for the zinc halide. | 8 |
BACKGROUND
Passive optical components can play an important role in the refinement and optimization of an optical signal in the MEMS/MOEMS (micro-electromechanical systems/micro-opto-electromechanical) regime. Passive optical devices are often used to control the qualitative properties of light in printing, laser scanning operations or data communications where optical signals are modulated and optical mode quality is integral to system performance. Hence, there is a need to provide passive optical devices for use in optical MEMS/MOEMS systems.
SUMMARY
Stress control in MEMS (micro-electromechanical systems) is important since uncontrolled stress may cause a MEMS component to bow or buckle. However, the ability to control stress in a MEMS context can be used to desirable effect. Stress gradient materials may be used to make three dimensional structures utilizing controlled stress release. Controlled stress in thin films can be used to accurately shape the optical surface of MEMS components. For example, tensile or stress gradient materials can be used to make cylindrical and spherical MEMS mirrors as well as tunable MEMS blaze gratings for use in the MEMS/MOEMS regime. Applications include the areas of optical communications, beam scanning and optical spectroscopy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a shows an embodiment of a cylindrical MEMS mirror in accordance with the invention.
FIG. 1 b shows an embodiment of a cylindrical MEMS mirror in accordance with the invention.
FIG. 2 shows an embodiment of a cylindrical MEMS mirror in accordance with the invention.
FIG. 3 a shows a metal pattern for a spherical MEMS mirror in an embodiment in accordance with the invention.
FIG. 3 b shows an embodiment of a spherical MEMS mirror in accordance with the invention.
FIG. 4 shows an embodiment of a MEMS blaze grating in accordance with the invention.
FIGS. 5 a - 5 f show the steps for making an embodiment of a cylindrical MEMS mirror in accordance with the invention.
FIG. 6 a shows the mask used in the step shown in FIG. 5 b.
FIG. 6 b shows the lift-off mask put down in the step shown in FIG. 5 d
FIGS. 7 a - 7 e show the steps for making an embodiment of a spherical MEMS mirror in accordance with the invention.
FIG. 8 a shows the lift-off mask put down in the step shown in FIG. 7 b.
FIG. 8 b shows the lift-off mask put down in the step shown in FIG. 7 d.
FIGS. 9 a - 9 f show the steps for making an embodiment of a MEMS blazed grating in accordance with the invention.
FIG. 10 shows the lift-off mask put down in the step shown in FIG. 9 d.
FIGS. 11 a - 11 e shows the steps for fabrication of a spherical mirror in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
Cylindrical reflection mirrors can be used for focusing diffused light into a line for applications such as optical communications. FIGS. 1 a and 1 b show an embodiment in accordance with the invention of a MEMS structure for cylindrical reflection mirror 100 . Conventional surface MEMS design and fabrication including polysilicon deposition and etching or silicon-on-insulator wafer material together with conventional lithography steps for pattern definition may be used for making cylindrical reflection mirror 100 .
Stress gradient layer 110 typically has a thickness of from about 500 nm to 1000 nm and is typically made of MoCr which is deposited as described in Table 1 below. Stress gradient layer 110 is deposited on top of structural layer 530 which is, for example, either polysilicon or a single crystal device layer if silicon-on-insulator wafer material is used. Stress gradient layer 110 has a built in stress gradient in the thickness direction varying from compressive on one side of layer 110 to tensile on the other side of layer 110 next to structural layer 530 . The stress gradient can be as large as 3.0 Gpa or more. After structure layer 530 is released from substrate 510 (see FIG. 5 ), the stress gradient in stress gradient layer 110 causes released structure layer 530 to bend.
Reinforcing beams 130 parallel to a common axis and spaced about 40 μm apart are present underneath structure layer 530 to prevent cylindrical reflection mirror 100 from bending in the direction perpendicular to the common axis. Typical dimensions for reinforcing beams 130 are a width of about 10 μm and a height of no more than about 5 μm. Typical dimensions for cylindrical reflection mirror 100 are about 200 mm by 250 mm.
