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The invention herein described was made in the course of or under a contract, or a subcontract thereunder, with the United States Department of the Air Force.
BACKGROUND OF THE INVENTION
This invention relates generally to turbomachines and, more particularly, to turbine vanes and blades.
In high performance gas turbine engines, the temperature of the hot gas stream which is generated within a combustor section exceeds the operating temperature capability of any practical material from which the turbine blades and vanes may be fabricated. In order to reduce the temperature of the parts to a point where sufficient strength is maintained, it has become an accepted practice to duct lower temperature, pressurized air from the engine compressor to the turbine components which operate in the hot gas stream environment. One of the most effective methods by which the metal temperatures of such components are cooled is to introduce the cooling air into hollow blades or vanes and then discharge the air into the hot gas stream. This cooling air reduces the component metal temperatures through various heat transfer mechanisms such as convective, impingement, or film-cooling action.
To this end, turbine blades and vanes are generally fabricated in the form of a generally hollow shell with a plurality of cavities and associated dividers forming the inner side thereof. However, the trailing edge portion of the airfoil, because of the constraint of aerodynamic efficiencies, tapers down to a very thin trailing edge. Accordingly, since the cavities cannot extend back to the trailing edge, this solid trailing edge portion will heat up to destructive temperatures unless it is cooled in some way. This cooling is commonly accomplished by the forming of a plurality of trailing edge cooling slots which extend between the internal cavities of the airfoil and the trailing edge thereof for the conduction of cooling air therealong.
Historically, cooling slots have been formed to emerge from the trailing edge portion of the airfoil at substantially the centerline thereof. However, it has been found that higher efficiency is accomplished in the performance thereof by ejecting the trailing edge cooling air on the pressure side of the trailing edge. One of the problems of this design is that with a straight slot formed in the trailing edge, the slot break-out length tends to be too long and the break-out point on the pressure side has a large location tolerance. Since the break-out location is critical to the temperature of the vane trailing edge, a stack-up of tolerances can easily result in a slot which does not satisfactorily cool the vane trailing edge.
One method of reducing the location tolerance is to use a curved air slot. Such a curved slot forms a larger angle with the pressure side of the vane and provides better axial location accuracy as a function of vane thickness and slot location tolerances.
In the case of a vane formed by casting, it is relatively easy to form a curved slot. However, very high turbine temperatures necessitate the use of certain types of material which are not adaptable to being cast but are only available in bar form (wrought form). Accordingly, with such noncast airfoils, the cooling holes and slots must be machined into the part in such a manner as by, for example, electrical discharge machining (EDM). One possible method of machining the curved slot by the EDM method is with the use of a curved electrode. However, with the extremely close tolerance conditions, and with the relatively large depth of the slot, such an exercise would be extremely difficult to accomplish.
It is therefore an object of the present invention to provide a noncast airfoil with an improved trailing edge cooling slot.
Another object of the present invention is to provide a trailing edge cooling slot which emerges on the pressure side of the airfoil trailing edge.
Yet another object of the present invention is the provision in the trailing edge cooling slot of a turbine airfoil for the limiting of the slot break-out length and location tolerance.
Yet another object of the present invention is the provision for accurately and effectively forming a curved trailing edge cooling slot in a noncast turbine airfoil.
These objects and other features and advantages become more readily apparent upon reference to the following description when taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in accordance with one aspect of the invention, an airfoil is fabricated in its wrought form to substantially the final desired shape except for the trailing edge being slightly uncambered. A straight slot is then formed in the trailing edge portion to connect an internal cavity of the airfoil with a point on the pressure side of the trailing edge. The trailing edge portion of the airfoil is then reformed toward the airfoil pressure side to its final shape, thereby reforming the trailing edge cooling slot to its final curved condition.
By another aspect of the invention, the airfoil may be fabricated to its final shape and elastically deflected toward the suction side of the airfoil and, after the cooling slot is formed therein, be allowed to spring back to its initial position; or, depending on the desired curved shape of the slot and the strength of the vane or blade material after it has been allowed to spring back as possible, it may be finally reformed as required to obtain the proper vane or blade shape.
In the drawings as hereinafter described, a preferred embodiment is depicted; however, various other modifications and alternate constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a transverse cross-sectional view of a turbine airfoil of the type to which the present invention is applicable.
FIG. 2 is a cross-sectional view of the trailing edge portion thereof when deflected to a first position.
FIG. 3 is a cross-sectional view of the trailing edge portion thereof when the deflecting force is removed and the trailing edge is allowed to spring back to a released position.
FIG. 4 is a cross-sectional view of the trailing edge portion thereof when a reforming force is applied to form it into a final shape.
FIG. 5 is a transverse cross-sectional view of the airfoil in its final shape.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown generally at 10 an airfoil representative of the type employed as vanes or blades in the turbine portion of the turbomachine. The airfoil 10 is generally hollow in nature with the curved pressure side 11 and suction side 12 partially defining a plurality of internal cavities 13 and 14. The pressure side 11 and suction side 12 are joined at the leading edge of the airfoil to form a blunt nose 16 and converge toward the rear end of the airfoil to form a very thin trailing edge 17. That tapered portion of the airfoil between the trailing edge 17 and the internal cavities of the airfoil 14 shall for purposes of this description be referred to as the trailing edge portion of the airfoil 18 and it is that portion of the vane to which the present invention is applicable.
Cooling of the airfoil is accomplished by supplying high pressure cooling air from the compressor or the like to the internal cavities 13 and 14 where it acts to lower the temperature of the metal by a combination of convection, impingement and film cooling. Impingement cooling is accomplished by directing cooling air against the inside surface of the airfoil through small internal high velocity air jets as, for example, those coming from holes 19. Convection cooling occurs inside the turbine airfoil cavities 13 and 14 through serpentine paths (not shown). Such convection cooling air eventually exits the airfoil by way of a plurality of holes such as those 21 in the airfoil nose. Once the cooling air has exited the airfoil, then film cooling is accomplished whereby a layer of cooling air is maintained between the high temperature gases and the external surfaces of the airfoil as shown in FIG. 1.
In order to cool the trailing edge portion 18 of the airfoil, it has been common practice to provide a plurality of trailing edge cooling slots between the internal cavity 14 and the trailing edge 17. Cooling air then flows along these slots to provide convection cooling to the trailing edge portion 18 of the airfoil. In order to obtain increased vane or blade aerodynamic efficiency it has been found desirable to eject such air on the pressure side of the trailing edge 17 rather than along the centerline thereof. For reasons discussed hereinabove, it is also advantageous to form the trailing edge cooling slots in a curvilinear shape. The process as described hereinafter is formulated for accomplishing such a design and in particular for use in airfoils of the noncast type (wrought form), wherein machining of the cooling slot is required.
FIG. 2 shows (partially in phantom lines) the trailing edge portion 18 of the airfoil 10 as it appears in FIG. 1. This represents the form in which it was originally fabricated by a noncasting method such as, for example, extrusion or the like. A pair of opposed, preformed dies 22 and 23 are then respectively applied to the pressure and suction sides of the trailing edge portion 18 to deflect that portion to a less cambered position as shown by the solid lines of FIG. 2. While the airfoil is held in such a deflected position, a straight trailing edge cooling slot 24 is formed therein by a suitable method such as for example electrical discharge machining (EDM) with a straight electrode. As can be seen by reference to FIG. 2, it is preferable that the cooling slot emerges on the pressure side 11 of the trailing edge 17 rather than at the centerline of the trailing edge itself.
After the forming of the straight cooling slot, the dies 22 and 23 are released and the trailing edge portion 18 of the airfoil springs back from its deflected position as shown by the dotted lines of FIG. 3 to a more cambered attitude as shown by the solid lines of FIG. 3. As this occurs, the cooling slot 24 will tend to curve in the desired direction as shown in FIG. 3. Depending upon certain design requirements, this form as shown in solid lines in FIG. 3 may be satisfactory for the final design since it does exhibit a curved cooling slot 24. However, if a greater curvature is required, or if the vane profile requires a greater camber for the final design, it is necessary to effect a further step. This is particularly true when the deflection process as shown in FIG. 2 causes the vane material to be stressed beyond its elastic limit such that when the deflecting force is removed as shown in FIG. 3, the trailing edge portion 18 does not spring back to its original position as shown in FIG. 1.
A final step which may be applied is shown in FIG. 4 where preferably a different pair of opposed dies 26 and 27 are applied to the unstressed trailing edge portion 18 to reform it from a position to which it is sprung back (as shown in dotted line) to a final more cambered position as shown in solid lines. As can be seen, the curvature of the slot 24 becomes even greater with this final deflecting process. Where it is desired to have a high degree of curvature of both the trailing edge portion 18 and the cooling slot 24, it may be necessary to form a plurality of successive reformations with intermittent cold work and heat treatment cycles after each of the partial bends so as to prevent cracking of the material along the line of curvature. The required number of such recrystallization steps is, of course, dependent upon the material and the amount of plastic reformation required.
The final profile of the finished airfoil is shown in FIG. 5 with the curvature form of the pressure and suction sides 11 and 12 meeting the predetermined specifications. As a result of the controlled fabrication process described hereinabove, the breakout location 28 of the curved cooling slot 24 is well within the allowed tolerances, and the breakout length as represented by the distance A is small so as to provide a very effective cooling function to the trailing edge 17. Further, it will be recognized that the thin fin 29 created at the pressure side break-out is of sufficient thickness to withstand oxidation which may otherwise cause failure thereof. This is to be contrasted with the straight slot (shown in dotted lines) of the prior art wherein the break-out length is represented by the larger dimension B and wherein the break-out location tolerance is necessarily greater. As mentioned hereinbefore, the break-out location and length are critical to the function of cooling the trailing edge 17. For example, it has been determined empirically that for a particular airfoil design, a reduction of 0.085 inch in the break-out length causes a reduction of 41° F. in the temperature of the trailing edge 17. Further, it will be recognized that the thin fin 31 resulting from the straight slot is much thinner than that 29 of the curved slot and therefore much more susceptible to oxidation and manufacturing tolerances.
It will be understood that while the present invention has been described in terms of a preferred embodiment, it may take on any number of other forms while remaining within the scope and intent of the invention. For example, it will be recognized that the deflection step as shown in FIG. 2 is not necessarily required. That is, the slot forming process may entail only the forming of a straight hole in the airfoil as initially fabricated and then a deforming, by one or a plurality of steps, as shown in FIG. 4 to arrive at the final airfoil shape and curved slot. Further, it will be recognized that the above-described method would apply not only to the slot which emerges on the pressure side of the trailing edge as described herinabove but also to a slot which emerges at the centerline of the trailing edge 17. | A curved slot is formed between an internal cavity of an airfoil and the trailing edge thereof by temporarily deflecting the airfoil trailing edge portion toward the suction side thereof, forming a straight slot in the trailing edge portion while it is in the deflected position, and releasing the deflecting pressure to allow the trailing edge portion to spring back into an unstressed condition so as to thereby curve the slot within the trailing edge portion. Further curvatures may be effected by subsequent reformation of the trailing edge portion toward the pressure side of the airfoil. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to the renting ot computerized means (software and/or hardware) in accordance with a schedule which depends on the actual use of this facility.
This schedule can be compiled on the basis of various measures such as the period for which a piece of software is made available, the duration of use of this piece of software, the number of transactions made or dossiers created, the number and quality (difficulty or rarity) of calculations, the number and quality of files consulted, especially, and more generally of any computing or remote-computing service made available to a user, and the operation of which is enabled at least in part by the said software.
A fair number of proposals have already been made for providing protection for the supplier (or designer) of a piece of software, especially: EP-A-0,430,734; IEICE transactions, vol. E 73, No. 7, July 1990, JP, pp 1133-1146; EP-A-0,265,183.
Thus, the concept is known of a computerized device, of the type including:
an operational facility, comprising at least one central processing unit, together with memory means allowing it to load an operating system and to implement at least one piece of software on the basis of this operating system, and together with at least one connection interface which can be accessed through a function of the operating system, and
a dedicated unit including a removable memory medium reader, such as a smart-card reader, connected to the central processing unit by the said connection interface of the latter,
while the software includes specific calls to the dedicated unit, for the purposes of conditioning the conduct of the execution of the said software, depending on the state of certain data contained in the removable memory medium.
This is done in EP-A-0 430 734, with the intention of the software sending results to the smart card which it will have to be able to retrieve therefrom subsequently, failing which the software cannot be fully executed.
These known solutions are not entirely satisfactory from the security standpoint, it being observed that a perfect security system is inconceivable.
SUMMARY OF THE INVENTION
The invention is therefore aimed firstly at improving security as regards protecting a piece of software against unauthorized use.
The invention is aimed, more precisely, at improving this security sufficiently for it to be possible for example to rely on it for pricing the charges for renting the software, as will be seen later.
The object of the invention is also to provide a solution which is applicable for several renters, several pieces of software and several possible simultaneous lessors.
The Applicant has observed that the difficulties of implementation originate from the manner in which the rental and protection processes are associated.
The invention stems from a computerized device of the aforesaid type.
According to one aspect of the invention the specific calls are configured in the form of communication commands, possessing send arguments, and whose completion state is suspended while awaiting a response of particular form, and the removable unit comprises:
a communication security module capable of disabling the response to a communication command originating from the central processing unit, depending on first conditions involving the expression of the communication command, and information contained in the card, and
at least one responsive module capable of recognizing such a communication command and of according it a favourable response, in the said particular form, only if second conditions pertaining to the arguments of the said command and to information contained in the card are complied with.
The responsive module can be a usage metering module, such as an electronic purse and/or a time metering module.
Provision may then be made for the said response of particular form to include a first state, affording authorization of normal operation of the software, and a second state, affording authorization of operation at the very most only in downgraded mode (reduced capabilities).
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will emerge on examining the detailed description below, and the attached drawings in which:
FIGS. 1, 1A and 1B are the general diagrams of three examples of installations in which the invention can be implemented,
FIGS. 2, 2A illustrate diagrammatically the "removable medium" part of the implementation of the invention, and
FIGS. 3 and 3A illustrate diagrammatically two versions of a handler used in one embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Being elements pertinent to security, it will be understood that certain parts of the device are described only as regards their principle.
Before describing the invention in detail, it is useful to recall all of the known solutions.
Certain rental processes are based on the number of transactions counted between a remote unit (placed under the control of the supplier) and local units; other rental charges are based on the time spent by the remote unit in processing these transactions. In both cases, accounting is performed by the remote unit.
In parallel with this, processes have been proposed which use electronic boxes which perform the decrementation of a counter on command from the leased software. These boxes are in general connected to a communication port of the computer. Depending on the variant, reincrementation of the counter is effected by inputting at the keyboard a code forwarded by the lessor, or via a link with a central computer. In all these cases, since the protection is either software-based or based on passive technology (ROM, epROM, eepROM or e2pROM), it does not offer a level sufficient for rental.
Other processes propose an electronic box incorporating a microprocessor. As these boxes, although removable, are not designed to be frequently connected and disconnected from the system, implementation is incompatible with the commercial constraints as soon as this system is associated either with several pieces of software, or with several renters.
Microchip (microprocessor or so-called hard-wired computational logic) card systems have also been proposed which contain a counter which is decremented on the basis of the time measured between two successive commands of the software; these commands normally intervene at known time intervals. Implementation of this process requires incorporating a timing interrupt command when this time is uncertain. Now, this interrupt command considerably weakens the level of security accorded by the microchip card.
Still other solutions invoke the means of incorporating, into the process, a module for protecting the leased software and a counter which is decremented in line with use; when this counter runs out, the protection module is disabled, thus causing the software to lock up. Now, in most cases, it is desirable for the software to continue to operate, with reduced capabilities (down-graded mode), nevertheless remaining protected against fraudulent use.
None of this, therefore, is really satisfactory.
The invention stems from a computerized facility which includes, in FIG. 1, at least one central processing unit 1, to which is adjoined a dedicated unit 2. These two units can communicate with each other, via an appropriate interface, which may be a port of the central processing unit, for example the serial port of a microcomputer, or again a connector of a peripheral controller mounted on an internal card, or on the mother card.
The central processing unit 1 is made up of computer hardware and/or software and/or files, at least a part of which is delivered either on a portable mass memory of the diskette 15, or compact disc 16 kind, or as permanent (epROM) or backed-up memory. This "delivered part" may comprise executable files (such as programs) or non-executable files (such as databases, or other data files, including audio and/or video, for example).
As a variant (FIG. 1A), a local central processing unit 12 is connected by modems (or some other link) 129 and 119 to a remote or supplier central processing unit 11 which, in this case, contains, on internal or external mass memory, part at least of the useful software and/or files. It is in principle necessary for a--small --part of the software to reside in the local station. In this instance these will be the minimal user interface functions for presenting the results of the service to the user, and the minimal functions (debit) to be executed on the smart card.
According to another variant (FIG. 1B), a wire transmission arrives at the modem 129, or else a radio transmission arrives at the reception facility 139. The local part of the computerized facility can then be based on a microcomputer station, as before, or else, as represented, on a unit 13 (games console for example) which cooperates with the monitor part of a television receiver 14.
In these three modes, which are non-limiting examples, the local unit 1, 12 or 13 is linked to the dedicated unit 2.
In what follows, the case of FIG. 1 will be adopted for simplicity. It will also be assumed that the dedicated unit 2 is linked to a serial port of the central processing unit 1 (although other links, especially to a PCMCIA port could be envisaged).
The operating system of the local processing unit 1 supplies a function or primitive for access to the serial port concerned.
The software to be executed includes calls to this access primitive, so as to be able to access the interior of the smart card 21.
According to one aspect of the invention, these so-called "specific" calls are configured in the form of communication commands, having send arguments, and awaiting a response of particular form. The send arguments are for example an identifier and a code respectively. The completion state of the specific call is suspended while awaiting the said response of particular form, which will condition the manner in which the execution of the software will be conducted. Of course, this suspension can be bounded by a maximum waiting time, at the end of which a negative response is presumed.
Thus, in other words, the local processing unit can execute commands for communication with the dedicated unit 2, the results of which authorize or disable normal or downgraded execution of this local processing unit 1.
For most applications, one of these commands will be of the "DECREMENT" type. It can be produced directly or else implicitly in association with another command.
Very generally, the dedicated unit 2 is made up of at least one removable part termed the card, for example a smart card 21, and of a card reader. Incorporated therein are modules which include processing means capable in particular of formulating the results of communication, on the basis of their own defined information stored or calculated beforehand.
The card 21 includes at least one communication security module 6 whose role is to make secure the exchanges of information between the central processing and dedicated units. As illustrated in the drawing by switchovers 251, this module 6 is able to intercept, in one and/or the opposite direction, part at least of the communications between the local processing unit 1 and the card 21, over the lines 203 to 207. This can be done by various kinds of control checks exercised on the flowing datastream. For example, the data of the stream can be enciphered or signed with the aid of a key which can be determined from the information contained in the memory (not represented) of the card 21. Any error of encipherment, respectively of signature, translates into the intercepting of the datastream placed under the control of the module 6. An error response destined for the central processing unit 1 is preferably appended thereto.
Thus, the module 6 exercises access control on one or more other so-called "responsive" modules, among which has been represented a usage counter 3, a time metering module 4 and a sequence control module 5.
More generally, this signifies that a hierarchy can be established in the "responsive" modules. A responsive module of higher priority can then intercept the commands addressed to other responsive modules of lower priority. The establishing of this hierarchy will depend on the applications, the illustration in FIG. 2 being merely an example of this.
Thus depicted, the proposed device offers a cascade of modules, each of which conditions access to those which follow (of lesser priority), down to the lowest priority level, which contains in particular the accounting functions related to the renting of the software (to which may be added other conditions), and ultimately conditions the conduct of the operations of this software.
On delivery the usage counter 3 contains a software use credit which can be read and/or decremented by the software in line with its use, under the control of the communication security module 6 and, as the case may be, of the sequence control module 5. Preferably, every decrementation operation is accompanied by a reading of the new value of the credit.
It may be beneficial to make provision for a command to be interpreted by the card as the combination of this command and another, implicit command. For example, a DATA command (201) can implicitly generate, in the card, a DECREMENT command.
In a particular embodiment, use is made of the sequence of states of the sequence control module 5. Changes of states are due to corresponding commands originating from the central processing unit 1, under the control of the communication security module 6, and/or to internal events in the card.
FIG. 3 and FIG. 3A are illustrations of a handler and the states thereof. Two states at least are necessary (states I and II). However, as the card is removable, and hence can be inserted and withdrawn, the sequence proposed according to the invention is as follows:
insertion 308: transfer to state I (311)
engagement 309: transfer to state II (312)
disengagement 310: transfer to state III (313)
withdrawal 308 and await insertion.
The card can be withdrawn and reinserted in the course of each of the states I (311) and II (312) without affecting this sequence. This presupposes that the handler of the module 5 is constructed in eepROM memory.
This sequence is intended, in particular, to oblige a fraudster to withdraw and reinsert the smart card into the reader with each engage/disengage simulation of the metering module, thus considerably slowing down the operations and making his task laborious.
Stated otherwise, the above is a looped handler with two (FIG. 3A), or preferably three states (FIG. 3) at least, with which are associated two, respectively three transitions. Entry into a state is permitted only in the presence of the transition associated with this state.
One of the transitions is the withdrawal/reinsertion of the card. A second transition is produced in the presence of one at least of the commands (at most, all of them, except, as the case may be, the disengage command) coming from the local processing unit 1, and/or upon an internal event in the card (and emanating from one of the other modules). The third transition is produced either in response to a disengage command, or likewise upon an internal event in the card, such as the exceeding of a maximum period during which the card has received no command.
The intermediate state II (awaiting "disengage") then serves as the basis for enabling certain functions in the card, such as time metering, which in turn conditions usage metering, or else command, and also control of the protection of the software, about which more will be said later.
As indicated by FIG. 3A, it is possible, for certain applications, to restrict the handler to two states, and the two transitions termed "engagement" 309 and "disengagement" 310 alone.
Although it is conceivable to do without it, the sequence control module 5 is currently regarded as providing an important security element.
This sequence control module 5 can contain a cycle counter. This counter decrements one credit of cycles each time a chosen one of the states is entered. In the case of the three-state handler, this counts the number of times the card is withdrawn or inserted into the reader. When this credit is zero, any communication controlled by the sequence control module 5 is disabled (252).
Thus, a fraudster who might have succeeded in developing a mechanical or electrical system capable of simulating the withdrawal and insertion of the card is limited in his operations by the number of possible cycles, this being relatively restricted in the case of normal use.
In other words, the sequence control module 5 exercises at 252 a second level of interception on the communications with the other modules, here 3 and 4. This control module 5 could moreover be regarded functionally as a constituent of the security module 6.
Preferably, the dedicated unit moreover includes a software protection module 7. The latter's exchanges of data with the local processing unit 1 may escape the control of the communication security module 6, especially if this software protection module incorporates a different encryption process, which is redundant or incompatible with that of the communication security module. In a known manner, this module 7 responds to input data 201 via results 202, in accordance with a rule which depends on information contained in the card, with the desired degree of complexity.
It is advantageous (link 210) to render the module 7 active at the same time as the state II (312) generated by the sequence control module 5. In this way, the software can function only if the dedicated unit has received an engage command, thus obliging execution of the sequence in spite of any attempt at fraud. As the disengage command does not intervene during normal operation of the software, any attempt at simulation of this disengagement will lock up the functioning of the software.
The dedicated unit can also include a time metering module 4 which runs a timer when this module is active.
This time metering module 4 disables (253) communication between the central processing unit and the usage counter 3 when the timer reaches a predetermined value.
Preferably, the time metering is implemented only during the state II of the sequence 5: the timer is activated (link 212) only when the sequence control module 5 has received an engage request 309, that is to say when the software is actually being operated (and not as soon as the dedicated unit is in service).
This function is intended, in particular, to define an "expiry period" for the card, not to be confused with any possible expiry date for this card, which may be managed by the communication security module 6.
The remaining period of this time metering module 4 can be read (205) by the central processing unit, under the control of the communication security module 6, and, as the case may be, of the sequence module 5.
The time metering module 4 can, internally, read (217) or decrement (216) the usage counter 3.
The engage request 309 and disengage request 310 of the sequence control module 5 can be activated internally in the dedicated unit 2:
engagement is effected implicitly on each communication with the central processing unit,
disengagement is effected if no communication has taken place for a predetermined duration.
FIG. 2A illustrates an example of an applicable smart card. The lines issuing from the connector are applied to a processing unit 20, equipped with a clock (not represented), and accompanied by a program memory 29. Added thereto are the encryption element 26, which comprises the basics of the module 6, the epROM element 27, which can contain customized encryption functions, the e2pROM element 23/24, which comprises the functions of the modules 3 and 4, and lastly the random-access memory element 25, which can contain the sequence control handler, while its possible counter is eepROM-based, in order to retain a memory record of the counting.
In a first particular embodiment, the smart card is of the COS type from the company GEMPLUS:
i) this card can incorporate an electronic purse function, constituting the usage counter module 3,
ii) the module 6 is built on the basis of a DES type encryption algorithm, customized through a secret set, protecting in particular the module 3,
iii) the DECREMENT and READ commands are of the form:
DECREMENT (Identifier, Session -- key, Transaction -- No., Debit -- amount),
READ (Identifier, Session -- key, Transaction -- No.),
iv) the awaited response is a certificate which will be an encrypted function of the above data,
v) the modules 4 and 5 are constructed by the expanding of instructions in eepROM or epROM, what engineers term a "specific mask". In respect of the module 5, this involves constructing the handler appropriate to the sequence described; the function of the module 4 is technically similar to that of the module 3, without external decrementation order, with use of the clock of the microprocessor of the card,
viii) the software protection module 7 can be constructed in any known appropriate manner, for example with the DES algorithm of the card, in order to decipher certain parts of the commands, enciphered beforehand in ECB mode.
In a second particular embodiment, in which the functions of the modules 4 and 5 are not deployed, the smart card is of the SCOT 30 type from the company BULL CP8. Implementation is as follows:
i) in respect of the module 3, at least one memory area is defined, forming a counter,
ii) this module 3 will be accessible only on input of an identifier and a code, which are checked by the communication security module 6, with respect to their values stored in the card,
iii) the DECREMENT and READ commands are then of the form:
DECREMENT (Identifier, Code, Debit -- amount)
READ (Identifier, Code)
iv) the awaited response is:
OK (remaining -- credit), or
NOTOK (Error -- type)
v) the module 7 can use the DES standard algorithm of the card, to decipher certain parts of the commands, enciphered beforehand in ECB mode.
It is clear that the implementation of the invention depends to a certain extent on the technology of the card used. However, the invention remains at least partially applicable whatever this technology, provided that the card incorporates a processing unit.
This being so, the expression "operating system" is here to be interpreted in the broad sense, and extends to any set of hardware and/or software functions making it possible to run a piece of software and to access at least one peripheral.
The dedicated unit 2 can contain several groups of modules, distributed in one or more cards, each corresponding to a central processing unit, renter, lessor, piece of software or other use unit. The word software is here used in the broad sense, and is aimed at both a program as well as all files or services made available to the user.
Each of these groups is assigned arguments of the commands which are at least in part different.
The example may be taken of two companies who propose common software but who wish to remain independent of each other. The benefit may be appreciated of a card which functions with two separate groups of modules, but which locks-out the use of the software on the request of one or other of these groups.
In practice, it is possible to use a disposable card, credited only once during manufacture, or a card which can be reloaded, possibly remotely. Furthermore, the expression "dedicated unit" implies merely that this unit at least partly escapes the control of the central unit; it does not preclude the dedicated unit from being physically built into the box of this central processing unit.
From another standpoint, it is clear that the invention could also be expressed in the form of processes, and that it applies not only to smart cards, but also to any type of portable object suitable for accommodating similar capabilities, such as for example "smart keys". | System comprising a central processing unit and a dedicated unit. Said dedicated unit receives a communication protection module which controls a sequence controlling module containing a state machine and a cycle counter, a timing module activated by said sequence controlling module and a software protection module also activatable by said sequence controlling module. | 6 |
BACKGROUND OF THE INVENTION
In recent years, there has been considerable interest in the production of glass fibers. Due to the tremendous usages of glass fibers, the interest has been particularly focused on increasing the production of individual fiber drawing stations. In the production of fibers, molten glass is typically passed through nozzles or orifices in a bushing to create individual fibers. In addition to the problem of increased production, the apparatus used in such processes is typically quite expensive as it often times involves the use of inordinate amounts of platinum, complex orifices, high pressure generating equipment, pressure resistant bushings, etc.
To increase the yield of the drawing stations, the obvious but difficult approach is to increase the number orifices per bushing through which the molten glass is directed and from which the individual fibers are formed. A few years ago, a standard bushing produced 204 fibers. After considerable expense and research, the capacity of the bushing has been increased to 2,000 orfices and, through a recent breakthrough in the art, arcuate bushings have been developed which are used in conjunction with high pressure glass and are capable of handling 6,000 orifices. While the total number of bushings per drawing station could, of course, be increased to raise the production of the station, such an approach would be self-limiting, increase the bulk of the station, complicate the operation as well as increase the costs and result in the decrease of uniformity of the individual fibers over the entire station. Therefore, it is the individual bushing orifice function and capacity which is a substantial limiting factor in the production of a high volume of quality fibers from a drawing station.
A single bushing 10-inch square, incorporated in the method and apparatus hereinafter to be described, can support 102,400 orifices. This represents 51.2 times the number of glass fibers which can be produced by the best of the current standard systems and 17 times more than the aforementioned arcuate bushing system are capable of producing. In spite of this tremendous gain, the present invention is remarkably simple both in concept and construction. It utilizes the simplest of bushings containing a minimum amount of platinum, the base of which is formed into a generally flat, thin horizontal orifice plate with just plain holes therein.
Plain holes in flat, wettable alloy plates have been utilized in the past, however, they have been quite limited with respect to the proximity of adjacent orifices. If the hole edges are closer than about one-half-inch apart, the glass will often times creep through capillary action along the underside of the plate to join and break an adjacent fiber. Such flow will continue in an ever-widening cycle resulting in a flooding of the entire bushing. The underside of the plate will become coated with a single, useless glob of glass. With non-wettable alloys, where the wetting angle is 55° or more, plain holes can, of course, be closer together, but the spacing nevertheless is limited to the diameter of the drops passing therethrough. Even with the best of non-wettable alloys, should two drops touch, they will immediately flow together to form a single larger drop and be forced to wet the plate. This wetting cycle will continue between the remaining orifices resulting in a totally unusable bushing.
There are other systems which employ plain holes in a flat bushing wherein a burnable gas is directed at the bushing and the forming cones. Upon contact with the high temperature of the issuing glass and of the bushing, the gas decomposes to deposit a carbon coating on the plate and glass. Due to the poor wetting characteristics of glass on carbon and graphite, the carbon which coats the glass drops allows the drops to be pushed together without coalescing. Despite the increased proximity within which the orifices may be placed in such a system, the overall production of the system is still quite limited due in part to the degrading effect of carbon on the glass. Moreover, such systems are unreliable because once flooding occurs, it is very difficult to effect separation thereafter. Other systems actually employ carbon inserts coaxially disposed around each orifice. Such systems occupy a greater amount of space and the carbon must be employed in an inert atmosphere. This, of course, further increases the cost of such a system and the inert gas along with the exposure of the carbon may have a damaging effect on the surface of glass fibers which desireably should be disposed in an oxidizing atmosphere. Such systems, therefore, do not present a satisfactory solution to the problem of increasing production.
U.S. Pat. No. 3,573,014 discloses a method and apparatus for producing fibers from glass which incorporates an arcuate bushing of the type referred to above. The system disclosed therein utilizes pressure on the glass substantially above a nominal pressure head to cause separation and prevent flooding of the bushing. To withstand such pressures, the bushing must have a pressure resistant configuration. This configuration is provided by the arcuate bushing. In such a system, separation is caused by what was originally termed the shower head effect wherein the molten glass is forced at high pressure through the apertures in the bushing and the formed jet overwhelms any thin film on the bushing and in fact sucks the surrounding area dry thereby preventing flooding and thereafter maintaining individual separated glass fibers. This high pressure, as well as requiring additional equipment for its generation, dictates the configuration of the bushing used in such a system which in turn limits the number of fibers which can be produced by such a system.
In providing an economical system with increased fiber production, in addition to developing a bushing with a greater number of orifices therein, it is necessary first to cause separation and thereafter to maintain the separation of each of the formed fibers. Glass has an unusually high surface tension and, therefore, a droplet is constrained to a generally spherical configuration. To distort the drop into a fiber forming cone requires the application of stress. As molten glass passes through an orifice and is forced to form into a fiber, the base of the fiber assumes the shape of a fiber forming, asymptote-like cone. As long as there is sufficient stress to maintain the geometry of the cone, i.e., to cause some concavity, an equilibrium between the fiber and its glass source will prevail. However, such fibers cannot be sustained without exercising considerable control over the asymptotic geometry of the feeding cone.
There are several means for cooling glass fibers. The standard means comprises one or two rows of orifices sandwiched between fins which in turn are cooled by liquid or air. Variations include several hundred individual streams of air, each one of which cools a single fiber base or row of fibers either through holes in fins or by air piped through hundreds of hyperdermic needle-like tubes to direct air at or in between each fiber. Such fins are sometimes perforated to cause an overall oozing of air streams to impinge at or near the fiber roots. Such systems either cross the fibers at 90° with respect to their axis or blow in a downward direction. An example to the contrary is found in U.S. Pat. No. 3,695,858 which apparently incorporates a pair of air jets for each formed filament, i.e., 20 air jets for each 10 fibers. Each of the air jet orifices are located only a few thousandths of an inch from each fiber and are downwardly and upwardly directed at 45°. The pairs of jets work in unison ostensibly to cause a controlled turbulence to cool a row two tips wide within a hooded enclosure. In such systems, the physical positioning of the air orifices is extremely critical and necessarily complex.
Such systems have several problems which the hereinafter described system eliminates. Jets, fins and hoods must be located adjacent to both bushing and orifices which in turn requires very carefully positioning and position maintenance. They absorb considerable energy in cooling the bushing, occupy valuable space on the bushing and, therefore, substantially decrease the number of orifices which can be employed. In addition, these jets, fins and hoods become a recepticle for condensates from the molten glass which cause fiber breaking "flys" and which degrades the cooling efficiency and necessitates frequent cleaning. Finally, such systems have a most serious weakness in that they are limited to cooling but a few rows of orifices. When air blows across several rows of orifices at 45° or less, a primary and contiguous layer hugs the plate in a laminar flow and blankets the plate to prevent additionally directed air from penetrating the blanket to cool the cones. The air tends to laminate to create successive layers which quickly become too deep to have any cooling effect on the very short fiber forming cones. Consequently, the air at the cone level over cools the first rows of fiber and under cools the successive rows. For this reason, air directed from 90° to 45° to the fiber axis is quite limited in the width of its quenching effect.
To constrain the cone to its fiber forming shape by cooling is not difficult with a single fiber because of 360° cooling nor is cooling difficult with any number of rows of fibers one or two fibers wide. However, when there is a press of thousands of orifices tightly grouped together in a single flat bushing, a continuous and identical geometrical constraint on each of these thousands of cones presents a substantial cooling problem. Should just one of the thousands of forming cones lose its shape, the force of wetting would at once dominate and the glass would creep to an adjacent cone which would then break, the cycle of breakage and wetting continuing thereafter in an ever-widening ring until the bushing would become flooded. Therefore, in addition to providing an economical system for increased glass fiber production which incorporates a bushing having an increased number of orifices therein, it is necessary to provide a temperature control for the creation and maintenance of the asymptotic geometry of the fiber forming cones.
DESCRIPTION OF THE INVENTION
It is one object of this invention to provide an improved method and apparatus for producing fibers from a high temperature molten material.
It is another object of this invention to provide an improved method and apparatus for the production of glass fibers.
It is yet another object of this invention to provide an improved method and apparatus for increasing the production of glass fibers from a single station.
It is still another object of this invention to provide an improved method and apparatus for increasing the production of glass fibers from a single bushing.
It is a further object of this invention to provide an inexpensive and economical method and apparatus for the production of glass fibers.
It is yet a further object of this invention to provide an apparatus for the production of glass fibers which incorporates a bushing having a high density of orifices.
It is still a further object of this invention to provide a method and apparatus for the production of glass fibers having improved temperature balance across the bushing and fibers pultruded therethrough.
In accordance with one aspect of this invention there is provided a method of forming glass fibers which comprises:
a. passing separate streams of molten glass through a generally flat orifice plate having at least four rows of orifices therein, with orifices spaced in flooding relationship;
b. drawing fibers from cones of molten glass formed at each said orifice; and
c. directing a bulk flow of rapidly moving gas upwardly to the orifice area in said plate:
i. to cool said cones to provide a stable cone formation and to maintain separation of cones thus preventing flooding;
ii. to impinge on said plate essentially to eliminate stagnant gas adjacent said plate and to cause gas to move outwardly along said plate in all directions from said orifice area, and
iii. to supply a source of gas sucked downwardly by the fibers.
In accordance with another aspect of this invention there is provided an apparatus for manufacturing glass fiber filaments comprising:
a. means for containing a head of molten glass;
b. a generally flat orifice plate having at least four rows of orifices therein with orifices spaced in flooding relationship through which said glass fibers are formed, said plate being constructed of a heat resistant material and being disposed at the base of said containing means;
c. means for controlling the temperature of said plate;
d. means for withdrawing said fibers from said plate and forming cones at said orifices; and
e. means disposed below said plate and being in communication with a gas supply for directing a bulk flow of rapidly moving gas upwardly to the orifice area in said plate:
i. to cool molten glass cones disposed below the orifices to provide a stable cone formation and to maintain separation of cones thus preventing flooding;
ii. to impinge on said plate essentially to eliminate stagnant gas adjacent said plate and to cause gas to move outwardly along said plate in all directions from said orifice area, and
iii. to supply a source of gas sucked downwardly by the fibers.
Other aspects of this invention are described below.
The advantages to be achieved from the present invention are manifold. As a threshold matter, the orifice plate or bushing is simple to manufacture and employs less extremely expensive metal alloy than commercial bushings in use today. Compared to conventional practice employing orifices with tips, the radiant heat given off by the bushing employed in this invention is less and therefore the operator is subjected to less exposure to radiant heat. Inasmuch as there is less radiation, the present invention affords the possibility of employing less electrical energy. The above is particularly dramatic when comparing bushings of equal throughput.
Since high orifice densities may be realized, the present invention provides increased production per unit area of orifice plate. Moreover, there is more throughput per orifice than is realized in conventional practice employing tips, because of a skin effect pumping action due to the cones being cooled by air, the shorter orifice length and the higher exit temperature from the orifice. The fibers have good uniformity and do not require complex manufacturing apparatus. This invention does not require the use and complexity of fins, hood enclosures, expensive, non atmospheric gas mixed with carbon plating gases to create a non-wettable carbon barrier, arcuate pressure bushings, high pressure systems and does not require non-wettable alloys. In addition, it utilizes the simplest of cooling means. From a gas (e.g., air) source located below and relatively far from the orifices, a stable environment is forced upon thousands of fibers to maintain the stability of each of the formed fibers. With this system, thousands of orifices can be crowded into a single bushing which is very small in proportion to its yield yet has virtually no length and breadth limitation and wherein the hole edges can be as close as 0.001 of an inch. In contrast, the standard bushings have virtually reached their economic limit at 2000 orifices. A system free from such limitations greatly increases the yield and lowers production costs over the systems heretofore available.
This invention also provides considerable flexibility with regard to the number of fibers to be drawn from a bushing. The number of fibers required for final product application readily may be drawn from a single orifice area. Final products may require bushings producing strands having 1600, 2000, 3200, 4000, 20,000, or more fibers. The present invention has the potential of eliminating roving operations.
This invention further provides more flexibility in choosing windup speeds because commercially acceptable production rates (lbs. of glass) may be achieved employing more orifices and lower windup speeds which tend to reduce the risk of fiber breakage. Even at higher windup speeds, it has been found that "snap-out", wherein a large multitude of fibers break at essentially the same time, does not occur. Since the orifice plate is overwhelmed with high velocity upwardly moving gas, which moves outwardly along the orifice plate, no adjacent ambient gas (which may carry impurities that contaminate the fibers and cause fiber breaking) is drawn around the cones so that the environment around the cones is cleaner.
With a relative high density of fibers passing over the dressing fluid (binder) applicator roll, there is less loss, and therefore less consumption, of dressing fluid than experienced in conventional commercial processes. Interfiber scrubbing action appears to prevent excess pick up of dressing fluid by individual fibers so that later sling off of dressing fluid by the fibers is materially reduced. Reduced sling off of dressing fluid will result in a reduction of sizing in the air and both equipment and the work area will stay cleaner, thereby affording a better environment for the operator. Rapid quench of the glass also will reduce the content of glass volatiles in the surrounding environment, and the cooling gas which moves laterally outwardly from the bushing readily can be removed from the operating area to keep the operating area cooler.
Finally, this invention provides high quality glass fibers. Rapid glass quench (order of magnitude 100:1 compared to conventional type bushings), with a reduced loss of volatiles from the glass, results in a fiber more nearly corresponding to the composition of the glass in the molten bath. Moreover, the substantially greater cooling of the glass in the cones by conduction and convection, rather than cooling by radiation, provides a more tempered glass fiber.
This invention readily may utilize conventional glass furnaces, and conventional auxiliary equipment, such as bushing heaters, dressing fluid applicators and windup equipment. Existing glass fiber operations may be converted for the practice of this invention by modification of the bushing and provision of proper cooling gas means.
This invention easily may be practiced with the head of glass normally maintained in a conventional glass furnace, which generally is from about 8 to about 14 inches of molten glass. Indeed, the present invention can be practiced with a glass head of only about 1 inch or less. Although pressures in excess of those provided by a head of glass require expensive equipment that may be difficult to maintain, such pressures may be employed if desired. The temperature of the molten glass in the bath obviously will depend upon the type of glass being used. With type E glass, the temperature will be about 2100°F to about 2400°F (1150°-1315°C). The choice of the temperature for the molten glass bath in the glass furnace for any type of glass is routinely established in conventional practice and is easily within the skill of the art.
The orifice plate used in this invention may be made of any alloy acceptable for operation under glass fiber forming conditions. The alloy may be wettable or non-wettable. A standard platinum alloy of 80% platinum and 20% rhodium, or an alloy of 90% platinum and 10% rhodium, readily may be employed. Zirconia grain stabilized platinum alloys which have creep resistance may also be employed.
The surface of the orifice plate is generally flat. Plates which have small dimples or are in the form of gentle concave and/or convex configurations may be used without adversely affecting the practice of this invention. Heat warpage of a flat orifice plate may result in convex and/or concave areas within the plate but such distortions can readily be tolerated. If desired, the orifice plate may be reinforced with ribs or a honeycomb structure on the molten glass side of the bushing.
With commercial tips, the gas (e.g., air) cools the tips substantially below the bulk temperature of the bushing. As the tips cool, the glass flowing through the tips is also cooled and becomes more viscous and flows less readily so that the tips act as a thermal valve which decreases glass throughput. In the practice of this invention, the metal temperature adjacent the orifice during operation should not become substantially less than the bulk temperature of the orifice plate so that significant adverse thermal valve effects are avoided.