Reflective layer 140 , typically of aluminum or gold, is deposited on top of stress gradient layer 110 to a thickness of about 200-500 nm by either thermal deposition or RF sputtering techniques in order to enhance the optical reflection characteristics of cylindrical reflection mirror 100 . Cylindrical reflection mirror 100 flatness is achieved by chemical and mechanical polishing structural layer 530 prior to deposition of stress gradient layer 110 and reflective layer 140 . Note that polishing is not needed if an SOI wafer is used. The curvature of cylindrical reflection mirror 100 is determined by the stress gradient in stress gradient layer 110 and the thickness of structural layer 530 . Increasing the stress gradient in stress gradient layer 110 and decreasing the thickness of structural layer 530 increases the curvature of cylindrical reflection mirror 100 . A typical thickness for structural layer 530 is about 100 nm to provide the mechanical support required while still avoiding the transfer of stress in structural layer 530 to cylindrical reflection mirror 100 which occurs if structural layer 530 is thinner than about 100 nm. If structural layer 530 is thinner than about 100 nm, an unacceptable level of anisotropic stress is present in cylindrical reflection mirror 100 . For a thickness above about 100 nm and below 500 nm anisotropic stress is not significant and the added thickness still allows for adequate bending of cylindrical reflection mirror 100 .
An embodiment in accordance with the invention of cylindrical reflection mirror 100 is shown in FIG. 2 . Cylindrical reflection mirror 100 is supported by torsion bar 220 . The angular position of cylindrical reflection mirror 100 is adjustable with sliding actuator 210 or an electrostatically driven comb drive actuator (not shown) such as described by M. J. Daneman et al. in “Linear Microvibromotor for Positioning Optical Components”, IEEE J. MEMs, vol. 5, no. 3, September 1996, pp. 159-165 which is incorporated by reference in its entirety.
A MEMS spherical mirror can focus light in two dimensions and is desirable for applications such as, for example, beam scanning or optical spectroscopy where a focused beam of light increases the light intensity for optimum results. The ability to control the stress of a metal thin film results in a semi-spherical reflecting surface. Stress gradient layer 110 , typically MoCr, with a controlled stress gradient is deposited on substrate 510 coated with sacrificial layer 520 (see FIG. 7 b ). In an embodiment in accordance with the invention, FIG. 3 a shows metal pattern 310 for spherical mirror 320 and release window 315 , typically having dimensions of about 400 μm by 400 μm. FIG. 3 b shows spherical mirror 320 upon release from substrate 510 typically having a radial extent of about 175 μm. The surface of spherical mirror 320 is typically coated with an aluminum or gold reflective layer by either thermal deposition or RF sputtering techniques. Sacrificial layer 520 is etched through release window 315 to allow release and lift of metal pattern 310 to form spherical mirror 320 . Single cantilever 325 anchors spherical mirror 320 to substrate 510 . After release, metal pattern 310 (see FIG. 3 a ) will conform to a spherical surface in the presence of biaxial stress.
The total lift and resulting radius of curvature can be designed using conventional micro-spring design recipes such as disclosed in U.S. Pat. No. 5,914,218 which is incorporated by reference in its entirety. For example, sputter conditions for forming stress gradient layer 110 for pattern 310 in MoCr with a thickness of about 500 nm and with an internal stress gradient of about 3.0 Gpa are as shown in Table 1 below.
TABLE 1
Sputter Deposition Conditions
Time (sec)
Pressure: 1.6 mT
390
Voltage: 518 volts
Current: 1.13 A
Pressure: 2.2 mT
330
Voltage: 470 volts
Current: 1.26 A
Pressure: 3.0 mT
300
Voltage: 457 volts
Current: 1.30 A
Pressure: 3.9 mT
330
Voltage: 453 volts
Current: 1.31 A
Pressure: 5.0 mT
300
Voltage: 457 volts
Current: 1.30 A
Sputter conditions for stress gradient layer 110 for cylindrical mirror 100 and tunable blazed grating membrane structure 410 are also described by Table 1.
If the lift is such that single cantilever 325 is raised above substrate 390 on the order of a few tens of microns, spherical mirror 320 can be electrostatically actuated using a metal contact (not shown) buried under sacrificial layer 520 (see FIG. 7 c ) below cantilever 325 of spherical mirror 320 . Electrostatic actuation allows precise adjustment of the cantilever angle and the option of removing spherical mirror 320 out of the optical path in applications where light is collected from a moving or adjustable position source. Spherical mirror 320 typically has a thickness of 2-3 μm or from 5-10 μm if using a silicon on insulator device layer.