The thickness chosen for an orifice plate will be a function of bushing size, alloy strength, orifice size, orifice density, and the like. Generally the orifice plate need not be greater than 0.06 inches thick and orifice plates 0.04 inches thick have been successfully employed. The orifice area in the bushing readily may have a minimum dimension of at least about one-half inch with minimum dimensions of at least about 1 inch being quite feasible. Orifice areas of 10 inches × 10 inches are possible. In accordance with the conventional practice, the orifice plate or bushing is provided with heating means. Generally heating is accomplished by electrical resistance means.
The orifices in the orifice plate will generally be less than about 0.1 inch in diameter and may be as small as about 0.020 inches in diameter. The arrangement of holes is a matter of choice and orifices may be arranged in a square, hexagonal or any other desired arrangement. In order to obtain maximum utilization of bushing area the orifices generally will be spaced not more than about 2 diameters, center-to-center, with spacings of from about 1.25 to about 1.7 diameters, center-to-center, being preferred. With smaller orifices, the metal between adjacent orifices may be as little as 0.001 inch. It is apparent that the orifice spacing will depend in part on the thickness of the orifice plate alloy. If desired, periodic spaces having no orifices can be provided to add strength to the bushing. Care should be exercised, however, to avoid uneven air flow in the event such spacings are employed.
The orifice plates used in the practice of the present invention are at least four rows of orifices, preferably are at least about 10 or 11 rows of orifices, and most desirably are at least about 15 rows of orifices wide (i.e., in any direction). This invention permits the orifices to be spaced closely together with orifices in each row being spaced from orifices in its row and in adjacent rows in flooding relationship which, of course, is diametrically opposed to present practice. An orifice plate which would normally flood and would not maintain cone separation for practical production at operating glass pressure and temperatures can readily be employed in this invention since the bulk gas movement establishes and maintains cone separation. Even though an orifice plate may flood and foreclose sustained production under normal operating conditions of glass pressure and glass temperature just over the plate, such plate can be employed adopting the practice of this invention. In production, at least 90% production efficiency is generally desirable. Such rates and more can readily be attained by this invention.
Generally, for practical production, orifice density will be at least about 50 orifices per square inch, preferably at least about 100 orifices per square inch, and most desirably about 200 holes per square inch of the orifice area in the bushing. With very small orifices, the densities may range from about 500 to about 1000 orifices per square inch. The greater the density of a given orifice size, the greater the production that can be achieved per square inch per orifice area. Although orifice densities are given in orifices per square inch, it should be understood that the area occupied by the orifices may be less than 1 square inch.
Air is particularly preferred for this invention and can be at ambient temperature, or can be heated or cooled. Steam, finely dispersed water, other liquid droplets or the like can be added in the air if desired to increase its cooling capacity. Other gases such as nitrogen, carbon dioxide or the like may be employed in combination with air or instead of air. A non-reducing gas or gaseous fluid, i.e., one that does not provide a reducing atmosphere at the cones and orifice plate is generally preferred. While a reducing gas is not preferred, such gas (e.g., methane, ethane, or the like) may be employed if desired, but because of the essential requirement of this concept: a large cross section of rapidly moving gas to constrain the cones to their asymtotic-like configuration to prevent flooding, would require a great deal of expensive gases and not have any advantages over air. Since the gas is employed for cooling purposes it is preferred to employ gases of temperatures of about ambient temperature or less (e.g., about 100°F or less). It should be understood, however, that the benefits of this invention can also be achieved by warmer gas which may be, for example, even at 500°F, providing the volume of air is increased accordingly.
For ease of presentation the description herein is couched in terms of air. It is to be understood, however, that the description is equally applicable to other gases.
In one method of start-up of the method of this invention, albeit one having a slower start-up, the orifice plate temperature which is about 1000°C from the previous shutdown is elevated to about the range of devitrification temperature, between about 1083°C and 1105°C for E type glass. This will also cause a thin layer of glass inside and above the orifice plate to be raised to this temperature. The mass of glass inside the bushing which has been maintained at a temperature of about 1150°C to 1315°C is not affected. When the small quantity of glass adjacent the plate passes through the orifices, it will pass therethrough as separated streams without wetting and without flooding the plate even though the plate may be constructed of a wettable alloy. This cooler glass is no longer a pure Newtonian liquid but has some crystalline growth therein. While the resulting fibers are brittle, if handled carefully and slowly withdrawn, while increasing the plate temperature well above the devitrification range and while simultaneously adjusting the air cooling, the small amount of devitrified glass can be quickly and completely rinsed out, at which time the glass can be handled in the standard fashion.
In somewhat different operation to speed start up, the temperature of the glass adjacent the plate is increased by increasing the temperature of the orifice plate itself so that the glass therefrom becomes less viscous and under the pressure of the head of molten glass within the bushing quickly begins to pass through the orifices in the bushing or orifice plate. Due to the wetting properties of the glass and the close proximity of orifices, the underside of the plate begins to flood. As soon as the volume of flooded glass is heavy enough to furnish the initial attenuating force, it is necessary to reduce the flow of the glass through the orifices, otherwise, separation cannot occur. In one preferred embodiment of this invention, this flow rate regulation is accomplished through temperature control of the orifice plate. In yet another preferred embodiment, the current flow to the plate can be kept constant, and the glass flow through the plate reduced to allow separation to occur by directing a steady flow of air to the plate thereby reducing the plate temperature. Once separation is achieved, this air flow can be reduced to allow the plate to heat up and function as described above.
As the glass drops flow through the orifices and flood the underside of the orifice plate, it is necessary to reduce the temperature of the orifice plate into or at the edge of the glass devitrification temperature whereby the orifice plate functions as a molten glass thermic flow valve. This temperature reduction of about 50° to 150°C virtually stops the flow of glass through the orifice and allows for the flooding glass to flow or be drawn from the underside of the plates into individual glass fibers. If the glass is slowly withdrawn, separation will occur with the formation of a cone at each orifice with a fiber extending from each cone. An alternative to free flow is to contact the flooding drops with a glass rod or the like and slowly withdraw the rod from the plate. The heat of the molten glass causes the coalesced flooding drops to be welded to the rod and, therefore, the withdrawal of the rod causes the giant flooding drop or drops to form into individual fibers extending from the several orifices.
The early withdrawal rate should proceed generally at about one-half inch per second to avoid glass starvation of the forming fibers and to allow the surface glass to be slowly pulled into the enlarged main stream of attenuation without accidental pinch-off. Such a deliberate and slow rate of pull should continue until the underside of the plate is unflooded and separation is obtained.
A considerable drag will be experienced as the plate is being cleaned up by the glass tendency to adhere to the plate. The tensile strength and self-wetting energy of the glass is stronger than its plate wetting energy so that the dynamic glass will pull almost all of the static surface glass on the plate into its moving column and the plate will almost completely clean up leaving only a layer of glass about 0.001 inch thick. If pulling is carefully and slowly continued without interruption, a very fine fiber will extend from each hole in the orifice plate when there is no more surface glass available and when the glass which is being pulled through each of the orifices becomes the fibers final and sole source. At this point, it is again necessary to prevent fiber starvation and pinch-off by an increase in the glass flow rate through the orifices by a slight warming to the plate. As the warming of the thermic gate proceeds to permit a renewed but limited flow rate through the individual orifices, the glass fibers which extend therefrom can be wound around a very slowly rotation collet. The rotational speed of the collet and the temperature of the plate which controls the flow therethrough can be simultaneously and gradually increased while the air cooling (to be discussed) is coordinately reduced in pressure until a maximum drawing speed at a maximum temperature is reached.
In increasing the rate of production from the initial start up of the apparatus, at which time the fibers are withdrawn at about one-half inch per second to the desired attenuation rate, careful regulation and correlation of the temperature of the orifice plate, velocity of quench air, and the speed of withdrawal is accomplished. Since glass wets itself more readily than it does even a wettable orifice plate, as long as the forming cone under each orifice is maintained in an asymptotic configuration, the glass will continue to flow and is drawn through the orifices constrained in this manner to form into glass fibers as opposed to its tendency to run along the underside of the orifice plate and thereby flooding the plate. The molten glass passing through the orifice is continuously sucked into the fibers and cannot flood. In a simple implementation of this invention, a microscope with about 7 to 20 diameters of power can be placed near the underside of the orifice plate to view these cones while manually controlling the parameters. Continual viewing of the cones allows an operator carefully to correlate the temperature and rate of draw increases while controlling the air velocity visually to maintain the asymptotic configuration of the fiber forming cones. Of course, after considerable testing, such correlations should be computer actuated thereby saving considerable adjustment time and further increasing the production of the individual stations, however, an experienced operator can reach full attenuation speed as quickly as the plate temperature can stabilize, in about 30 seconds or less. Generally speaking, by properly maintaining the above described concavity of the forming cones, the attenuation rate can be increased to the limits of stress on the winding or other accumulating equipment. During operation, as glass passes through an orifice, a stress is provided by the forces of attenuation which are resisted by the viscosity drag of the glass through the cone, the base of which is fastened to the rim of the orifice by surface tension, the wetting energy of the glass and the partial vacuum inside the cone. Through this dynamic sucking stress, more glass is pulled through the orifice than would flow by gravity alone and there is a continuous flow of glass toward the filament and flooding is avoided.
As hereinafter noted, to maintain this asymptotic geometry of the fiber forming cones and therefore maintain separation of the individually formed fibers, it is necessary to cool substantially identically each of the fibers and the fiber forming cones as well as maintain the proper correlation between the rate of withdrawal, the temperature of the orifice plate and the flow rate through the individual orifices. In order uniformly to cool each of the individual fibers and cones, an air source is disposed below the orifice plate. The distance of the source from the plate depends upon the area of the orifices, size of the air nozzle or nozzles and the like. The distance is generally between 1 and 20 inches and with the particular size nozzle described below is between 2 and 4 inches. Preferably the upwardly moving air is introduced at a distance of from about 2 to about 12 inches from the bushing. With larger orifice areas the source of upwardly moving air will often be at least about 4 inches from the plate so that the air stream readily can impact on the entire orifice area.
The upwardly quenching air flow moves in between the individual fibers to each of the hundreds or thousands of cones. While it may appear that a tremendous number of fibers emanating from the orifices would prevent air travel therethrough, there may be, however, paradoxically over 40,000 times more air cross section than glass cross section which is considerably more open space than occupied space. For example, on a 3 × 10 inch bushing using a C filament whose cross-sectional area is 2.54 × 10.sup. -8 square inches, 30,000 orifices (0.020 in. dia. on 0.032 in center) can be drilled. This represents 7.6 × 10.sup. -4 square inches for the entire 30,000 fibers, which move through 30 square inches of open space to leave a vast unopposed openness for the air to move upwardly through the fibers to the forming cones. Despite the small area occupied by the fibers, the fast moving filaments will entrain the air and begin to function as an air pump. Within the first fractions of an inch from the orifices, however, the skin drag of the fibers is unable to accelerate the skidding air vortices thereby to a speed at which this entrainment pump becomes effective. But as the fibers are brought closer together and the air skids faster and faster along the fiber boundary layers, this pumping effect rapidly increases. Ordinarily, fill-in quenching air is sucked immediately across the plate and into the first few inches of fiber strands wherein the glass fiber pump becomes more effective closer to the plate. Accordingly, it appears as though this pumping action which begins at once would make it quite difficult to quench the fiber forming cones. However, as soon as air is directed upwardly between the fibers, this sucked in air is stopped and cooling air therefore is able to pass virtually unopposed upwardly between the fibers through generally quiescent air to the orifice plates. There is nevertheless sufficient downward skidding of air in the immediate vicinity of the fiber boundary layers between the bushing and the air nozzle to cause the rapid upwardly moving air to invert and flow inwardly and downwardly in the direction of the high speed moving fibers. This air increases in speed as it assumes an umbrella-like shape in the cone area whose analogous handle is a rapidly descending trumpet-shaped tube of air which cascades 360° around the fiber forming cone, cooling the cone from its plate secured base to the extended fiber apex. When the ascending turbulent air reaches the interstices between the orifices, it splits to form a hexagonal star, the moving points of which flow toward the area between the fibers while the remainder is perfectly proportioned, providing even 360° cooling of the fiber forming cones. As this cool air turns downwardly, hugging the convex shape of the cone as well as hugging and skidding the full fiber length, it accelerates to a very high speed as it follows the filament into the high pumping zone. A continuous mixing of cool ascending air with hot turbulent air in the vortices caused by the skin effect surrounding the descending fibers provides a uniform and stable environment over the entire length of the formed fiber. Through such cooling, the asymptotic geometry of hundreds or thousands of fiber forming cones can be continually maintained thereby allowing for a large increase in fiber production from a relatively very small orifice plate.
The upwardly directed air, in addition to cooling the surface of the cones and providing air to be drawn down the fibers, also serves to prevent pockets of stagnant air on the underside of the bushing which can result in local hot spots and cause flooding. The upwardly directed bulk air movement impinges on the underside of the bushings and tests indicate that a portion of that air moves laterally outwardly in all directions from the orifice area. The macro-cooling with the upwardly moving bulk air establishes and maintains cone and fiber separation.
Diametrically opposed to a conventional bushing with tips, it has been determined that, at a constant windup speed and constant plate temperature, more cooling by the air will provide a larger diameter fiber. Apparently the skin cooling in the cone creates a pumping action as the fiber is drawn from the cone. In this regard it should be noted that cooling occurs by extremely rapid conduction so that the skin of the fiber-forming cone is cooler than the interior. In conventional practice with fins, cooling is largely by radiation so that the interior of the transparent cone tends to be at more nearly the same temperature as the skin.
In proper operation the cone lengths are stable to the eye and the visual length of the cone is very short, generally not more than about 21/2 times the orifice diameter and, in any event, generally not longer than about one-eighth inch. In preferred operation the cone length is not more than about 11/2 times the orifice diameter. Many times, the pumping action caused by the cooled skin of the cone results in the base of the cone receding part way up the side of the orifice in the bushing. The glass temperature at the tip of the cone will be approximately the annealing temperature of the glass, and generally will be from about 1400°F (760°C) to about 1700°F (927°C).
The angle of air flow will vary somewhat depending on the number of rows and the density of orifices. Generally, process control is best maintained by positioning the air as vertical as possible consistent with the needs to draw fibers. While with extremely close control, the air may be directed upwardly at an angle of about 40° from horizontal, tests with a 17 row orifice plate and a 10 row orifice plate have indicated that for realistic control in commercial operation, the angle of the air should be at least about 45° or 46° from the horizontal, but preferably at least about 60° from the horizontal. With only a few rows the angles may be somewhat less critical. Air angles of from about 70° to about 85° are particularly preferred. The term horizontal is employed here to mean the plane in which the orifice plate generally lies.
Any mechanical arrangement that provides a bulk flow of air (i.e., a generally single upwardly moving air column at the cone and plate area) that impinges on the orifice plate is satisfactory for this invention. Multiple nozzles or a nozzle with a slit can be employed. Deflector plates which deflect air to an upward path can also be employed. While introduction of the upwardly moving air from one side of the orifice plate is entirely satisfactory and is preferred, the air can, if desired, be introduced from two or more sides of the bushing. The cross-sectional size of the air stream at the orifice plate should be at least as large as the orifice area in the orifice plate. The fibers can be pulled somewhat off to one side to accommodate the mechanical arrangement for introducing the air. The same benefit can be obtained by pulling the fibers vertically and tilting the bushing slightly.
The air pressures to be employed may readily be determined by the routineer and may vary from 2 inches of water to 5 psig or 10 psig or more depending on nozzle size, nozzle location and the like. Pressures from about 1 to about 5 psig are generally preferred, particularly for bushing of 10 rows or more. Generally the linear velocity of the air leaving the nozzle will be at least about 100 feet per second and preferably at least about 200 feet per second. Air velocities on the order of 400 feet per second and higher are readily employed in this invention. The velocity or pressure chosen, as noted above, will depend, in part, on the particular arrangement chosen. In any event the air flow should be sufficient to cool the cones and provide stable separated cones, to impinge on the plate essentially to eliminate stagnant air adjacent the plate and to provide a source of gas sucked downwardly by the fibers. It is apparent that cooling should not be so pronounced that fiber production is materially adversely affected.
While the above represents the preferred embodiment of cone stabilization, another method of in-mass cooling is provided by a series of thin curtains of cool air which sweeps across orifice plate in rapid succession. These curtains should be aimed at an angle of 46° to 90° to the plate surface to sweep in a broom-like fashion removing the hot stagnant air from the plate. By controlling the rate and frequency of the sweep and the velocity of the air, an average ideal temperature can be maintained across the fibers and fiber forming cones. These curtains of quenching air can be created by an air nozzle having one or more orifice slits therein, which nozzle is continually rotated 90° to the fiber axis to provide the described broom effect of these curtains of air.
Other variations in cooling such as the utilization of a staccato series of controlled annular vortices moving onto and generally normal to the face of the bushing can also be incorporated. The slow moving donuts of air with high internal angular momentum would continuously exchange the heated air from the plate, sweeping it into its annular vortex to scrub the plate surface while growing in size continuously to replace stagnant hot air. If these annular vortices of air are repeated at rapid intervals, the effect is to maintain an average desirable temperature over the length of formed fibers including the vital forming cones. Similarly, spiraling air currents could be employed whose vortices rotate generally in a plane with the plate similar to that produced by a fan blade. These spiraling cool vortices act to sweep away the hotter stagnant air remaining on the surface of the bushing. In each of these systems, the air is directed substantially parallel and in an opposite direction to the motion of the fibers so that the air is able to pass generally unopposed between the fibers and to utilize a substantial pumping effect created by the formed fibers. Early pumping created by the rapidly moving fibers is easily overwhelmed and through the vast open spaces cool air reaches each of the forming cones rigidly to maintain its required configuration.
The close orifice spacing and the stability of the cones can result in self-correction of localized flooding, should such flooding occur during operation. If a fiber breaks and the orifice floods to an adjacent fiber, that fiber will exert an increasing amount of attenuating force on the flooded glass to reinstitute cone and fiber formation from the flooded orifice. If necessary, localized cooling air as known in the art, for example, from a hand air lance may be applied to the multiple coalesced fibers to correct the flooding and reinstitute normal operation.
A slight instability may appear in the cones along the periphery of the orifice area. This occurs because the plate and glass are cooler due to heat losses to the exposed edges of the bushing. Stability can be improved providing the peripheral orifices are made slightly larger (for example, from about 0.001 to about 0.003 inches in diameter larger) than the interior orifices. Such adjustment will provide a mere stable operation without materially affecting uniformity of fiber size. Since the volume of glass, not just its skin, flowing through the peripheral orifices is cooler, glass will flow through the orifice less readily so that use of a slightly larger orifice will compensate for the reduced ability of the glass to flow.
In order to insure that molten glass from an orifice will controllably flood if the fiber breaks, one embodiment of this invention contemplates the provision of capillary grooves between orifices. These capillary grooves will cause the plate to act as though it had a controlled but perfect wettability. Since only a small volume of glass from the oozing orifice will first contact a neighbor fiber, the increase of acceleration load will be gradual, as the whole fiber pulls more glass out of the groove its own cross section enlarges and becomes stronger until a single larger fiber is fed by two orifices. It is described elsewhere how to separate such single fibers into two fibers. In this embodiment, each orifice is joined to at least two adjacent orifices so that if a fiber breaks, controlled flowing of the glass to the adjacent orifice is virtually assured. The grooves may be as wide as the orifices but preferably about one-third of the diameter of the orifice and may have a depth of around one-half the thickness of the bushing plate. Since the outer orifices may tend to flood more often than interior orifices, only outer orifices may be provided with grooves. Viewed in the context of start-up and self-correction of flooding, a bushing made of a highly wettable alloy, which more easily floods, is preferable to a bushing made of a so-called non-wettable alloy. All alloys, of course, will flood if the temperature of the glass is sufficiently high to cause the glass to be quite fluid.
The cooled fibers are coated with a dressing fluid or sizing by contacting the fibers with an applicator roll or the like, and the fibers then may be wound up on a package. The drawing or windup speeds of the fibers may vary widely from, for example, of about 100 ft. per minute up to about 13,000 ft. per minute or more. Determination of wind-up speeds or attenuation force for any given set of conditions is within the skill of the art. Windup speeds of over about 5,000 feet per minute are employed in conventional processes and may readily be employed here. Low draw off speeds may permit matching of fiber production with the rate of fiber usage in the manufacture of a final product so that the fiber or strand could be employed directly in the final production. In view of the orifice density such procedures would still be within the range of practical production. Dressing fluids, dressing fluid applicators and windup apparatus are conventional in the art and will not further be described here.
Good quality glass fibers are manufactured by the method of this invention. As a threshold matter, the extremely rapid quench of the molten glass below the orifices results in less loss of volatiles from the glass so that the glass composition of the fiber will closely conform to the glass composition in the glass bath. Moreover, this invention permits the production of tempered fibers. With a super quench due to the upwardly flowing air, the surface is cooled more rapidly than the interior glass and the temperature gradient is greater above the annealing temperature than below. As a result, the surface of the final fiber is under compression. In a conventional process employing long tips quite the reverse occurs. The temperature gradient is greater below the annealing temperature than above. In conventional processes, snap-out sometimes occurs wherein the fibers at temperatures below the annealing temperature all break substantially at the same time. Snap-out has been attributed to circumferential and length-wise temporary tensional forces. As noted earlier, snap-out has not been observed in the method of this invention, and logically so.
While a conventional glass furnace and auxiliary equipment readily can be employed in the practice of this invention, a particular apparatus wherein the head of glass can be maintained independent of the level of the glass bath is shown in the attached drawings.
FIG. 1 is a schematic view of the glass fiber filament production equipment.
FIG. 2 is an enlarged sectional view of the bushing and orifice plate illustrated in FIG. 1.
FIG. 3 is an enlarged sectional view taken along Line 3--3 of FIG. 1 showing the bushing and orifice plate.
FIG. 4 is a schematic view of glass fiber production equipment.
FIG. 5 is a view taken along line 5--5 of FIG. 4 looking upwardly at the lower surface of an orifice plate in which the orifices are connected by capillaries.
FIG. 6 is an enlarged sectional view taken along line 6--6 of FIG. 5 showing an orifice and capillary.
Referring now in detail to the drawings, an apparatus 10 for producing glass fibers 12 is illustrated in FIG. 1. As shown therein, a head of molten glass 14 is maintained within a bushing 16. The bushing is comprised of a tubular reservoir portion 18 which can be square, rectangular or cylindrical in shape and an enlarged base portion 20 which terminates at the lower end thereof in a flat orifice plate 22. The orifice plate has a plurality of tightly spaced plain holes 24 therein. As an example, in a 2,000 hole orifice plate 2.7 inches square, the holes or orifices are 0.04 inches in diameter and spaced 0.06 inches from center line to center line. Typically, the lengths of the holes in the orifice plate vary from 0.03 inches to 0.06 inches and T-shaped reinforcing bars 26 or, alternatively, a honeycomb structure (not shown) may be provided on the orifice plate to add strength thereto and to prevent plate sag. It is also entirely feasible to employ a generally flat orifice plate without any reinforcing.
A valve 28 which communicates the interior of the bushing with a liquid glass supply 30 can be disposed atop bushing 16 to permit a change in fiber diameter, with high heads tending to provide somewhat larger filaments. By opening and closing valve 28, glass is allowed to flow from the supply 30 into the reservoir portion of the bushing 16 thereby maintaining the desired head of the glass within the bushing. Of course, the fiber withdrawal rate, cooling air and plate temperature also are adjusted to obtain a stable fiber. To facilitate the regulation of the glass head within the bushing, an elongated platinum tube 32 extends upwardly from the interior of the bushing, through valve 28 to a sonic depth indicator 34. The sonic depth indicator is coupled with a valve regulator 36 which reacts to signals therefrom to move the valve 28 upwardly or downwardly on the bushing thereby opening and closing the valve and allowing the liquid glass to pass thereby.
In the embodiment illustrated in FIG. 1, the valve 28 is in threaded contact with regulator 36 by means of a threaded bar 37. Rotating the bar 37 causes the valve to move vertically with respect to valve seat 39 thereby regulating the flow of glass into the bushing 16. In this manner, a desired head of glass is continually maintained within the bushing as the glass fibers are drawn through the orifices 24 in the orifice plate 22.
The majority of applications will require no head control, therefore an envelope geometry of a bushing may be employed that is a duplicate of a conventional configuration, one that can exactly fit into a standard forehearth position. Because this geometry is well known in the art, further description is redundant.
As shown in FIG. 1, a platinum bus bar 38 communicates with an electrical source of about 3 volts and 1,000 amps with the orifice plate whereby the temperature of the plate can be increased. A water-cooled copper bus bar 40 is provided on the platinum bus bar 38 to make the electrical contact between the platinum bus bar 38 and the electrical source and reduce the necessary length of the platinum bus bar thereby reducing costs. The copper bus bar 40 is water cooled to reduce the temperature at the point of contact between the two bus bars and thereby preserve the copper and is spaced a minimum distance of about 1.5 inches from the orifice plate 22 so as to have a minimal effect on the temperature of the plate while limiting the length of the platinum bus bar. It can be seen that by controlling the electrical flow through a regulator, the temperature of the orifice plate can be carefully regulated. As an alternative to the above described plate heating method, it should be noted that the temperature of the orifice plate can also be controlled through induction heating without the need for the aforesaid bus bars. In general, orifice plate temperatures will range from about 2050°F (1120°C) to about 2300°F (1260°C) during operation.
Upwardly directed air 49 flows through nozzle 45 disposed on the end of supply hose 47, through connection 44. A row of nozzles can, of course, be employed to provide a substantially single column of air that impinges on the orifice plate and cools the cones to maintain them in a stable configuration. The attenuation of the fibers is effected by rotating drum 42.
In addition to the aforementioned temperature regulation controls of the orifice plate, fibers and cones, additional insulation and heating is provided to prevent temperature loss from the system which would necessarily effect the viscosity of the molten glass and consequently, the forming of the glass fibers. As shown in FIGS. 1 and 2, the base portion of the bushing is surrounded by a ceramic support 46 which, in addition to providing support for the bushing, further insulates the exterior position thereof which is adjacent the orifice plate. The ceramic support 46 and tubular reservoir portion 18 of of the bushing are surrounded by a layer of insulation material 48 which additionally extends between the platinum copper bus bars and the supply of liquid glass. The insulation material 48 terminates short of the walls of the bushing to provide an annular area 50 about the reservoir portion of the bushing in which a heating coil 52 is disposed to provide compensation for heat loss due to conduction through the insulation. The heating coil is connected to a thermocouple 53 to control the current therethrough and thereby regulate the compensating heat generated thereby. A second layer of insulation material 54 is disposed over and spaced from the liquid glass supply 30 thereby providing an insulation gap 56; as shown in FIG. 1. Of course, the above represents merely an exemplary embodiment of an insulation and supplementary heating configurations and other varying configurations could be employed to adequately maintain the desired temperatures. For example, to compensate for heat loss from the bushing due to conduction, resistance heating could be employed using the bushing as an element of an isolated circuit. In such an embodiment, a 400 cycle generator has been found to be an excellent power source.
Lastly, as shown in FIG. 1, a sizer 58 is provided to size the individual fibers with a standard lubricant type material such as starch to reduce abrasion between adjacent fibers and to assist resin wetting for future laminating. A roll sizer may also be employed to reduce consumption of sizing.
In FIG. 4, bushing 110 positioned in a glass furnace and surrounded by ceramic insulating material 111, contains a bath of molten glass 112. Glass fibers 113 are drawn by collet 114 from the orifices 102 in bushing 110. Cooling air is introduced through nozzle 115. The orifice area in bushing 110 contains capillary grooves in the underside of the plate connecting adjacent orifices which can be better seen in FIGS. 5 and 6.
As shown in FIG. 5, orifices 102 of orifice plate 101 are connected by capillaries 102. An elevational sectional view taken along line 6--6 is shown in FIG. 5. In FIG. 5, capillary 103 in the underside of orifice plate 101 connects adjacent orifices 102.
The following examples are included for illustrative purposes only and are not intended to limit the scope of the invention.
EXAMPLE I
A conventional tipless bushing was employed in this example made from a 0.040 inch thick platinum allow (80% platinum -- 20% rhodium) flat sheet. Orifices 0.052 inches in diameter were drilled in the flat plate in a hexagonal pattern on 0.070 in. centers. The rectangular orifice area in the bushing was approximately 1.25 in. wide and approximately 2.85 in. long with alternating 17 and 18 orifice rows. Each row contained about 46 orifices.
Type E glass was melted in a conventional glass furnace to provide about a 10 in. deep glass bath having a temperature of approximately 2300°F and glass fibers were manufactured employing the above plate. The plate was equipped with a heater and maintained a temperature of about 2100°F. A standard sizing was applied by a roll to the fibers which were wound at a speed of about 3,000 ft. per minute.
In order to maintain fiber separation, air was directed upwardly from the long side of the orifice area at an angle of approximately 15° from vertical through six 1/4-in. diameter nozzles arranged in a row on one side of the orifice area about 5 inches below the orifice plate. Air pressure within the range of 3-5 psig was employed.
Fibers were successfully drawn in stable operation and filament separation was maintained.
During usage the orifice plate exhibited some warpage and developed both concave and convex areas. The warpage of the orifice plate did not hamper fiber manufacture.
EXAMPLE II
In order to illustrate the benefits of this invention, the performance of the orifice of Example I is compared to the performance of two conventional tip bushings, (designated A and B) employing fin coolers. The overall bushing face areas were the same in each case but the orifice section of the bushing of Example I covered less than one-fourth of the entire face of the bushing. In each case Type E glass was used.
______________________________________ Bushing Ex. I A B______________________________________No. Holes 804 390 390Hole Dia (in.) .052 .078 .090Throughput (lb/hr) 65.0 39.0 51.6Area of Each Hole (in.sup.2 × 10.sup..sup.-4) 21.23 47.78 63.62Hole Area Ratio 1 2.25 3Orifice Plate Area (in.sup.2) 3.56 15.62 15.62Throughput (lb/in.sup.2 /hr) 18.3 2.5 3.3Holes per inch.sup.2 of Bushing 226 25 25______________________________________
The above demonstrates that this invention provides more throughput per unit of bushing area in the bushing as compared to conventional practice. This invention also provides more throughput per hole area as compared to conventional practice. More clearly to envision the magnitude of difference, if an equal size of orifice section were used, Example I bushing would have produced 3527 fibers with a throughput of 285 pounds per hour.
Changes and modifications may be made in carrying out the present invention without departing from the spirit and scope thereof. Insofar as these changes and modifications are within the purview of the appended claims, they are to be considered as part of the invention.
EXAMPLE III
The bushing employed in this example was made from a 0.060 inch thick platinum alloy (80% platinum - 20% rhodium) flat sheet. One thousand six hundred and seventy orifices were drilled in the flat plate in a hexagonal pattern on 0.070 inch centers. The rectangular orifice area in the bushing was approximately 11/8 inch wide and approximately 61/2 inches long. The peripheral orifices were 0.049 inches in diameter and the remaining orifices were 0.047 inches in diameter.
Type E glass was melted in a conventional glass furnace to provide about a 10 inch deep glass bath having a temperature of approximately 2300°F and glass fibers were manufactured employing the above plate. The plate was equipped with a heater and maintained a temperature of about 2240°F. A standard sizing was applied by a roll to the fibers which were wound at a speed of about 2,500 feet per minute.
In order to maintain fiber separation, air was directed upwardly from the long side of the orifice area at an angle of approximately 20° from vertical through 12 1/4-inch diameter nozzles arranged in a row on one side of the orifice area about 5 inches below the orifice plate. Air pressure within the range of 3-5 psig was employed.
Fibers were successfully drawn in stable operation and filament separation was maintained. The peripheral cones were quite stable. | A method and apparatus for forming glass fibers employing a generally flat orifice plate having closely spaced orifices is disclosed. A bulk flow of upwardly directed cooling gas which impinges on the orifice plate to eliminate stagnant gas pockets and which surrounds and cools the molten glass cones beneath each orifice is employed to maintain fiber separation and improve fiber formation and properties.
This a division of application Ser. No. 500,303, now U.S. Pat. No. 3,905,790, filed Aug. 26, 1974, which is a continuation-in-part of Ser. No. 432,997, filed Jan 14, 1974, abandoned. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the invention
[0002] The present invention relates to a packing box for a cartridge container in which flat cartridges with tape reels housed respectively therein and, more particularly, to a cardboard packing box for packing and carrying a cartridge container with tape cartridges are contained.
[0003] 2. Description of Related Art
[0004] Typically, it is general in an ordinary distribution process to secure impact protection for a package of one-reel type electromagnetic tape cartridges by filling a cardboard packing box 5 with a substantial number of the tape cartridges 1 individually encased in cartridge cases 3 , respectively, as shown in FIG. 6 . An inconvenience encountered by the collective package is that the cardboard packing box 5 has to be opened in order to check its contents and/or the type of the tape cartridges 1 packaged therein. Further, if the cardboard packing box 5 is bedewed with water, the cardboard packing box 5 is damaged or broken at its worst.
[0005] Such being the case, there has been marketed a cartridge packing case 7 for collective packing of tape cartridges 1 such as shown in FIG. 7 . Such the transparent plastic packing box 7 is known, for example, in the name of UTO-Ultrum L-pack (Trade name of TDK Co., Ltd.). This cartridge packing case 7 , which may be named an individual packing type, has an interior space separated into a number of compartments 9 by separation rails 11 for individually receiving tape cartridges such as shown in FIG. 6 . Accordingly, the tape cartridges are put in the cartridge packing case 7 one by one. In the case that a heavy number of the tape cartridges are packed, it can be hardly said that the cartridge packing cases 7 are handy. Further, because the compartments 9 are separated from one another so as to share isovolumetric capacities, a full weight load of packed tape cartridges concentrates on corners 13 and 15 of the cartridge packing case 7 , so that the cartridge packing case 7 is poor in impact resistance and has only a low impact absorption capacity upon falling.
[0006] In these circumstances, the inventor of this application has developed a cartridge container which has high packing efficiency besides high impact resistance. Reference is made to FIGS. 8 , 9 A- 9 B and 10 A- 10 B for the purpose of providing a brief description of the cartridge container 100 that will enhance an understanding of the and operation of the cardboard packing box of the present invention.
[0007] Referring to FIGS. 8 , 9 A- 9 B and 10 A- 10 B, the cartridge container 100 is used suitably for containing flat tape cartridges 21 with electromagnetic tape reels incorporated, respectively, therein. The tape cartridge 21 incorporates a tape reel (not shown) having a core axis extending in a direction of thickness of the tape cartridge 21 therein. The following description will be directed to a square tape cartridge by way of example and held true in a rectangular tape cartridge.
[0008] The cartridge container 100 comprises a case shell made up of two mating case shell halves, namely upper and lower mating case shell halves 23 and 25 . These upper and lower mating case shell halves 23 and 25 are identical in structure and shape with each other. The upper and lower mating case shell halves 23 and 25 are detachably fitted together by engagement so as to be opened and closed. For this detachable fitting of the upper and lower mating case shell halves 23 and 25 , there are formed a plurality of, for example four in this embodiment, compartments 27 for receiving four tape cartridge sets 29 . The tape cartridge set 29 to be received in the compartment 27 comprises a predetermined number of, for example five in this embodiment, tape cartridges 21 arranged closely side by side in a direction of thickness in block As shown in FIG. 8 , in order to protect tape egress/ingress slots of the tape cartridges 21 which are generally weak in mechanical structure against impact from the outside of the cartridge container 100 , it is preferred to put the tape cartridge set 29 so as to position the tape egress/ingress slots on the side of a boundary between adjacent compartments 27 and faced upward. It is more preferred to put the cartridge sets 29 in the compartments 27 so that the tape egress/ingress slots of the cartridge sets 29 in adjacent compartments 27 are opposed one another. In this instance, the compartment 27 has a storage volumetric capacity which is approximately the same as the cubic measure of the five tape cartridges 21 . Accordingly, the tape cartridges 21 are neatly arranged in the compartment 27 even if put in the compartment 27 in a careless way. This is because there is no parting strip for the tape cartridges 21 in the compartment 27 . Since it is enabled to hold two or three tape cartridges 21 together by hand and put them into the compartment 27 , the cartridge container 100 bring a marked improvement in tape cartridge packing operation as compared with the conventional cartridge container or box which needs to put tape cartridges 21 one by one.
[0009] As described above, according to the structure of the cartridge container 100 , since the tape cartridges 21 are contained in lots of multiple units, the cartridge container 100 is possible to acquire an extra area uninvolved in storage in the case of the same storage area as the prior art cartridge container 7 including a flange which is adapted to receive the tape cartridges 21 individually. The extra area of the cartridge container 100 is utilized for what is called a crushable or impact absorption zone. The transverse flanges 35 of the mating case shell halves 23 and 25 at the respective short sides have rectangular openings 33 , respectively, used as carrying handgrips of the cartridge container 100 . Therefore, the cartridge container 100 can not only be carried in a horizontal position by grasping the both handgrips 33 but also be carried in a vertical position by gripping either one of the opposite handgrips 33 . If a carrier accidentally drops the cartridge container 100 while carrying it in a vertical position by one hand, the cartridge container 100 has a first hit against a floor at the far side flange 31 . At this time, the far side flange 31 , that performs as an impact absorption member, is deformed or crushed by the weight of the cartridge container 100 and its contents so as to absorb impact strength, thereby absorbing a direct shock against the tape cartridges 21 .
[0010] In the general, the tape cartridge 21 has a weakness for impact in a direction of thickness or axis of the tape reel, because a roll of electromagnetic tape 21 does not always have even side surfaces but has irregularities at opposite sides thereof. The electromagnetic tape is not always wound on the tape reel with side edges of convolutions of the tape neatly flush with one another, so that a roll of the electromagnetic tape wound in the tape reel has irregularities at opposite sides. The irregularities possibly cause the electromagnetic tape to hit against the flanges of the tape reel at the side edges due to external force while winding the electromagnetic tape in the tape reel, resulting that the electromagnetic tape is crushed and/or broken back in a transverse direction at its side edges as being wound in the tape reel. The electromagnetic tape having crushed and broken irregularities brings down an adverse effect on smooth winding and unwinding, and besides causing defective record at its worst. In contrast, the container 100 having the crushable flanges 35 arranged at the short sides thereof has enhanced impact resistance in the lengthwise direction in which the tape cartridge 21 is mechanically weak.
[0011] As shown in FIGS. 10A and 10B , the cartridge container 100 has a number of side buffering ribs 35 rising outside from an external peripheral wall thereof. The side buffering rib 35 is formed so as to provide a side clearance space 35 ′ in an internal peripheral wall as shown in FIG. 10B . The side buffering ribs 35 function as cushioning means against external impact on the cartridge container 100 . In addition, the cartridge container 100 has a corner buffering rib 37 , like the side buffering rib 35 , rising outside from an each corner of the external peripheral wall thereof and a corner clearance space 37 ′, like the side clearance space 35 ′, in an internal peripheral wall thereof. These side and corner buffering ribs 35 and 37 function as cushioning means against external impact on the cartridge container 100 . In particular, the corner clearance space 37 receives a vertical edge of the tape cartridge 21 placed adjacently to the short side wall of the cartridge container 100 , so as thereby to prevent the tape cartridge 21 being deformed or damaged at the edge when the tape cartridge 100 is dropped.
[0012] The mating case shell half 23 , 25 has a case coupling structure comprising a top fitting rails 41 extending half around an opening thereof and a generally U-shaped top fitting groove 43 extending separately half around the opening as male and female fitting components, respectively. These male and female fitting components are formed on opposite sides of a longitudinal center line 47 of the mating case shell half 23 , 25 and completely equal in overall length to each other. The top fitting rail 41 of one of mating case shell halves 23 and 25 is fitted in the top fitting groove 43 of the other by insertion so as thereby to couple the mating case shell halves 23 and 25 together. The cartridge container 100 provided by coupling the mating case shell halves 23 and 25 together though fitting between their tip fitting rails 41 and the top fitting grooves seals up the interior, i.e. the compartments 27 , thereof, so that the tape cartridges 21 in the cartridge container 100 are protected from moisture, water, water splashes, dust and harmful substances. According to the cartridge container 100 , the mating case shell halves 23 and 25 are compatible with each other, in other words, available even as a container body or as a cap. This brings about an advantage that it is only needed to provide a single mold for production of both mating case shell halves 23 and 25 .
[0013] The mating case shell half 23 , 25 is provided with partition walls 47 arranged in cruciform for defining the respective compartments 27 . In order to protect the tape cartridges 21 from external impact the partition wall 47 has a shape and thickness such as described later so as to be easily deformable for absorption of external impact to the sets of tape cartridges 29 upon a drop of the cartridge container 100 even in a vertical or a horizontal position. That is, the cartridge container thus structured prevents sets of tape cartridges from having an effect of inertial impact on one another even when the respective sets of tape cartridges are individually affected by impact.
[0014] The cartridge container 100 with four cartridge sets 29 packed therein is boxed in a cardboard packing box (not shown) for carrying about. The cardboard packing box is dimensioned so as to snugly receive the cartridge container 100 therein. In order to take out the cartridge container 100 with ease, the flange 31 is cut off at opposite corners 49 at approximately 45 degrees so as to form triangular spaces between the cartridge container 100 and the cardboard packing box for easy access to the cartridge container 100 by fingers. This cut off corner 49 may be provided with a catch tab (not shown) so that the catch tabs at each cut off corners of the mating case shell halves 23 and 25 overlap each other when the mating case shell halves 23 and 25 are coupled together. Accordingly, the mating case shell halves 23 and 25 can be easily uncoupled by pulling away the catch tabs from each other.
[0015] Further, the mating case shell half 23 , 25 is provided with a lateral rim extending entirely along either one of the top fitting rail 41 and the top fitting groove 43 and bent toward the counterpart so as to cover the periphery of the mating case shell half 23 , 25 of the other of the top fitting rail 41 and the top fitting groove 43 of the counterpart for improved dustproof and waterproof.
[0016] The mating case shell half 23 , 25 also has a container coupling structure comprising two pairs of quadrilateral bottom fitting frames, namely a pair of larger quadrilateral fitting frames 53 a and a pair of smaller quadrilateral bottom fitting frames 53 b, formed as male and female fitting components, respectively, on an external bottom surface thereof The larger bottom fitting frame 53 a defines an aperture into which the smaller bottom fitting frame 53 b is snugly fitted by insertion. These bottom fitting frames 53 a and 55 a are located correspondingly to the respective compartments 27 and arranged on opposite sides of the longitudinal center line 45 (see FIG. 9B ) of the mating case shell half 23 , 25 . The bottom fitting flames 53 a and 55 a are dimensioned so that the bottom fitting frames 55 a of the mating case shell halve 23 , 25 are fitted in the bottom fitting frames 53 b of the mating case shell halve, 23 , 25 of another cartridge container 100 by insertion. By means of the container coupling structure, a plurality of the cartridge containers 100 piled on top of another are prevented from striking relative slide and, in consequence, from tumbling down.