The fill-factor of spherical mirror 320 and the reflectivity may be increased by inserting webbing (not shown) between petals 321 of spherical mirror 320 in an embodiment in accordance with the invention. Dielectric or metal layers with no built in stress are deposited prior to deposition of stress gradient layer 110 and patterned using standard lithographic techniques. The dielectric or metal layers are then dry or wet etched to define shape. The webbing layer is released simultaneously with metal pattern 310 of stress gradient layer 110 and deformed into a spherical shape by the stress relaxation of metal pattern 310 on release.
MEMS tunable blazed gratings have applications for spectrophotometers. FIG. 4 a shows tunable blazed grating membrane structure 410 in accordance with an embodiment of the invention. Stress gradient layer 110 typically 500-1000 nm thick is deposited on amorphous silicon or polysilicon layer 920 which is deposited on substrate 510 . After release of patterned amorphous silicon or polysilicon layer 920 , layer 920 is curled up due to the stress in stress gradient layer 110 to form blazed grating membrane structure 410 . Blaze angle 415 is adjustable by applying a bias voltage greater than about 100 volts across substrate 510 and each blazed grating membrane 945 . Each blazed grating membrane curls up on release by removal of dielectric layer 520 in a timed etchant, for example 49% hydrofluoric acid.
Equation (1) is the grating equation:
a sin θ m =mλ (1)
where a is the grating pitch, and light is assumed to be normally incident to the grating. In an embodiment in accordance with the invention, for example, taking a=3 μm and λ=670 nm results in first order diffraction angle θ 1 =12.9° and second order diffraction angle θ 2 =26.5°. With blaze angle 415 adjusted to equal to 13.25°, the specular reflection of the blaze matches the positive second order of diffraction. Adjusting blaze angle 415 to 6.45°, the specular reflection matches the first order of diffraction.
FIGS. 5 a - 5 f show the steps for fabrication of cylindrical mirror 100 in accordance with an embodiment of the invention. FIG. 5 a shows bulk silicon substrate 510 . FIG. 5 b shows deposition, typically by either sputtering or plasma enhanced chemical vapor deposition (PECVD) and patterning of sacrificial layer 520 on silicon substrate 510 . A typical composition for sacrificial layer 520 is SiO 2 , although other materials such as Si 3 N 4 may be used if silicon on insulator is not used for bulk silicon substrate 510 . Mask 610 is placed over sacrificial layer 520 for creation of reinforcing beams 130 . FIG. 5 c shows silicon substrate 510 after etching with a 45% KOH (potassium hydroxide) solution. FIG. 5 d shows deposition of sacrificial layer 525 and polysilicon layer 530 . Lift-off mask 620 shown in FIG. 6 b is placed over polysilicon layer 530 . The open center of lift-off mask 620 indicates where stress gradient layer 110 , for example, a MoCr layer, is left on silicon substrate 510 when lift-off mask 620 is removed. FIG. 5 e shows deposition of MoCr layer 110 as described in Table 1 above. Finally, FIG. 5 f shows release of layer 530 using a 49% HF (hydrofluoric acid) wet etch to remove SiO 2 sacrificial layers 520 and 525 . Release of layer 530 results in release of cylindrical mirror 100 .
FIGS. 7 a - 7 e show the steps for fabrication of spherical mirror 320 in accordance with an embodiment of the invention. FIG. 7 a shows bulk silicon substrate 510 . Sacrificial layer 520 , typically SiO 2 , is deposited on silicon substrate 510 as shown in FIG. 7 b . Photoresist lift-off mask 710 is shown in top view in FIG. 8 a . Silicon substrate 510 is patterned using photoresist lift-off mask 710 followed by deposition of stress gradient layer 110 , typically MoCr as described in Table 1, shown in FIG. 7 c . Subsequently, lift-off mask 710 is removed along with excess MoCr associated with stress gradient layer 110 in an acetone soak lift-off process. Finally, photoresist mask 720 , shown in top view in FIG. 8 b , is deposited on stress gradient layer 110 using spin-on techniques to cover the sections of stress gradient layer 110 not to be released. Exposed regions of stress gradient layer 110 are released using a 49% HF (hydrofluoric acid) wet etch for sacrificial layer 520 removal. Duration of the HF etch is typically about 15 minutes for release of spherical mirror structure 320 . Photoresist mask 720 allows petals 321 of spherical mirror 320 to be underetched while the remainder of spherical mirror structure 320 is protected from etching. As noted above, the efficiency of spherical mirror 320 may be enhanced by introducing webbing material between petals 321 .