[0017] The mating case shell half 23 , 25 is preferably made in the form of an integral product of a plastic resin such as those relatively easy in handling. Therefore, it is enabled to produce the mating case shell half 23 , 25 provided with sufficient toughness for reliable protection of the tape cartridges 21 stored in the cartridge container 100 and appropriate impact absorbability and to be suitable for commercial and inexpensive production of the cartridge container 100 . It is preferred to use any one of polyethylene terephthalate, polypropylene and polystyrene for the mating case shell halves 23 and 25 by reason of easy availability of the material, easy and inexpensive vacuum molding of the mating case shell halves 23 and 25 , and collection and reclamation of waste cartridge containers 100 . It is further preferred to use translucent plastic resins by reason of visibility of the tape cartridges 21 put in the cartridge container 100 and easiness of keeping track of a contained state of the tape cartridges 21 in the cartridge container 100 hermetically closed.
[0018] In order to economically acquire required minimum structural strength of the respective compartments 27 of the cartridge container 100 , and besides minimizing the cartridge container 100 in weight while satisfying required minimum structural strength of the cartridge container 100 , it is possible to form the mating case shell halves 23 and 25 by stretching press of a plastic resin sheet having a thickness of 0.5 to 2.0 mm. In addition, the usage of such a thin plastic resin sheet results in allowing the cartridge container 100 to cause proper deformation due to external impact, so as thereby to secure most appropriate impact absorbability for the tape cartridges 21 . In this instance, if the plastic resin sheet has a thickness less than 0.5 mm, the cartridge container 100 causes deformation too easily, so that it is incapable of bringing about an appropriate impact absorption effect. On the other hand, if the plastic resin sheet has a thickness greater than 2.0 mm, the cartridge container 100 encounters a difficulty in deformation which allows external impact to be directly transmitted to the tape cartridges 21 put therein. The cartridge container 100 whose thinnest part is confined in thickness to that range in the limits is provided with an optimized crushable or appropriate impact absorbable zone.
[0019] FIG. 11A-11D shows a cartridge packing procedure in the case of packing four sets of five tape cartridge units in a transparent cartridge container by way of example. In first step, an upper transparent mating case shell half 23 and a lower transparent mating case shell half 25 are set out as a container cap and a container body, respectively, as shown in FIG. 11A . On the other hand, four sets of five tape cartridge units (first and second sets of five tape cartridge units C 1 and C 2 are shown and the remaining two sets of five tape cartridge units are hidden behind the two sets of five tape cartridge units C 1 and C 2 ) are prepared. In second step, the respective sets of five tape cartridge units C 1 and C 2 are individually put in the compartments 27 of the lower case shell half 25 separately in position as shown in FIG. 11B . In the sane manner, the remaining two sets of five tape cartridge units are individually put in the compartments 27 of the lower case shell half 25 separately in position. Subsequently, in third step, the upper case shell half 23 is placed over the lower case shell half 25 as shown in FIG. 11C . Then, in forth step, the upper case shell half 23 is pushed down against the lower case shell half 25 so as to fit the top fitting rails 41 of the case shell halves 23 and 25 in the top fitting grooves 43 of them by insertion, respectively, thereby coupling the mating case shell halves 23 and 25 together as shown in FIG. 11D . In this procedure, a cartridge container 100 in which two sets of tape cartridges are received in the respective compartments is completed. The cartridges are seen through the transparent cartridge container for checking the type and the state of the contents.
[0020] FIG. 12A and 12B show, respectively, a cartridge container 100 1 with four sets of five tape cartridge units (two sets of five tape cartridge units C 1 and C 2 and the remaining two sets of five tape cartridge units are hidden behind the two sets of five tape cartridge units C 1 and C 2 ) contained therein which is prepared in the procedure shown in FIGS. 11A-11D and a cartridge container stack comprising two units of the cartridge containers 100 a by way of example. As shown, the cartridge container 100 a is made up two mating case shell halves 23 and 25 coupled together through fitting between the top fitting rails of the case shell halves 23 and 25 in the top fitting grooves 43 of them by insertion. As was described previously, the mating case shell half 23 , 25 has two frame-shaped bottom fitting flames 53 a and two frame-shaped bottom fitting flames 53 b as male and female fitting components, respectively, on an external bottom surface thereof (bottom fitting frames 53 b of the upper mating case shell half 23 and bottom fitting frames 53 a of the lower mating case shell half 25 are hidden behind bottom fitting frames 53 b and 53 a, respectively). When stacking another cartridge container 100 b on the cartridge container 100 1 as shown in FIG. 12B , the other cartridge container 100 b is placed on the cartridge container 100 b so as to bring the bottom fitting frames 53 a and 53 b of the lower mating case shell half 25 of the other cartridge container 100 b into alignment with the bottom fitting frames 53 b and 53 a of the upper mating case shell half 23 of the other cartridge container 100 a, respectively and then pushed down against the other cartridge container 100 a so as to fit the bottom fitting frames 53 a and 53 b to the bottom fitting frames 53 b and 53 a, respectively, by insertion. In this way, the two cartridge containers 100 a and 100 b are firmly coupled together, so that the stack of two cartridge containers 100 1 and 100 2 is prevented from collapse with a bit of oscillations.
[0021] Incidentally, it is general in an ordinary distribution process to pack the cartridge container 100 in a cardboard packing box by a procedure such as shown in FIGS. 13A-10C . As shown in FIG. 13A , a cartridge container 100 and a cardboard packing box 200 with a cover 200 a opened are prepared. The cardboard packing box 200 is designed to receive and hold the cartridge container 100 therein. Subsequently, as shown in FIG. 13B , the cartridge container 100 is put in the cardboard packing box 200 and, then, as shown in FIG. 13C , the cover 200 a is closed.
[0022] The cardboard packing box 200 is ordinarily designed to keep its given structural strength in a horizontal position. In consequence, although the cardboard packing box 200 having the cartridge container 100 packed therein has no problem as long as placed horizontally on a floor or a flat table as shown in FIG. 14A . However, the trouble the cardboard packing box 200 having the cartridge container 100 packed therein encounters is that when dropped in a vertical position, the cartridge container 100 is significantly damaged at the flanges 31 themselves, portions of the mating case shell halves 23 and 25 at corners of the case shell half 23 and G 1 and roots G 2 and distal ends G 3 of the flanges 31 .
SUMMARY OF THE INVENTION
[0023] It is therefore an object of the present invention to a cardboard packing box for packing a cartridge container with a plurality of tape cartridges contained which prevents a cartridge container from being damaged upon falling down.
[0024] The foregoing object of the present invention is accomplished by a cardboard packing box for storage of a cartridge container which has a case shell comprising two mating case shell halves identical in dimensions with each other and forming a plurality of compartments for receiving sets of a specified number of flat tape cartridge units therein respectively, each mating case shell half having at least one pair of bottom fitting flames different in size so that one of the bottom fitting frames of one of the two mating case shell halves is fitted in another of the two mating case shell halves by insertion so as thereby to be able to couple the cartridge container to another cartridge container together. The cardboard packing box comprises a cardboard box having internal dimensions substantially identical with a horizontal projection of the case shell of said cartridge container and a pair of cardboard backing pads each of which has an external dimension substantially identical with an internal dimension of said cardboard box and has a pair of openings in which the bottom fitting frames of each mating case shell half are fitted respectively by insertion. The cardboard backing pad may have two or more pairs of the openings correspondingly to the number of pairs of the bottom fitting flames of each mating case shell half. It is preferred for the cardboard backing pad to have at least one fingerhold opening formed therein. Further, it is preferred for the cardboard backing pad to comprise a combination of at least two cardboards different in thickness.
[0025] The cardboard box has an internal dimension of 300 mm×400 mm. In the case of the cardboard box having an internal dimension of 300 mm×400 mm, the cardboard backing pad may be shaped so as to have a clearance between 0 and 20 mm with said cardboard box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The foregoing and other objects and features of the present invention will be clearly understood from the following detailed description when reading with reference to the accompanying drawings wherein same or similar parts or mechanisms are denoted by the same reference numerals throughout the drawings and in which:
[0027] FIG. 1 is an exploded perspective view of a cardboard packing box according to a preferred embodiment of the present invention;
[0028] FIG. 2 A(a) is a side view of a lower case shell half of a cartridge container for use with the cardboard packing box;
[0029] FIG. 2 A(b) is a front view of the lower case shell half of the cartridge container for use with the cardboard packing box;
[0030] FIG. 2 B(a) is a side view of the lower case shell half of the cartridge container to which a cardboard backing pad is attached;
[0031] FIG. 2 A(b) is a front view of the lower case shell half of the cartridge container to which a cardboard backing pad is attached;
[0032] FIG. 2C is a front view of the lower case shell half of the cartridge container in which sets of five cartridge units are put;
[0033] FIG. 2D is a front view of the cartridge container before an upper case shell half is coupled to the lower case shell half;
[0034] FIG. 2E is a front view of the cartridge container before a cardboard backing pad is attached to the upper case shell half;
[0035] FIG. 3A is a front view of the cartridge container before packing;
[0036] FIG. 3B is a longitudinal-sectional view of a package of the cartridge container in the cardboard packing box;
[0037] FIG. 3B is a longitudinal-sectional view of a package of the cartridge container in the cardboard packing box;
[0038] FIG. 3C is an explanatory view for showing the package dropped vertically down;
[0039] FIGS. 4A to 4B are plane views of various cardboard backing pads;
[0040] FIG. 5 A(a) to 5 A(c) are plan views of various pallets standardized in different countries;
[0041] FIG. 5 B(a) to 5 B(c) are plan views of layouts of the packages placed on the pallets shown in FIGS. 5 A(a) to 5 A(c), respectively,
[0042] FIG. 6 is an exploded perspective view of a conventional cartridge case package;
[0043] FIG. 7 is a perspective view of a conventional cartridge container;
[0044] FIG. 8 is an exploded perspective view of a cartridge container for use with the cardboard packing box shown in FIG. 1 ;
[0045] FIG. 9A is a plane view of a mating case shell half of the cartridge container;
[0046] FIG. 9B is a front view of the mating case shell half of the cartridge container;
[0047] FIG. 10A is a side view of the mating case shell half of the cartridge container;
[0048] FIG. 10B is a perspective view showing a part of the interior of the mating case shell half of the cartridge container;
[0049] FIGS. 11A to 11D are explanatory views for showing steps of completing a cartridge container with cartridges contained therein;
[0050] FIG. 12A is a front view of a completed cartridge container;
[0051] FIG. 12B is a front view of a stack of two cartridge containers;
[0052] FIGS. 13A to 13C are views for showing steps of packing a completed cartridge container in a conventional cardboard packing box;
[0053] FIG. 14A is an explanatory view showing the package placed on a floor; and
[0054] FIG. 14B is an explanatory view for showing the package dropped vertically down.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] Referring to the accompanying drawings in detail, and in particular, to FIG. 1 , there is show a packing box 300 comprising a cardboard box 310 and two cardboard backing pads 320 according to an embodiment of the present invention for use with the cartridge containers 100 each of which is made up of two mating case shell halves and has the male-female container coupling structures formed on bottom surfaces thereof (see FIGS. 8 to 10 A- 10 B). The cardboard box 310 may be of conventional such as shown in FIG. 6 . The cardboard backing pad 320 has two pairs of quadrilateral fitting apertures 320 a and 320 b different in size. The first pair of quadrilateral fitting apertures 320 a are shaped so as to snugly fit on the larger bottom fitting frames 53 a of the mating case shell half 23 , 25 , respectively, and the second pair of quadrilateral fitting apertures 320 b are shaped so as to snugly fit on the bottom fitting frames 53 b of the mating case shell half 23 , 25 , respectively. It is preferred to provide the cardboard backing pad 320 by the use of various types of commercially available cardboards in appropriate combination according to the height of the bottom fitting flames 53 a of the mating case shell halves 23 and 25 of the cartridge container 100 . Specifically, standard cardboards commonly available for general packing boxes include types of A-flute having a thickness of 5 mm, B-flute having a thickness of 3 mm and W-flute having a thickness of 8 mm. In this instance, it is preferred for the cardboard backing pad 320 to employ these standard cardboards individually or in any combination.
[0056] FIGS. 2 A(a) and 2 A(b) to 2 E show a procedure of attaching the cardboard backing pads 320 to the cartridge container 100 in use. At the outset, the mating case shell half 25 used as a container body is prepared as shown in FIGS. 1 A(a) and 1 A(b) (labels (a) and (b) indicate side and front views, respectively). The cardboard backing pads 320 is attached to the mating case shell half 25 by fitting the fitting frames 53 a and 53 b of the mating case shell half 25 into the fitting apertures 320 a and 320 b of the cardboard backing pad 320 , respectively, by insertion as shown in FIGS. 2 B(a) and 2 B(b) (labels (a) and (b) indicate side and front views, respectively). Thereafter, as shown in FIG. 3 , four sets of five tape cartridge units (first and second sets of five tape cartridge units C 1 and C 2 are shown and the remaining two sets of five tape cartridge units are hidden behind the two sets of five tape cartridge units C 1 and C 2 ) are put in the respective compartments 27 of the mating case shell half 25 . The mating case shell half 23 used as a container cap is prepared in the subsequent step shown in FIG. 2D and coupled to the mating case shell half 25 through fitting between the top fitting rails 41 and the top fitting grooves 43 of the mating case shell halves 23 and 25 by insertion. On the other hand, another cardboard backing pad 320 is prepared as shown in FIG. 2E and attached to the mating case shell half 25 by fitting the bottom fitting frames 53 a and 53 b of the mating case shell half 25 into the fitting apertures 320 a and 320 b of the cardboard backing pad 320 , respectively, by insertion (see FIG. 3A ). In this way, the cartridge container 100 with four sets of five tape cartridge units contained is brought to completion. It is of course that the cardboard backing pads 320 is attached to the mating case shell half 25 prior to coupling the mating case shell halves 23 and 25 . In this way, then, the cartridge container 100 is placed ready for package. The cartridge container 100 with the cardboard backing pads 320 attached thereto is packed in the cardboard box 310 in an ordinary way.
[0057] The cartridge container 100 with the cardboard backing pads 320 attached thereto is placed ready for package as shown in FIG. 3A and then packed in the cardboard box 310 in an ordinary way as shown in FIG. 3B . Because the cardboard box 310 is designed and made to maintain its given structural strength in a horizontal position, there is no problem as long as it is put on a flat table or a flat floor. When the cartridge-contained cardboard box 310 is fallen in a vertical position against a floor and elsewhere, the impact applied to the package is absorbed or significantly absorbed not only by the flanges 31 of the mating case shell halves 23 and 25 of the cartridge container 100 but also by the cardboard backing pads 320 , so that the impact applied to the package at a position G 3 where the flanges 31 abut against the cardboard box 310 is down by half. In addition, although it is conceivable that the cartridge container 100 encounters heavy vertical waggle due to the acceleration of impact at bottom corners G 1 , the cartridge container 100 is prevented from waggling vertically by the cardboard backing pads 320 . This protects the flanges 31 against crush or significant deformation at their roots G 3 . The cardboard backing pad 320 is tightly fitted in size to the horizontal cross section of the cardboard box 310 , in other words, it has a shape identical with a horizontal cress-section of the cardboard box 310 which is the same horizontal projection as the mating case shell half 23 , 25 of the cartridge container 100 and is, in rerum nature, received in the cardboard box 310 leaving no gap therebetween. However, in the case where it is desired to distribute external impact to both the cardboard backing pads 320 and the cartridge container 100 in order to disperse the impact, the cardboard backing pad 320 may be shaped so as to leave an appropriate clearance with the cardboard box 310 .
[0058] The tight-fitting cardboard backing pad 320 encounters an inconvenience for handpicking. In order to eliminate this inconvenience, the cardboard backing pad 320 may be provided with one or more fingerhold openings as shown in FIGS. 4B-4D . Specifically, a cardboard backing pad 320 A shown in FIG. 4B has a fingerhold cut K 1 in the form of a triangular cut at one of four corners thereof. A cardboard backing pad 320 B shown in FIG. 4C has a semi-circular fingerhold notch K 2 at one of opposite short sides. A cardboard backing pad 320 C shown in FIG. 4D has a fingerhold holes K 3 in close vicinity to edges of opposite short sides, respectively. According to these cardboard backing pads 320 A, 320 B and 320 C, it is easy to detach the cardboard backing pad from the cartridge container 100 by picking the top cardboard backing pad at the fingerhold with a finger or fingers and pulling it up. The cartridge container 100 with the top cardboard backing pad removed away is easily grasped by hands and unboxed.
[0059] FIGS. 5 A(a) to 5 A(c) show various pallets as used to loading or carrying a cargo in major countries such as, for example, Japan, U.S.A. and Europe. As was described previously, the cardboard box 310 preferably has substantially the same horizontal cress-section as the horizontal projection of the cartridge container 100 . In light of the dimensional requirement, a study was made on preferred lengthwise and breadthwise dimensions of the cardboard box 310 . As a result, the cardboard box 310 determined based on the notion that it is preferred to standardize the cardboard package boxes by a single unitary size. As is well known, the pallet varies in standard size depending upon countries. Specifically, the pallet 400 standardized in Japan is 1100×1100 mm as shown in FIG. 5 A(a), the pallet 401 in U.S.A. 1219×1016 mm as shown in FIG. 5 A(b) and the pallet 402 in Europe 1200×800 mm as shown in FIG. 5 A(C). It was found that the optimum size of the cardboard package box, and hence the cartridge container 100 in horizontal projection, is 300×400 mm in order to set the cardboard package boxes on the pallets 400 , 401 and 402 as many as possible with least void spaces.
[0060] FIGS. 5 B(a) to 5 B(c) show loading patterns of the cardboard boxes 310 of 300×400 mm on Japanese pallets 400 , U.S. pallet 401 and European pallet 402 , respectively. As shaded in FIGS. 5 B(a), 5 B(b) and 5 B(c), Japanese pallet 400 can stow eight packing boxes 300 leaving a 200 mm-square redundant space in the center and two 100 mm-width redundant spaces along two sides, U.S. pallet 401 can stow nine cardboard packing boxes 300 leaving a 116 mm-width marginal redundant space along one side and a 19 mm-width marginal redundant space along another side, and European pallet 402 can stow eight cardboard packing boxes 300 leaving no redundant space. As seen in the above examples, the 300 mm×400 mm cardboard packing box can be carried efficiently in quantity by any major pallets. In order to meet the requirements for both dispersion of external impact and enhanced carrying efficiency of the 300×400 mm cardboard packing boxes 300 , it is preferred for the cardboard backing pad 320 to have a clearance with the cardboard box less than 20 mm.
[0061] It is also to be understood that although the present invention has been described with regard to preferred embodiments thereof, various other embodiments and variants may occur to those skilled in the ark which are within the scope and spirit of the invention, and such other embodiments and variants are intended to be covered by the following claims. | A cardboard packing box for packing a cartridge container which has a case shell including two mating case shell halves identical in dimensions with each other and forming a plurality of compartments for receiving sets of a specified number of flat tape cartridge units therein, respectively, each mating case shell half having a pair of bottom fitting frames different in size so that one of the bottom fitting frames of one mating case shell half is fitted in another mating case shell half by insertion so as thereby to be able to couple the cartridge container to another, comprises a cardboard box identical in internal dimension with a horizontal projection of the case shell of the cartridge container; and a pair of cardboard backing pads each of which has a pair of openings in which the bottom fitting frames of each mating case shell halves are fitted respectively by insertion. | 1 |
FIELD OF THE INVENTION
This invention relates to water delivery systems for buildings and vehicles. More specifically, the invention relates to a system that recirculates for later use water that is hotter or colder than currently desired.
BACKGROUND OF THE INVENTION
Conventional plumbing systems are wasteful; they waste water and they waste the energy used to heat the water. For example, when a person tests or adjusts the temperature of water dispensed from a faucet, water that is too cold or too hot is generally spilled down the drain and wasted. A utility expended resources to acquire, store, treat, and deliver that water; the building owner paid money to buy and heat that water.
When such wastage occurs throughout a whole building or a whole utility, the losses are significant. Reducing such wastage would decrease expenses for landlords and hoteliers, and would allow utilities to build smaller reservoir, treatment and delivery systems for a given number of customers. In areas where water is scarce, a reduction in wastage might lead to a reduction in rationing. A system for reducing wastage might similarly find advantageous use on planes, boats and recreational vehicles that carry water subject to weight or space limitations.
The fundamental disadvantage in a conventional plumbing system is that it has only two types of pipes: incoming pipes for delivering clean water and outgoing pipes for removing waste water. Clean water dispensed at an incorrect temperature has no place to go except down the drain with the waste water. What is needed is a plumbing system that provides for recirculation of clean water dispensed at the wrong temperature.
The present invention is directed to such a system.
SUMMARY OF THE INVENTION
According to one aspect of the invention there is provided a system for supplying a mixture of fluid from first and second sources to a consumption device comprising: a mixing vessel having: a mixing chamber, a first valved inlet adapted to receive fluid from the first source for mixing in the mixing chamber, a second valved inlet adapted to receive fluid from the second source for mixing in the mixing chamber, and a first valved outlet adapted to dispense fluid mixed in the mixing chamber into the consumption device, as well as means for sensing the temperature of the fluid mixture inside the mixing chamber, and means for controlling the first valved inlet responsive to the temperature sensing means. The system might further include means for controlling the second valved inlet responsive to the temperature sensing means, means for sensing the rate of flow of fluid through the first valved outlet, and means for controlling the first valved outlet responsive to the flow rate sensing means. The system might also include means for sensing the amount of fluid dispensed into the consumption device where such means might be a fluid level detector or a timer. The system could further include means for controlling the first valved outlet responsive to the amount sensing means and such controlling means can include a microprocessor. The system might further include a holding tank, wherein the mixing vessel further includes a second valved outlet adapted to discharge water into the holding device. The system might include means for controlling the second valved outlet responsive to the temperature sensing means and means for reinjecting fluid from the holding tank into the first source. The reinjecting means might include a pump connected to draw fluid from the holding tank toward the first source, a check valve connected to receive fluid from the holding tank and to supply the fluid to the first source, means for controlling the pump responsive to the fluid level in the holding tank which pump controlling means might be a microprocessor, means for controlling the pump responsive to the fluid pressure at the first source, and means for damping pressure transients where the pressure damping means might be a pressure accumulator.
According to another aspect of the invention, there is provided a method of supplying a mixture of fluid from first and second sources to a consumption device comprising: connecting a mixing vessel having a mixing chamber with a first valved inlet, a second valved inlet, and a first valved outlet to the first and second sources and the consumption device such that: the first valved inlet receives fluid from the first source for mixing in the mixing chamber, the second valved inlet receives fluid from the second source for mixing in the mixing chamber, and the first valved outlet dispenses fluid mixed in the mixing chamber into the consumption device, sensing the temperature of the fluid mixture inside the mixing chamber, and controlling the first valved inlet responsive to the temperature in the mixing chamber. The method might include controlling the second valved inlet responsive to the temperature in the mixing chamber, sensing the rate of flow of fluid through the first valved outlet, controlling the first valved outlet responsive to the flow rate, sensing the amount of fluid dispensed into the consumption device, and controlling the first valved outlet responsive to the amount of fluid dispensed into the consumption device. The method might further include connecting a second valved outlet in the mixing chamber to a holding tank such that second valved outlet discharges fluid mixed in the mixing chamber into the holding tank. The method might include controlling the second valved outlet responsive to the temperature in the mixing chamber, and reinjecting fluid from the holding tank into the first source, wherein the reinjecting step is executed with a pump connected to draw fluid from the holding tank toward the first source. The method might include controlling the pump responsive to the fluid level in the holding tank, and controlling the pump responsive to the fluid pressure at the first source, and damping pressure transients between the pump and the first source.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawing which is a schematic diagram of a plumbing system embodying one aspect of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawing, a plumbing system 100 embodying one aspect of the invention includes a supply subsystem generally illustrated at 200, a mixing subsystem generally illustrated at 300 connected to receive water from the supply subsystem 200, a consumption subsystem generally illustrated at 400 connected to receive water from the mixing subsystem 300, and a recirculation subsystem generally illustrated at 500 connected to receive water from the mixing subsystem 300 and to recirculate it into the supply subsystem 200.
The supply subsystem 200 begins at a cold water inlet 210 which is connected to receive water from the mains. The cold water inlet 210 feeds a cold water line 212. The cold water inlet 210 also feeds a water heater 214 through a heater valve 216. The water heater 214 in turn feeds a hot water line 218.
The mixing subsystem 300 is formed around a mixing chamber 310. The mixing chamber 310 is connected to receive cold water from the cold water line 212 through a cold water inlet valve 312 and connected to receive hot water from the hot water line 218 through a hot water inlet valve 314. As will be described further under system operation, the mixing chamber 310 is connected to dispense water into the consumption subsystem 400 through a dispensing valve 316 and connected to discharge water into the recirculation subsystem 500 through a recirculation valve 318.
The mixing subsystem 300 is controlled by a mixing microprocessor 320. The mixing microprocessor 320 is connected to receive information signals from a temperature sensor 322 in the mixing chamber 310, from a flow sensor 324 at the dispensing valve 316, from a quantity sensor 326, such as a fluid level detector, at the consumption subsystem 400 and from an operator keypad 328. The mixing microprocessor 320 is connected to control the cold water input valve 312, the hot water input valve 314, the output valve 316 and the recirculation valve 318.
The consumption subsystem 400 includes a consumption device 410 such as a sink, a tub or a shower which has an inlet port 412 connected to receive water from the mixing subsystem 300 dispensing valve 316. The consumption device 410 might also include a hot water bypass valve 414 connected to receive water directly from the hot water line 218 and a cold water bypass valve 416 connected to receive water directly from the cold water line 212 without engaging the mixing subsystem 300. These bypass valves 412, 416 would be normally closed but could be opened to operate the consumption device 410 when the mixing subsystem 300 was not operational.
The recirculation subsystem 500 includes an insulated holding tank 510 that is connected to receive water from the mixing subsystem 300 recirculation valve 318. The holding tank 510 includes a reinjection outlet 512 as well as an emergency overflow outlet 514. The reinjection outlet 512 is connected to feed the hot water heater 214 via a reinjection pump 516, a check valve 518, and a pressure accumulator 520. A recirculation microprocessor 522 is connected to receive information signals from a maximum level sensor 524 and a minimum level sensor 526 in the holding tank 510, and from a line pressure sensor 528 between the check valve 518 and the pressure accumulator 520. The recirculation microprocessor 522 is connected to control the reinjection pump 516 and the heater valve 216.
In operation, the operator uses the keypad 328 to instruct the mixing microprocessor 320 to dispense water to the consumption device 410. The operator can select such characteristics for the water as temperature, quantity, flow rate, or flow duration. The mixing microprocessor 320 opens the cold water input valve 312 and/or the hot water input valve 314 to bring water into the mixing chamber 310 in approximately the right proportion to achieve the temperature selected. If the temperature sensor 322 indicates that the water mixture inside the mixing chamber 310 is not at the temperature selected by the operator, the mixing microprocessor 320 adjusts the cold water input valve 312 and/or the hot water input valve 314 as needed and opens the recirculation valve 318 to discharge the water mixture* into the recirculation subsystem 500 for later use. If the temperature sensor 322 indicates that the water mixture inside the mixing chamber 310 is at the temperature selected by the operator, the mixing microprocessor 320 closes the recirculation valve 318 and opens the dispensing valve 316, thereby allowing the mixed water to flow into the consumption subsystem 400. The flow sensor 324 at the dispensing valve 316 and the quantity sensor 326 at the consumption device 410 provide the mixing microprocessor with the information needed to adjust the dispensing valve 316 such that the right amount of water is dispensed for the right amount of time at the right pressure.
Recirculated water is stored in the insulated holding tank 510 for subsequent reinjection into the hot water tank 214. When the water in the holding tank 510 rises above a maximum preset level, the maximum level sensor 524 informs the recirculation microprocessor 522. The recirculation microprocessor 522 closes the heater valve 216 to isolate the hot water tank 214 from the mains and then checks the pressure sensor 528 to determine whether the hot water tank 214 is already filled to capacity. If so, the recirculation microprocessor 522 will continue to monitor the recirculation system 500 but will not engage any device. If the holding tank 510 continues to fill under such conditions, excess water may eventually spill from the emergency overflow outlet 514.
When the pressure sensor 528 indicates to the recirculation microprocessor 522 that the hot water tank 214 can accept water, the recirculation microprocessor 522 turns on the reinjection pump 516. The reinjection pump 516 discharges water from the holding tank 510 through the check valve 518 into the hot water tank 214 via the pressure accumulator 520. Water being incompressible, the pressure accumulator 520 is used as a means to discourage the line pressure from increasing rapidly the moment the pump 516 is engaged. If the line pressure were allowed to rise unchecked, the pressure sensor 528 would detect falsely that the hot water tank 214 was full and would incorrectly indicate to the recirculation microprocessor 522 that the pump 516 must be stopped immediately after it is started.
When the pressure sensor 528 indicates to the recirculation microprocessor 522 that the hot water tank 214 is full, the recirculation microprocessor 522 stops the reinjection pump 516. When the minimum level sensor 526 indicates to the recirculation microprocessor 522 that the water level in the holding tank 510 has fallen below a minimum level, the recirculation microprocessor 522 stops the reinjection pump 516 and opens the heater valve 216 to reconnect the hot water tank 214 to the mains.
Although a specific embodiment of the present invention has been described and illustrated, the present invention is not limited to the features of this embodiment, but includes all variations and modifications within the scope of the claims.
For example, it is contemplated that more than one consumption subsystem 400 could be connected to the system 100.
It is also contemplated that either microprocessor 320, 522 could be replaced by other electronic control devices or even a mechanical equivalent. For example, much of the functionality of the mixing microprocessor 320 could be achieved by a set of mechanical thermostats.
It is further contemplated that the recirculation subsystem 500 could be easily adapted to work with gravity fed plumbing systems such as those commonly found in parts of Europe and the United Kingdom. In particular, the expansion tank could function directly as the holding tank 510 so that the recirculation pump 516 and its accompanying control system would not be needed.
It is still further contemplated that the mixing subsystem 300 could be constructed as either an integral part of the consumption device 410 or as a retrofitable addition.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | A water conservation and delivery system for a building includes a first subsystem for dispensing clean water from a faucet, a second subsystem for draining waste water from the vessel supplied by the faucet, and a third subsystem for recirculating clean water prior to dispensement back into the dispensing subsystem while the dispensing temperature and flow are adjusted. | 4 |
RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119 to European Patent Application No. 09006523.6 filed May 14, 2009, the disclosure of which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION AND DESCRIPTION OF PRIOR ART
[0002] The present invention relates to a multi-beam deflector array means for use in a particle-beam exposure apparatus employing a beam of charged particles, said multi-beam deflector array means comprising a main body of overall plate-like shape having a membrane region and a buried CMOS-layer, said membrane region comprising a first side facing towards the incoming beam of particles and a second side opposite to the first side, an array of apertures, each aperture allowing passage of a corresponding beam element formed out of said beam of particles, and an array of electrodes, each aperture being associated with at least one of said electrodes and the electrodes being controlled via said CMOS layer.
[0003] In such a particle-beam exposure apparatus a particle beam is generated by an illumination system and illuminates a pattern definition (PD) means. The PD means has an array of apertures which define a beam pattern to be projected on a target surface.
[0004] Applications of a particle beam exposure apparatus of this kind range from the field of nano-scale patterning, e.g., by direct ion beam material modification or by electron or ion beam induced etching and/or deposition, to the field of maskless particle-beam lithography.
[0005] In maskless particle-beam lithography, a desired pattern is defined on a substrate surface. This is done by covering the substrate surface with a layer of radiation-sensitive resist and exposing a desired structure on the resist which is then developed. The developed resist is used as a mask for further structuring processes such as reactive etching and the like.
[0006] U.S. Pat. No. 6,768,125 and U.S. Pat. No. 7,084,411 by the applicant/assignee present a multi-beam maskless lithography concept, dubbed PML2 (short for ‘Projection Mask-Less Lithography #2’), that employs a PD device comprising a number of plates stacked on top of the other for use in a lithography apparatus. The PD device comprises at least two different plates, namely an aperture plate and a deflector array plate. These plates are mounted together at defined distances, for instance in a casing.
[0007] The aperture plate has a plurality of apertures used to define beamlets permeating the PD device. The deflector array plate has a plurality of openings, each opening corresponding to an aperture of the aperture plate, and is used to individually blank out selected beamlets (‘blanking plate’). Each blanking opening is provided with a beamlet deflection means, e.g., electrodes, that can be controlled by a blanking signal between two deflection states, namely, a first state (‘switched on’) and a second state (‘switched off’). In the first state, the electrodes have assumed a state in which particles passing through the opening are allowed to travel along a desired path. In the second state the electrodes are deflecting particles transmitted through the opening off said path, preferably towards some absorbing surface within the lithography apparatus.
[0008] Another function, absorbing the majority of heat load imposed by the incoming beam, may be provided by a specific ‘cover plate’ or included in the aperture plate which is then placed as a first plate as seen along the direction of the beam.
[0009] Each of the plates is preferably realized as a semiconductor (in particular silicon) wafer in which the structures have been formed by micro-structuring techniques known in the art.
[0010] The deflection means comprise a set of beam blanking electrodes, the set preferably consisting of two electrodes. U.S. Patent Publication No. 2005/0242302 A1 of the applicant/assignee proposes to form the electrodes around the blanking openings by perpendicular growth employing state-of-the-art electroplating techniques.
[0011] U.S. Patent Publication No. 2008/0203317 A1 of the applicant/assignee discloses, among other things, a deflector array plate (‘blanking plate’) with a plurality of apertures, wherein each aperture is associated with one depression which is formed in one of the sides of the blanking plate. Each aperture is associated with at least one electrode, the electrodes being located in the depression around the aperture and not protruding over the surface of the side of the blanking plate where the depressions are formed. As a consequence, the electrodes which are energized for beam switching do not lead to any significant changes of the electrostatic field outside the depressions. The electrodes, depressions and apertures are structured by a suitable combination of lithographic processes known in the art.
[0012] EP 1 993 118 A2 describes a solution where a deflector array means has a plurality of electrostatic deflector electrodes for each beamlet. Counter electrodes are electrically connected to a counter potential independently of the deflection array means through a counter-electrode array means. The counter potentials may be a common ground potential or individual potentials. One implementation of said solution is to use one electroplated electrode on a CMOS wafer membrane with a multi-aperture array, and place another membrane with a second multi-aperture array, carrying the counter electrodes which have a uniform potential, above.
SUMMARY OF THE INVENTION
[0013] The present invention sets out to improve the solutions set forth in prior art.
[0014] This task is solved according to the invention by abovementioned multi-beam deflector array means, wherein the electrodes are pillared, standing proud of the main body of the multi-beam deflector array means, the electrodes being connected to one side of the main body of the multi-beam deflector array means by means of bonding connections.
[0015] The solution according to the invention allows shielding of neighboring apertures from stray fields and, thus, reducing cross-talk between the apertures. The term “pillared” signifies that the electrodes are oriented vertically to the main body of the multi-beam deflector array means, bonded at their lower ends to the main body of the deflector array means. The electrodes are basically shaped like columns. Generally speaking, the lower end of the electrodes is the end that is oriented towards the main body. In the arrangement of FIG. 1 , where the particle beam runs vertically downward and the electrodes are fixed to the first side of the main body of the multi-beam deflector array means, the lower ends of the electrodes are literally the low ends with regard to the arrangement of the electrodes. Consequently, the term “upper ends” of the electrodes refers to the ends of the electrodes facing towards the incoming beam (in FIG. 1 ) or the ends of the electrodes opposite to the lower ends.
[0016] In a preferred embodiment of the invention, indium is used to realize the bonding connection between the electrodes and the main body of the multi-beam deflector array means. Indium has the advantage of being soft and malleable and is frequently used in the semiconductor industry, although for different purposes like the sealing of bearings in production machines. Indium allows for a good conductive connection between the electrodes and the main body (and the CMOS-circuitry) of the multi-beam deflector array means and easy mounting of the electrodes. It is, however, possible to use other materials like copper-tin alloys, to name only one of many options known to one skilled in the art.
[0017] The electrodes are preferably made of silicon.
[0018] In another embodiment of the invention, the top area of the electrodes, “top” here signifying the end of the electrodes that is directed towards the main body of the multi-beam deflector array means, is larger than the area taken by the bonding connection. In other words, the area of the cross sectional area of the electrodes as taken parallel to the plane of the support plate is larger than the area occupied by the bonding connections. This means that the bonding material in the state of an established connection does not occupy the entire area of the top of the electrode to prevent the oozing out of the bonding material from the space between electrode and main body.
[0019] In yet another embodiment of the invention, protrusions (or: noses) are present on the outer boundary of the top area of the electrodes, a protrusion being an area that is elevated relative to the remaining area of the top of the electrodes. Elevated here means that the surface of the protrusion is closer to the surface of the main body than the remaining area of the top of the electrode. Metaphorically speaking, the top area of the electrode features at least one or more protrusions or may even be surrounded by a (continuous) ring of protrusions that are elevated relative to the rest of the top surface of the electrode.
[0020] These protrusions help to shield the beamlet transgressing the multi-beam deflector array means from stray fields that might emerge from the region close to the bonding connection. For instance, it is possible that the insulating layer surrounding the bonding connections gets charged by stray particles from the beamlet and thus influences the beamlet in return. Furthermore, the protrusions help to decrease cross-talk between neighboring apertures.
[0021] In a variant of abovementioned embodiment, the protrusions are restricted to the part of the top of the electrodes close to the respective apertures of the main body.
[0022] In yet another variant of this embodiment, an isolating coating is applied to the top of the protrusion.
[0023] This isolating coating might also be applied to the side of the main body facing towards the electrodes, the isolating coating being located at the places where the protrusions touch on the main body.
[0024] Advantageously, the isolating coating may be retracted from the side of the protrusion facing the respective aperture in the main body of the multi-beam deflector array means. Thus, the isolating coating is partly shielded from stray particles of the beamlet pervading the aperture in the main body and is not charged by such particles. The term retracted means, that the isolating coating is pulled back from the edge of the electrode with its protrusion.
[0025] In a favourable variant of the invention the electrodes may be free-standing and mechanically independent from each other. This means that no fixations are provided between the electrodes, like ligaments, connecting membranes and the like. The electrodes are not connected mechanically.
[0026] In one suitable aspect of the invention, a support plate is arranged on the side of the electrodes facing away from the membrane region, the support plate being connected with the electrodes and an insulating layer isolating the support plate from the electrodes, the support plate comprising an array of openings which correspond to the apertures of the membrane region. The support plate gives further stability to the system, fixing the electrodes in their position and protecting the part of the multi-beam deflector array means with the CMOS-layer from highly energetic impinging particles. The support plate further allows efficient shielding of stray fields which are generated by the deflecting electrodes during operation. The support plate is connected to the main body of the multi-beam deflector array means via the electrodes. Accurate alignment between the support plate and the main body of the multi-beam deflector array means is required. The insulating layer is essentially arranged on the lower end of the electrodes between the electrodes and the support plate. “Lower end” here signifies the ends of the electrodes being oriented towards the support plate. In an arrangement as depicted in FIG. 1 , where the particle beam is oriented vertically downwards, the “lower end” is oriented towards the incoming particle beam. The insulating layer is preferably a high-resistance layer, with a resistance of around 1 MO, to reduce the power.
[0027] The diameter of the openings of the support plate is equal to or larger than the diameter of the apertures of the membrane region.
[0028] In yet another embodiment of the invention, the support plate acts as aperture plate (in addition to shielding and stability reasons) with the openings of the aperture plate exhibiting a smaller diameter than the subsequent apertures in the main body.
[0029] In such an arrangement, an upper part of the wall of the openings in the support plate may preferably have a smaller diameter than a lower part of the wall and the subsequent aperture in the main body. The aperture plate forms the beamlets out of the impinging broad beam of energetic charged particles. The combination of aperture plate and support plate allows for the saving of one additional plate to perform the beam-forming, renders the device more compact and facilitates installation of the multi-beam deflector array means into a particle-beam exposure apparatus, to name only one of different possible applications.
[0030] In a straightforward implementation of the invention, the electrodes are arranged on the first side of the main body of the multi-beam deflector array means. In another embodiment of the invention, the electrodes are arranged on the second side of the main body of the multi-beam deflector array means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In the following, the present invention is described in more detail with reference to the drawings, which schematically show:
[0032] FIG. 1 is a schematic overview of a particle-beam exposure apparatus according to prior art in a longitudinal section, but suitable for the invention,
[0033] FIG. 2 is a sectional view of a detail of a multi-beam deflector array means according to an embodiment of the invention,
[0034] FIG. 3 is a sectional simplified view of the entire main body of a multi-beam deflector array means with a membrane region,
[0035] FIG. 4 is a sectional view of another embodiment of the invention with a support plate,
[0036] FIG. 5 is a sectional view of yet another implementation of the invention with a modified support plate which serves as aperture plate to the multi-beam deflector array means where the main body and the support plate are separated,
[0037] FIG. 6 is the setup of FIG. 5 where the main body and the support plate are connected by means of a bonding connection,
[0038] FIG. 7 is a sectional view of another embodiment of the invention,
[0039] FIG. 8 is another embodiment of the invention in a sectional view,
[0040] FIG. 9 is a plan view of the embodiment of FIG. 8 along line A-A, and
[0041] FIG. 10 is a plan view of the embodiment of FIG. 8 along line B-B.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The preferred embodiment of the invention discussed in the following is a development for a PML2-type particle-beam exposure apparatus with a pattern definition (PD) system as disclosed in the U.S. Pat. No. 6,768,125 (=GB 2 389 454 A) of the assignee/applicant, and with a large-reduction projecting system. In the following, first the technical background of the apparatus is discussed—as far as relevant to the invention—, then the invention is presented in detail.
[0043] It should be appreciated that the invention is not restricted to the following embodiments or the particular layout of the PD-system, which merely represent one of the possible applications of the invention; the invention is suitable for other types of processing systems that employ a particle-beam with projector stages as well.
Maskless Charged Particle-Beam Processing Apparatus
[0044] FIG. 1 shows a schematic overview of a maskless particle-beam processing apparatus PML2 which itself is known from prior art but is suitable to embody the present invention. The components are not shown to size; in particular, the lateral width of the particle beam lb, pb is exaggerated. In the following, only those details are given as needed to disclose the invention. For more details, the reader is referred to the U.S. Pat. Nos. 6,768,125 and 7,276,714 the disclosure of which is incorporated by reference herein in its entirety.
[0045] The main components of the lithography apparatus 101 —corresponding to the direction of the lithography beam lb, pb which in this example runs vertically downward in FIG. 1 —are an illumination system 102 , a PD system 138 , a projecting system 104 and a target station 105 with a substrate 113 which is held and positioned by a wafer stage 114 . The whole apparatus is contained in a vacuum housing (not shown) held at a high vacuum to ensure an unimpeded propagation of the beam lb, pb along the optical axis cx of the apparatus. The optical systems (illumination system 102 , projecting system 104 ) are realized using electrostatic or electromagnetic lenses which are depicted symbolically by reference numbers 106 .