FIGS. 9 a - 9 f show the steps for fabrication of tunable blazed grating membrane structure 410 in accordance with an embodiment of the invention. Sacrificial layer 520 is deposited on glass or bulk silicon substrate 510 to a thickness of about 5 μm as shown in FIG. 9 a . Sacrificial layer 520 is typically SiO 2 but sacrificial layer 520 may also be silicon nitride (Si 3 N 4 ) or silicon-oxynitride (SiON x ), for example. Sacrificial layer 520 is patterned using standard lithography as shown in FIG. 9 b with mask 999 (see FIG. 10) to expose anchor positions 950 for each individual grating 988 . Polysilicon or amorphous silicon layer 920 is deposited using chemical vapor deposition over sacrificial layer 520 as shown in FIG. 9 c . Polysilicon or amorphous silicon layer 920 functions as the mechanical support layer for individual grating membranes 945 . Layer 920 is patterned using mask 999 shown in FIG. 10 with the exposed portions being dry etched to expose sections of sacrificial layer 520 and defining individual grating membranes 945 in polysilicon layer 920 as shown in FIG. 9 d . Layer 920 is again patterned using standard lithography for a MoCr lift-off process. As shown in FIG. 9 e , MoCr layer 110 is deposited using the process described in table 1 with excess resist being removed in the lift-off process which leaves MoCr layer 110 only on the tops of individual gratings 988 . Sacrificial layer 520 is removed using a wet etchant, typically 49% hydrofluoric acid. As FIG. 9 f shows, individual grating membranes 945 , typically having a length of 100 μm, are left anchored to substrate 510 and grating membranes 945 curl up as shown in FIG. 4 .
FIGS. 11 a - 11 e show the steps for fabrication of spherical mirror 320 in accordance with an embodiment of the invention. FIG. 11 a shows silicon on insulator wafer (SOI) 1100 with single crystal silicon (SCS) layer 1120 as the fabrication starting point. As noted earlier, SOI wafer 1100 may be substituted for silicon substrate 510 in accordance with the invention. Use of commercially available SOI wafers 1100 reduces the number of processing steps and provides SCS layer 1120 which provides higher optical and mechanical quality than polysilicon material. Single crystal silicon (SCS) layer 1120 is typically 100 nm thick with sacrificial layer 520 typically having a thickness of 2 μm. FIG. 11 b shows lithographic patterning using the photographic negative of mask 710 (see FIG. 8 a ) and etching (etchant??) of SCS layer 1120 . Following etching of SCS layer 1120 , photoresist mask 710 (see FIG. 8 a ) is put over SCS layer 1120 as shown in FIG. 11 c and stress gradient layer 110 is deposited as described in Table 1. Unwanted portions of stress gradient layer 110 are then removed in a lift-off process using acetone solvent. Finally, photoresist mask 720 , shown in top view in FIG. 8 b , is put on stress gradient layer 110 using spin-on techniques to cover the sections of stress gradient layer 110 not to be released as shown in FIG. 11 d . Exposed regions of stress gradient layer 110 are released using a 49% HF (hydrofluoric acid) wet etch for sacrificial layer 520 removal as shown in FIG. 11 e . Duration of the HF etch is typically about 15 minutes for release of spherical mirror structure 320 . Photoresist mask 720 allows petals 321 (see FIG. 3 b ) of spherical mirror 320 to be underetched while the remainder of spherical mirror structure 320 is protected from etching. Again, the efficiency of spherical mirror 320 may be enhanced by introducing webbing material between petals 321 as described above.
While the invention has been described in conjunction with specific embodiments, it is evident to those skilled in the art that many alternatives, modifications, and variations will be apparent in light of the foregoing description. Accordingly, the invention is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and scope of the appended claims. | A method is disclosed for making shaped optical moems components with stressed thin films. In particular, stressed thin films are used to make mirror structures. | 1 |
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