[0046] The illumination system 102 comprises, for instance, an electron gun 107 , an extraction system 108 as well as a condenser lens system 109 . A general blanking deflector 109 a may be present as well. It should, however, be noted that in place of electrons, in general, other electrically charged particles can be used as well. Apart from electrons these can be, for instance, hydrogen ions or heavier ions, charged atom clusters, or charged molecules. In the context of this disclosure, “heavier ions” refer to ions of elements heavier than C, such as O, N, or the noble gases Ne, Ar, Kr, Xe.
[0047] By means of the condenser lens system 109 , the particles emitted from the illumination system 102 are formed into a wide, substantially telecentric particle beam serving as lithography beam lb. The lithography beam lb then irradiates the PD system 138 which is held at a specific position in the path of the lithography beam lb. The PD system 138 comprises a number of plates with a plurality of openings and/or apertures 130 , arranged in regular arrays, which define a beam pattern to be projected on the substrate 113 .
[0048] Some of the apertures and/or openings are “switched on” or “open” so as to be transparent to the incident beam in the sense that they allow the portion of the beam (beamlet) that is transmitted through it to reach the target. The other apertures and/or openings are “switched off” or “closed”, in the meaning that the corresponding beamlets cannot reach the target (even though they may leave the PD system and travel through some portion of the projecting system 104 ); effectively, these “switched off” apertures and/or openings are non-transparent (opaque) to the beam from the target's perspective.
[0049] As a consequence the lithography beam lb is structured into a patterned beam pb, emerging from the PD system 138 . The pattern of switched on apertures and/or openings—the only portions of the PD system 138 which are transparent to the lithography beam lb—is chosen according to the pattern to be exposed on the substrate 113 . It should be noted that the “switching on/off” of the beamlets usually is realized by a blanking means of a suitable kind provided in one of the plates of the PD system 138 : “Switched off”-beamlets are deflected off their path (by very small angles) so they cannot reach the target but are merely absorbed somewhere in the lithography apparatus, e.g., by an absorbing plate 110 . The beam deflection angle is largely exaggerated in FIG. 1 ; it is, in general, very small, typically 0.2 to 2 thousands of a radian.
[0050] In FIG. 1 only five beamlets of the patterned beam pb are shown as representatives for an actual large number of beamlets. One of the beamlets is switched off and is absorbed at the absorbing plate 110 while the other four beamlets are directed to the substrate 113 and there form images of the respective apertures 130 .
[0051] In the embodiment shown in FIG. 1 , the projection system 104 is composed of a number of consecutive particle-optical projector stages, consisting of electrostatic or electromagnetic lenses and other deflection means. These lenses and means are shown in symbolic form only, since their application is well known from prior art. The projection system 104 employs a demagnifying imaging through crossovers c 1 , c 2 . The demagnification factor for both stages is chosen such that an overall demagnification of several hundred results, e.g., 200× ( FIG. 1 is not to scale). A demagnification of this order is particularly suitable with a lithography setup, in order to alleviate problems of miniaturization in the PD device.
[0052] In the whole projection system 104 , provisions are made to extensively compensate the lenses and/or deflection means with respect to chromatic and geometric aberrations. As a means to shift the image laterally as a whole, i.e., along a direction perpendicular to the optical axis cx, deflection means 111 , 112 are provided in the projection system 104 . The deflection means can be realized as, for instance, a multipole electrode system which is either positioned near the crossover, as shown in FIG. 1 with the first deflection means 111 , or after the final lens of the respective projector, as in the case with the second stage deflection means 112 in FIG. 1 . In this apparatus, a multipole electrode is used as deflection means both for shifting the image in relation to the stage motion and for correction of the imaging system in conjunction with the alignment system. These deflection means 111 , 112 are not to be confused with the deflection array means of the PD system 103 which are used to switch selected beamlets of the patterned beam pb “on” or “off”, since the former only deal with the particle beam as a whole.
[0053] Suitably, a scanning stripe exposure strategy, where the substrate 113 is moved under the incident beam pb, is utilized. It should be noted that, since different parts of the substrate 113 are to be patterned differently, the number of “switched on” apertures changes when the substrate is moved under the patterned beam. At the same time, the current, i.e., the particles traversing the optical column of the lithography apparatus 101 after the absorbing plate 110 , may change considerably.
[0054] In one typical implementation, the size of the image of an array of apertures in the PD system 138 on the substrate 113 is 80 μm square. The substrate 113 is moved with a velocity of 3 mm/s underneath the patterned beam; so, a completely new area with a—possibly—different pattern is reached roughly every 30 ms. The cycle time of the deflection means is around 5 μs. Consequently, the deflection states of the apertures may change in a matter of microseconds (e.g., from a “switched on” state into a “switched off” state), whereas the patterns on the wafer change in a matter of milliseconds. The optics of the lithography apparatus 101 have to cope with the changing current, i.e., the changing number of particles crossing the optical column.
[0055] FIG. 2 shows a sectional view of a schematic detail of a multi-beam deflector array means 203 to illustrate the basic concept of the invention. FIGS. 4 to 8 show other, more developed embodiments of the invention. For the sake of clarity, only one of many apertures 230 with its associated electrodes 222 , 223 is shown here. Strictly speaking, FIG. 2 depicts a partial view of the membrane region of the main body 200 of the multi-beam deflector array means 203 , the apertures 230 being located in said membrane region.
[0056] FIG. 3 shows a simplified schematic view of the main body 300 of a multi-beam deflector array means 303 with a membrane region 331 with a number of apertures and their associated electrodes. FIG. 3 is not to scale, furthermore the number of apertures is only three for the sake of clarity.
[0057] The main body 300 of the multi-beam deflector array means 303 comprises a wafer with a thickness of around 300 μm. Preferably, it is a “CMOS”-wafer, the term “CMOS” here signifying a wafer having silicon as bulk material, as well as a layer of circuitry beneath the surface, near to one side of the silicon wafer. For the sake of clarity, the layer of circuitry is not shown in FIG. 3 . The upper side of the main body 300 of the multi-beam deflector array means 303 is the first side FS facing towards the incoming beam of particles, the opposite side is the second side SS. It is, however, possible for the multi-beam deflector array means 303 to be arranged the other way round so that the second side SS is oriented towards the incoming beam of particles.
[0058] The main body 300 features a membrane region 331 in its inner area (“inner” here means offset from the borders of the wafer that forms the main body) where it is thinned by means of appropriate processes. In this membrane region 331 , the thickness of the wafer is usually around 50 μm. This means that a multi-beam deflector array means 303 according to the invention usually has a “frame” 332 with a thickness of 300 μm surrounding the membrane region which has a thickness of around 50 μm.
[0059] In a realistic implementation the lateral width of the membrane region 331 will be distinctly greater than the lateral width of each frame 332 .
[0060] In the following, the term “multi-beam deflector array means” always refers to the membrane region of the main body since the FIGS. 4 and 6 all show partial views of said part of the multi-beam deflector array means.
[0061] Referring again to FIG. 2 , the multi-beam deflector array means 203 is fabricated from a “CMOS”-wafer with one or more layers of circuitry 216 . The layer of circuitry 216 is covered by a contact layer and a passivation layer. The term “circuitry” here includes a number of intrinsic layers, e.g., four to 16 or more; not all of these layers are shown here for the sake of clarity. The upper side of the main body 200 of the multi-beam deflector array means 203 in FIG. 2 is the first side FS facing towards the incoming beam of particles, the opposite side is the second side SS.
[0062] The apertures 230 of the multi-beam deflector array means 203 in FIG. 2 are located in the membrane region. The diameter of the apertures is around 7 μm, for instance. Two metallic pads 217 , 218 are located next to each aperture 230 . These pads 217 , 218 are connected to the circuitry layer 216 with via contacts 219 . Beneath the metallic pads 217 , 218 an insulating layer 220 is applied to electrically separate the pads 217 , 218 from the wafer. The insulating material may be silicon oxide, for instance.
[0063] The first side FS of the wafer is covered with a metallic layer 221 , serving as ground layer. The ground layer extends into the aperture 230 and covers a portion of the vertical walls of the aperture 230 . The metallic layer is applied using well established methods, e.g., electro-plating or sputtering.
[0064] On the metallic pads 217 , 218 two electrodes 222 , 223 , e.g., made of silicon, are arranged, one on each pad 217 , 218 . The arrangement is accomplished by bonding the electrodes 222 , 223 to the main body. This bonding is done using indium bonds 215 . However, other forms of bonding as known to anyone skilled in the art or other materials, like copper-tin alloys, may be employed as well. The bonding connection is the only means to hold the electrodes 222 , 223 in place. The electrodes 222 , 223 are free-standing and mechanically independent from each other, i.e., no connections like ligaments or connection membranes are provided. As explained earlier, the embodiment in FIG. 2 serves to explain the basic principle of the invention and is one of a number of suitable embodiments. In other feasible embodiments, in particular those to be produced industrially, mechanical support for the electrodes may be provided by means of a support plate or the like, as explained further below.
[0065] One of the electrodes 222 , 223 serves as ground electrode 223 which is connected to the ground potential, the other electrode acts as deflecting or blanking electrode 222 . The term “ground potential.” in the present disclosure refers to a potential that is used as a common reference potential for the electrodes associated with the individual beamlet deflectors. This ground potential is usually the same as, but may be different from, a ground potential of other electrical systems of a lithography apparatus or other application areas of a pattern definition device.
[0066] The electrical field generated by means of the “pillared” electrodes 222 , 223 is not confined to the area between the electrodes 222 , 223 and affects neighboring apertures. To reduce this effect, adequate shielding of cross talk is necessary, for example by using so-called counter electrodes as described in the U.S. Publication No. 2008/0283767 A1 by the applicant/assignee, the disclosure of which is incorporated by reference herein in its entirety. Another possibility would be to provide a plate that is arranged upstream (if the electrodes 222 , 223 are located on the first side FS, facing towards the incoming particle beam(lets)) or downstream (if the electrodes 222 , 223 are located on the second side SS) and comprises shielding structures that extend in the spaces between neighboring apertures 230 . In this way, the apertures 230 and their respective electrodes 222 , 223 are shielded from each other and cross talk is suppressed.
[0067] A possible way to produce a setup as depicted in FIG. 2 is as follows. The electrodes 222 , 223 are produced from a SOI (silicon on isolator)-wafer using techniques commonly applied in the semiconductor industry. Once the wafer with the electrodes is connected to the main body 200 of the multi-beam deflector array means via bonding connections, the bulk of the SOI-wafer with the electrodes is removed with techniques like etching and grinding, resulting in a setup as depicted in FIG. 2 , with free-standing, mechanically independent electrodes 222 , 223 .
[0068] FIG. 4 shows another embodiment of the multi-beam deflector array means 403 according to the invention. The multi-beam deflector array means 403 again comprises a main body 400 with a membrane region featuring a plurality of apertures, of which only one aperture 430 is depicted in FIG. 4 for the sake of simplicity. Each aperture 430 is associated with two electrodes 422 , 423 which are connected to the wafer by means of a bonding connection, using indium bonds 415 , for instance.
[0069] The present embodiment further comprises a support plate 424 which is arranged on top of the electrodes 422 , 423 , parallel to the main body 400 of the multi-beam deflector array means 403 . The support plate 424 , which may consist of silicon, has openings 425 corresponding to the apertures 430 in the membrane region of the main body 400 . The support plate 424 mechanically supports the electrodes 422 , 423 . The electrodes 422 , 423 are connected with the support plate 424 .
[0070] The openings 425 in the support plate 424 are usually slightly larger in diameter than the apertures 430 . This means that with the apertures 430 having a diameter of around 7 μm, the diameter of the openings 425 is equal to or larger than 7 μm. The walls of the openings 425 are vertical in the embodiment depicted in FIG. 4 . Between support plate 424 and electrodes 422 , 423 an insulating layer 426 , e.g., 300 nm of oxide, is provided to electrically separate the support plate 424 from the electrodes 422 , 423 .
[0071] The openings 425 in the support plate 424 may either be fabricated before the plate is fixed to the electrodes 422 , 423 or may be etched after the plate has been bonded to the electrodes. In order to arrive at a good match between the openings 425 of the support plate 424 and the corresponding apertures 430 in the multi-beam deflector array means 403 the alignment marks in the main body of the multi-beam deflector array means 403 can be used. FIG. 3 shows such alignment marks 333 , 333 ′, 334 , 334 ′, with two upper alignment marks 333 , 334 being arranged on the first side FS of the multi-beam deflector array means 303 and their corresponding lower alignment marks 333 ′, 334 ′ being arranged on the second side SS.
[0072] In one possible embodiment, the electrodes 422 , 423 and the support plate 424 might be produced from one single wafer using methods well known in the field of semiconductors. For instance, a SOI-wafer could be used, and trenches and apertures are fabricated according to the required profile.
[0073] In case a setup as depicted in FIG. 4 is used in a PD-system, an aperture plate has to be provided in front of (“in front of” as seen in the direction of the particle beam) the multi-beam deflector array means according to the invention to shape beamlets out of the impinging broad beam of charged particles. It is, however, possible to combine the task of the aperture plate and the task of the support plate into one plate, as it is the case in FIGS. 5 , 6 and 7 .
[0074] FIGS. 5 and 6 show another embodiment of the invention in two consecutive situations in the process of fabricating a multi-beam deflector array means, namely the main body 500 , 600 of the multi-beam deflector array means and the support/aperture plate before ( FIG. 5 ) and after ( FIG. 6 ) bonding.
[0075] In the embodiment of FIGS. 5 and 6 , the support plate 524 , 624 also acts as aperture plate, defining the beamlets out of the impinging beam of energetic charged particles. Therefore, the openings 525 , 625 in the support plate 524 , 624 are smaller in diameter than the apertures 530 , 630 in the main body of the multi-beam deflector array means. Thus, the impinging particle beam is split up into beamlets at the support/aperture plate 524 , 624 and pervade the openings 525 , 625 and apertures 530 , 630 without hitting the main body of the multi-beam deflector array means.
[0076] The walls of the openings in the support plate 524 , 624 are cascaded in the embodiment of FIGS. 5 and 6 , the upper part 526 , 626 (i.e., the part that is oriented towards the incoming beam) having a smaller diameter (around 3.75 μm, for instance) than the lower part 527 , 627 of the wall. By this measure the diameter of the beamlet pervading the multi-beam deflector array means 503 , 603 is smaller than the diameter of the subsequent openings/apertures, so, the energetic particles of the beamlet do not damage the subsequent structures. Naturally, the cascaded structure of FIGS. 5 and 6 is only one possible variant and is not intended to constitute any limitation to the invention.
[0077] FIG. 5 shows a situation where the main body 500 of the multi-beam deflector array means and the support plate 524 (support-aperture plate, respectively) are still separate from each other. Preceding the bonding connection between the main body 500 and the support plate 524 , indium bumps 515 ′, 515 ″ are provided on the metallic pads 517 , 518 on the main body 500 and on the electrodes 522 , 523 .
[0078] The bumps 515 ′, 515 ″ can be produced by depositing the bonding material on the entire surface of the main body 500 and support plate 524 and removing the material everywhere except on the locations where the bumps 515 ′, 515 ″ are to be situated. Other methods to apply bonding bumps 515 ′, 515 ″ are well established and can be implemented by the person skilled in the art.
[0079] The support plate 524 depicted in FIG. 5 can be produced from a customary SOI-wafer. Trenches are etched into the silicon until the layer of oxide in order to produce the electrodes 523 , 522 insulated from each other. The openings 525 can be produced using the same methods. In principle it would also be possible to remove the support plate 524 using etching techniques to arrive at a setup as depicted in FIG. 2 . However, the setup of FIG. 4 (and FIGS. 5 and 6 ) is more favourable due to its increased mechanical support to the electrodes.
[0080] The support plate 524 and the main body 500 are connected with each other by moving them in the direction of the vertical arrows in FIG. 5 , resulting in the setup of FIG. 6 .
[0081] The bonding connection has to be established with low pressure and low temperatures (preferably below 300° C., depending on the thermal stability of the pre-processed plates and structures) in order to protect the structures in and on the main body 600 and the support plate 624 . By connecting the indium bumps 515 ′, 515 ″ with each other, indium bonds 615 are established, connecting the main body 600 and the electrodes 622 , 623 mechanically and conductively.
[0082] The shape of the electrodes 622 , 623 slightly differs from the shape of the electrodes of FIGS. 2 and 4 . In FIG. 6 , the electrodes 622 , 623 have protrusions 635 (also referred to as “noses”) on their lower ends on the side next to the apertures 630 . The term “lower end” used here is to be understood in connection with the arrangement of FIG. 6 and describes the ends of the electrodes 622 , 623 that are oriented away from the support plate 624 and towards the main body 600 of the multi-beam deflector array means 603 .
[0083] Even though the protrusions 635 approximate the main body 600 very closely, there still remains a gap between electrode and main body.
[0084] The protrusions 635 serve as additional shielding of the beamlet transgressing the device against stray fields. The insulating layer 620 between the metallic pads 617 , 618 and the main body 600 has generally a not well defined surface potential and can get charged by stray particles from the beamlet of charged particles transgressing the device—this electrostatic disturbance or charge could easily affect the proper functioning of the electrodes 622 , 623 . Hence the protrusions 635 to shield the beamlet from the insulating layer 620 . Care has to be taken not to bring the protrusions too closely to the metallic layer 621 to prevent a short cut or leakage current.
[0085] FIG. 7 shows a setup similar to FIG. 6 ; however, in FIG. 7 an isolating coating 736 is applied to the electrodes 722 , 723 , namely on the side directed towards the main body 700 . When the bonding connection between support plate 724 and main body 700 is established, the two parts are brought together until the isolating coating 736 sits solidly on the metallic layer 721 of the main body 700 . Thus, an equivalent shielding of the beamlet transgressing the openings 725 (in the support plate 724 ) and apertures 730 (in the main body 700 ) of the device is achieved, while at the same time it is guaranteed that no electric short-circuit is produced between the electrodes and the main body after bonding.
[0086] In principle, the isolating coating 736 may also be applied to the main body 700 . In this case, the bonding connection can be established as described in the previous paragraph—the electrodes 722 , 723 themselves do not have an isolating coating 763 but sit on the isolating coating 736 applied on the main body 700 .
[0087] The isolating coating 736 is retracted from the apertures 730 and the side of the electrodes 723 , 723 facing the aperture 730 , respectively. This is done in order to prevent charging of the isolating coating 736 by stray particles from the transgressing beamlets.
[0088] Yet another embodiment of the invention is depicted in FIG. 8 . Here, only one blanking electrode 822 is connected to the main body 800 via a bonding connection 815 . The protrusion 835 of this blanking electrode 822 extends all around the circumference of the lower end of the blanking electrode 822 , “lower end” here again signifying the end of the electrode that is directed towards the main body 800 of the multi-beam deflector array means 803 . The second electrode 823 serves as ground electrode. It is connected to the ground potential via the support plate 824 (connection not shown in FIG. 8 —see FIG. 10 ) and, as a consequence, does not have to be connected to the main body 800 and its circuitry 816 by means of a bonding connection at the location of the electrode.
[0089] Typically, every ground electrode is connected to the CMOS element that switches the deflection electrode to the local CMOS ground potential (e.g., by flip-flop), for example, by a bonding element near that electrode. An example of such a connection can be seen in FIG. 10 (offset bonding connection 1037 —see also discussion of FIG. 10 below). By this, undesired “ground bouncing”, i.e., electrical noise on the ground signal during CMOS-operation, would affect the ground electrode and the deflection electrode in the same way, and therefore not cause angular errors by slight deflections in the state where the beam is switched on (both electrodes are on the same potential, even in case of ground bouncing).
[0090] The vertical shaping of the flanks of the openings 825 in the support plate 824 are vertical unlike in FIGS. 5 , 6 and 7 .
[0091] FIGS. 9 and 10 show sectional views of the setup in FIG. 8 along the lines A-A ( FIG. 9 ) and B-B ( FIG. 10 ) in FIG. 8 .
[0092] It is remarked that the proportions in FIGS. 2 to 8 are not to scale for the sake of comprehensibility. FIGS. 9 and 10 show more realistic ratios. Even though FIGS. 9 and 10 show sectional views of FIG. 8 they do not exhibit identical proportions and relations as FIG. 8 .
[0093] FIG. 9 shows a plurality of sets of electrodes 922 , 923 being arranged next to apertures 930 in a fragment of the main body 900 of a multi-beam deflector array means 903 . For the sake of visibility, the apertures 930 are marked with a pattern of small lines—id clear that the apertures 930 extend through the main body 900 and are, in fact, see-through.
[0094] The features of the invention are explained by one set of electrodes, but this information is valid for all other sets in FIG. 9 as well. In FIG. 9 it is shown that the blanking electrode 922 is fabricated as a stand-alone pillar, whereas the ground electrode 923 is more like a ligament.
[0095] The sectional view of FIG. 10 dissects the multi-beam deflector array means 1003 on the level of the bonding connections 1015 . It can be seen that on this level, the blanking electrode exhibits only the protrusion 1035 that is formed on the outer boundary of the electrode. Inside of the protrusion 1035 is the bonding connection 1015 . The bonding connection 1015 is arranged on a metallic pad (not shown in FIG. 10 ) that is surrounded by an insulating layer 1020 . Again, the aperture 1030 is marked with a pattern of small lines.
[0096] FIG. 10 further shows the connection of the ground electrodes 1023 to the ground potential. For that means, offset bonding connections 1036 are provided between the sets of electrodes 1022 , 1023 and openings 1030 . A sufficient number of such offset bonding connections 1037 may be provided not too far from their respective set of electrodes 1022 , 1023 —the potential may vary over the surface of the main body 1000 , potentially resulting in malfunctions of the system.
[0097] While the above description contains many specific embodiments of the invention, these should not be construed as limitations on the scope of the invention, but rather as an example of one embodiment thereof. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents.
LIST OF REFERENCE SIGNS
[0000]
200 , 300 , 400 , 500 , 600 , 700 , 800 , 900 main body
101 lithography apparatus
102 illumination system
203 , 403 , 803 , 903 , 1003 multi-beam deflector array means
104 projecting system
105 target station
106 electrostatic or electromagnetic lens
107 electron gun
108 extraction system
109 condenser lens system
109 a general blanking deflector
110 absorbing plate
111 first deflection means
112 second deflection means
113 substrate
114 wafer stage
215 , 415 , 815 , 1015 indium bonds
515 ′, 515 ″ bump
216 , 816 layer of circuitry
217 , 218 , 517 , 518 , 617 , 618 metallic pads
219 via contact
220 , 1020 insulating layer
221 , 721 metallic layer
222 , 422 , 522 , 622 , 722 , 822 , 922 , 1022 blanking electrode
223 , 423 , 523 , 623 , 723 , 823 , 923 , 1023 ground electrode
424 , 524 , 624 , 724 , 824 support plate
425 , 525 , 625 , 725 , 825 openings
326 insulating layer
426 upper part
527 , 627 lower part
130 , 230 , 430 , 530 , 630 , 930 , 1030 aperture
331 membrane region
332 frame
333 , 334 upper alignment marks
333 ′, 334 ′ lower alignment marks
635 , 835 , 1035 protrusion
736 isolating coating
1037 offset bonding connection
138 pattern definition (PD)-system
c 1 , c 2 crossover
cx optical axis
FS first side
SS second side
lb lithography beam
pb patterned beam | The invention relates to a multi-beam deflector array means for use in a particle-beam exposure apparatus employing a beam of charged particles, said multi-beam deflector array means having an overall plate-like shape with a membrane region and a buried CMOS-layer, said membrane region comprising a first side facing towards the incoming beam of particles and a second side opposite to the first side, an array of apertures, each aperture allowing passage of a corresponding beam element formed out of said beam of particles, and an array of electrodes, each aperture being associated with at least one of said electrodes and the electrodes being controlled via said CMOS layer, wherein the electrodes are pillared, standing proud of the main body of the multi-beam deflector array means, the electrodes being connected to one side of the main body of the multi-beam deflector array means by means of bonding connections. | 7 |
BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein generally relates to air conditioning systems, and in particular relates to an air conditioning system having a ventilation mode.
[0002] Air conditioning systems are used to provide heating, cooling and ventilation to buildings. As buildings become more insulated due to energy efficiency demands, operating the air conditioning system in a ventilation mode of operation occurs more commonly, to introduce fresh, outdoor air to the building. Improvements in the energy efficiency of air condition system ventilation modes would be well received in the art.
BRIEF DESCRIPTION OF THE INVENTION
[0003] One embodiment is an air conditioning system having a supply fan for supplying air to a supply duct; a fan motor for driving the supply fan; and a controller for controlling a speed of the fan motor, the controller operating the fan motor at a first speed in a first mode, a second speed lower than the first speed in a second mode and a third speed lower than the second speed in a ventilation mode.
[0004] Another embodiment is a method of controlling an air conditioning system having supply fan for supplying air to a supply duct and a fan motor for driving the supply fan, the method comprising: determining the commanded mode of operation; and controlling a speed of the fan motor, the controlling including operating the fan motor at a first speed in a first mode, operating the fan motor at a second speed lower than the first speed in a second mode and operating the fan motor at a third speed lower than the second speed in a ventilation mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 depicts an exemplary air conditioning unit.
[0006] FIG. 2 is a flowchart of a control process in an exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0007] Shown in FIG. 1 is a typical packaged rooftop air conditioner having a condenser section 11 , an evaporator section 12 and an economizer section 13 . The condenser section 11 includes a compressor 14 for receiving refrigerant vapor from the evaporator section 12 and compressing the vapor before it is condensed. Also included in the condenser section 11 is a condenser coil 16 and a condenser fan 17 for passing ambient air through the condenser coil 16 .
[0008] The evaporator section 12 includes a supply fan 18 which is driven by a fan motor 19 . The fan motor 19 is adapted to operate at variable speeds to meet the cooling/heating requirements of the system and provide ventilation as described in further detail herein. A heater 23 is placed in a downstream position from the supply fan 18 .
[0009] Leading into the evaporator section 12 from the economizer section 13 is a cooling coil 21 and its associated filters 22 . In operation, the supply fan 18 draws air in through the filter 22 and the cooling coil 21 where it is cooled by refrigerant passing through the cooling coil 21 . The cooled air then passes to the supply air duct 24 from which it is distributed within the building. Alternatively, in the heating mode, the air is passed from the supply fan 18 through the heater 23 where it is heated prior to being passed into the supply air duct 24 .
[0010] Included within the economizer section 13 is an outside air intake vent 26 , an exhaust air vent 27 and its associated exhaust fan 28 , and an economizer damper 29 . The economizer damper 29 includes an inlet air damper 30 and a return air damper 35 . The inlet air damper 30 and a return air damper 35 may be linked so that the dampers move in concert. Inlet air damper 30 and a return air damper 35 include an actuator responsive to position commands from controller 32 to adjust the position of the dampers. As described in further detail herein, inlet air damper 30 and a return air damper 35 are adjustable by controller 32 to selectively mix an amount of outside air coming in the outside air intake vent 26 with the portion of the return air that is flowing into the economizer section 13 from the return air duct 31 . Another portion of the return air is caused to pass out the exhaust air vent by the exhaust fan 28 .
[0011] A controller 32 receives commands signals from thermostat 40 and controls fan speed 33 of fan motor 19 and damper position 34 of the inlet air damper 30 and a return air damper 35 . Controller 32 may be a microprocessor-based device that executes computer program code to perform the functions described herein.
[0012] In embodiments of the invention, fan 18 is driven in a ventilation mode to reduce power consumption and still meet desired ventilation thresholds. FIG. 2 is a flowchart of a control process in an exemplary embodiment. The process begins at 100 with thermostat 40 indicating a mode for operation, and optionally a desired air flow rate. If the mode is high heating or high cooling, at 102 flow proceeds to 104 where controller 32 commands fan motor 19 to run at a first speed. This first speed corresponds to a high air flow mode, which may be 2000 cubic feet per minute (CFM). If the mode is low heating or low cooling, at 106 flow proceeds to 108 where controller 32 commands fan motor 19 to run at a second speed slower than the first speed. This second speed corresponds to a low air flow mode, which may be 1340 cubic feet per minute (CFM).
[0013] If the mode is ventilation, at 110 flow proceeds to 112 to where controller 32 commands fan motor 19 to run at a third speed slower than the second speed. This third speed corresponds to a ventilation air flow mode, which may be 130 cubic feet per minute (CFM) in exemplary installations. The third speed of fan motor 19 will vary depending upon the ventilation demand of the space supplied by supply air duct 24 . For example, the third speed of the fan motor 19 may be set based on regulations from industry entities (e.g., ASHREA 90.1) to meet certain minimum ventilation levels or ventilation demands of the space supplied by supply air duct 24 . The installer may program the third speed of fan motor 19 as a fraction of the first speed or second speed. Further, the third speed of fan motor 19 may be programmed into controller 32 by an installer when the system is installed. This allows the ventilation demands of the space to be determined before the third speed is set.
[0014] At 114 , controller 32 adjusts positions of the inlet air damper 30 and a return air damper 35 . In ventilation mode, controller 32 opens inlet air damper 30 and closes return air damper 30 such that so that the airflow that is being circulated through the space is close to being 100% outdoor air. Return air from return duct 31 is drawn through exhaust air vent 27 and by exhaust fan 28 . At 116 , controller 32 monitors temperature of the space (e.g., via thermostat 40 ) to determine if the space has become too warm or cold, in response to the influx of outdoor air.
[0015] In exemplary embodiments, fan motor 19 is a three speed motor that operates at the first speed, second speed and third speed based on commands from controller 32 . Controller 32 and fan motor 19 may use a variety of techniques to achieve the three speeds including using an electronically commutated motor (ECM), pulse width modulation (PWM) of drive signals, variable frequency drive (VFD), etc.
[0016] Embodiments provide a third speed for the fan motor to gain additional energy savings. This third fan speed is utilized whenever the unit is ventilating (the space is not requiring either heating or cooling). As the third speed is lower than the first and second speeds, less power is needed to operate the fan motor 19 at the third speed. The energy savings of this third speed would vary by locale and application, but could be as high a 40%
[0017] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. | An air conditioning system having a supply fan for supplying air to a supply duct; a fan motor for driving the supply fan; and a controller for controlling a speed of the fan motor, the controller operating the fan motor at a first speed in a first mode, a second speed lower than the first speed in a second mode and a third speed lower than the second speed in a ventilation mode. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to a method and apparatus for handling samples of body fluids, such as blood. In particular, the invention relates to assays and to instruments where the samples are small disks punched out of dried blood spots on carrier material like filter paper or other fibrous substrate and transferred into sample containers, such as wells of a microtiter plate.
RELATED ART
[0002] Sample analyses are frequently carried out using microtiter plates, the wells of which contain a piece of sample-containing substrate. Examples of substrates include fibrous cards and especially paper cards. An example of such analysis is screening of newborn babies or neonates using blood as a sample. Such analysis comprises collecting blood samples from neonates by impregnating blood to certain areas of fibrous cards so as to form sample spots on the cards. The samples are dried onto the cards. The cards are thereafter fed to a manual or an automatic card handling apparatus, which punches one small-diameter disk from each sample for each analysis. The punched disks are placed to the wells of a microtiter plate so that one well contains one disk. After subjecting the wells containing disks to necessary chemical or biochemical assay steps, such as addition of reagents and incubation at the chosen temperature for the chosen time, the amount or activity of the analyte can be determined optically, for example, using prompt fluorescence, time-resolved fluorescence, absorbance, luminescence measurements or alternatively by mass spectrometry.
[0003] It is crucial to the reliability of the measurement that the optical measurement step is reliable. Reliable measurement step is easily achieved in heterogeneous assays including disk removal and washing step(s). By contrast, there is no wash step in homogeneous assays and blood disks, eluted blood and incubation buffer are in the wells throughout the assays, also during measurement. Additionally, blood disks have a tendency to float on the surface of incubation buffer. It has been found that even after incubation of several hours, a low percentage of the disks are still floating (c.f. U.S. Pat. No. 5,204,267). Although a sufficient elution takes place even if a disk floats, the floating disk can severely interfere with the optical detection, because light can not enter or exit the liquid freely. The same applies for other bodies, such as dust particles and hair in the sample container. Furthermore, blood spot cards, usually filter paper, give fluorescence signal. In some fluorescence measurements floating disks contribute to the signal obtained in assays and thus affect the determination of analytes. For example, in fluorescence measurement of GALT (galactose-1-phosphate uridyl transferase) assay, the maximum emission wavelength of the generated reaction product, NADPH, is 460 nm. However, upon excitation at 330-370 nm the sample disk has an intrinsic fluorescence emission at 460 nm and emission peak at 455 nm. Thus, if the disk is floating in the light path during measurement, a higher signal is obtained than in the case when the disk is not floating. A higher signal indicates a higher concentration of formed NADPH, which in turn indicates a higher GALT activity. Signals in GALT assays given by floating disks are roughly the same as signals obtained with samples of normal GALT activity. Consequently there is a risk that a sample with no or very low GALT activity may be interpreted as normal due to the fact that measurement of NADPH fluorescence has given a result in the normal range due to a floating disk.
[0004] Whether there are floating disks in the wells or not is conventionally checked before the measurement by visual inspection by the operator of the measurement device. As each plate typically contains 96 wells or even more, this inspection is time-consuming. Moreover, such inspection is prone to human errors, as the disks are not always clearly visible as they may, for example, reside vertically against the walls of the wells, or partly below the surface level of the measurement liquid. In addition, in an automatic measurement device, the plates are typically hidden within the device during the entire assay protocol, including dispensing of liquid to the wells, whereby visual inspection right before the optical measurement is impossible. In screening applications the number of samples is large and therefore not only high-throughput testing of the samples is required, but also the large number of samples need to be measured with high accuracy and reliability in order to avoid false, in particular false negative, screening results.
[0005] Transmittance measurements have also be used for detecting air pockets and debris within the measurement wells. Such method is disclosed in U.S. Pat. No. 6,853,666. However, transmittance measurements are not possible in all cases, e.g. if the liquid in the wells is opaque. In addition, a transmittance measurement is not able to distinguish between floating and non-floating sample substrates. Transmittance/absorbance measurement is utilized also in U.S. Pat. No. 5,204,267. An abnormality detection method based on measurement of fluorescence from DNA microarrays is described in US 2005/0227274 and from photosynthetic samples is disclosed in US 2007/0224659. However, neither these methods are suitable or suggested to be used for detecting floating blood sample disks.
SUMMARY OF THE INVENTION
[0006] It is an aim of the invention to provide a reliable automatic method for the detection of floating blood sample disks or the like undesired measurement conditions prevailing in a sample container, such as a well in a microtiter plate. It is a particular aim of the invention to provide a detection method suitable for automated screening of a plurality of samples for avoiding false screening results.
[0007] It is also an aim to provide a more reliable measurement apparatus removing the need for visual inspection and thus to avoid problems associated with visual inspection of the wells of sample plates before the measurement.
[0008] The aims are achieved by the method and apparatus as defined in the independent claims.
[0009] The invention is based on the finding that temporal behaviour or/and spectral characteristics of fluorescent light emitted from a sample well can be used for determining whether a disk is floating in the well or not. In particular, it has been found that although prompt fluorescence characteristics of the incubation buffer (containing blood eluted from the disk) and the sample disk may be very similar, the time-resolved fluorescence properties of the disk and the buffer containing eluted blood are usually different. On the other hand, if the incubation buffer contains a component having certain characteristic time-resolved fluorescence properties, prompt fluorescence properties of the disk are usually different from those of the buffer. Exemplary methods are:
1. Measurement of the well using a time-resolved fluorescence in order to detect a unique time-resolved fluorescence property of a floating sample disk. 2. Measurement of the well using prompt fluorescence in order to detect a unique prompt fluorescence property of a floating sample disk.
[0012] As defined herein, “incubation buffer” is a solution typically comprising analyte specific reagents such as substrates, cofactors, label molecules, antibodies, enzymes, and buffer components.
[0013] As defined herein, “unique property” is a temporal or a spectral property which is characteristic of the sample disk but not of the incubation buffer contained in the well. Alternatively, the analysis can be based on the detection of absence of a property which is characteristic of the incubation buffer containing eluted blood but not of the sample disk. “Unique property” means also combinations of fluorescence mode (prompt vs time-resolved) and excitation and emission bands.
[0014] In addition to the detection of a floating disk in a well, the method can be used, for example, for
detecting foreign bodies such as dust and hair in the well, detecting the presence of a disk in a well after an automated disk-transfer from one measurement plate to another.
[0017] The measurement indicative of floating disks should be carried out before or after the actual measurement of the analyte. A typical homogeneous assay to measure enzyme activity in a blood disk (e.g. GALT assay) comprises
addition of a sample disk and incubation buffer into a well of a microtiter plate, incubation (typically for at least 1 hour), optionally, addition of incubation buffer and second incubation (typically for at least 1 hour), detection of potentially floating disks by time-resolved fluorescence (excitation, for example, at 340 nm and detection of time-resolved emission, for example, at 615 nm), determining whether the amount of time-resolved signal is indicative of a floating disk, measurement of the analyte by prompt fluorescence (excitation, for example, at 340 nm and detection of emission, for example, at 460 nm).
[0023] It is notable that the invention generally takes advantage of a signal-suppressing property of the incubation buffer containing eluted blood sample. The measurements are performed such that both the excitation source and detector are located above the sample. The incubation buffer containing eluted blood significantly prevents a signal from a disk on the bottom of a well to be measured. Suppression of the excitation or emission light, or both, may take place. This approach has proven to be effective and reliable, in particular for samples from which significant amounts of light-suppressive components are eluted to the incubation buffer. In particular, it is known that haemoglobin which elutes from blood samples absorbs efficiently ultraviolet and visible light at 250-550 nm, and particularly at 300-450 nm. Consequently, also the signal in the measurement of the analyte results from the uppermost layer of the incubation buffer containing blood and/or other absorbing components. Thus, it is preferable that the excitation and/or emission wavelengths used in the detection of floating disks lies in the abovementioned wavelength range. Instead of haemoglobin, the same principle can be applied to other substances present in the incubation buffer itself or eluted from a sample disk and having absorption in the ultraviolet and/or the visible range of light.
[0024] The method is typically applied in combination with automated measurement of a concentration or an activity of a component contained in a sample substrate, such as a fibrous blood sample disk (also called a dried blood spot). In such analyses, the component of interest is eluted from the sample-containing substrate to an incubation buffer in a sample container, such as a well of a microtiter plate. The analysis of the component of interest is performed using known chemical or biochemical analysis techniques, for example, by measuring the amount of the component eluted to the incubation buffer using a direct optical measurement (e.g. a fluorescent component) or by measuring an activity of the component (e.g. an enzymatic activity). The component of interest can be an enzyme. For example, in the GALT assay, NADP is converted to fluorescent NADPH in the presence of certain enzymes, NADP/NADPH acting as a necessary cofactor and also as a label molecule indicative of the enzyme content of the sample.
[0025] According to one embodiment, the sample-containing substrate is a fibrous substrate, such as a disk punched from a sample card commonly used in collecting samples for neonatal screening. The problem of floating is emphasized in the case of fibrous disks as they are porous and thus remain easily on the surface of the measurement liquid. In addition to the substrate material itself, the tendency of a particular disk to float may depend also on the individual blood sample contained therein and on any possible preparation steps of the disk before or after punching.
[0026] According to one embodiment the optical measurement method used in the detection of floating disks is time-resolved fluorescence. In particular, detection at an emission region characterized by optical filters typically used in the detection of time-resolved fluorescence emission from lanthanide chelates for example at 545-642 nm, which has proven to give a response signal characteristic to fibrous sample disks. Since the time-resolved or phosphorescence emission from fibrous substrates has a broad emission spectrum, any filter at the emission region 400-1000 nm could be used in the measurement.
[0027] According to an alternative embodiment, the optical measurement method for the detection of floating disks is prompt fluorescence.
[0028] In screening applications it is typically necessary to analyse a large number of samples. Therefore, the detection of floating disks may be carried out for a plurality of wells of a microtiter plate or the like sample container in successive or parallel manner, depending on the instrumentation used. This greatly reduces the risk of human errors which are particularly likely when a large number of wells are analysed.
[0029] The invention can be used in connection with screening of samples in laboratory instrumentation utilizing optical detection, for example, according to the GALT or G-6-PD measurement protocol.
[0030] According to one embodiment the present invention comprises an apparatus comprising
an optical measurement unit for measuring an optical property of contents of the sample container, and a computing unit adapted to determine, based on the optical property, whether the sample container contains a floating sample disk.
[0033] Exemplary sample containers are tubes, wells in a microtiter plate, sample cups and cartridges.
[0034] According to one embodiment, the optical measurement unit is capable of prompt fluorescence and/or time-resolved fluorescence measurements. The computing unit may be adapted to calculate the optical property and to decide whether there is a disk floating in the well, as discussed above. The decision can be made, for example, by comparing the property to a predefined threshold value for that property.
[0035] Fluorescence-based measurements are robust and due to the ability to utilize spectral and temporal information, they are well adjustable for the present method irrespective of the type of the substrate/sample/analyte/buffer used.
[0036] An automated plate-handling and measurement apparatus typically comprises one or more, even all of the following units:
a storage unit for storing a plurality of microtiter plates, dispensing unit(s) for dispensing incubation buffer to a plurality of wells in a microtiter plate, an incubating unit, measurement unit(s) providing the capability of optically measuring the wells (typically the same unit is used for the detection of floating disks and for the actual analysis of the analyte), and a manipulator for automatically transporting the microtiter plate between the units.
[0042] The term “elution” is used to describe any process capable of releasing at least one component, i.e. the “analyte” from a substrate containing an impregnated sample, such as a dried blood spot. The “analyte” (or “component of interest”) can thereafter be measured by any optical measurement method suitable for its measurement, preferably by a fluorescence measurement.
[0043] Embodiments and advantages of the invention are described in more detail in the following with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIGS. 1A , 1 B and 1 C show schematic cross-sectional pictures of wells in a microtiter plate having a submerged, a partially submerged and a floating sample disk, respectively.
[0045] FIG. 2A depicts a well matrix of a microtiter plate, some of the wells denoted as containing a floating disk,
[0046] FIG. 2B shows a three-dimensional graph of TRF measurement results obtained from a microtiter plate of FIG. 2A ,
[0047] FIG. 3 shows a graph of TRF counts for the detection of floating disks.
DETAILED DESCRIPTION OF EMBODIMENTS
[0048] Some embodiments of the invention are described below using a fibrous blood disks as exemplary sample-containing substrates and microtiter plates as an exemplary sample containers. Time-resolved fluorescence is generally referred to as the method of detection.
[0049] A specific analysis of the sample is carried out by bringing the disks into contact with the incubation buffer in the wells of the plate. After a certain period of incubation, for example 2 hours, the microtiter plate is transferred to an optical measurement unit for the measurement of the assay outcome and the detection of possible floating disks.
[0050] FIGS. 1A-1C illustrate three possible situations in a well of a microtiter plate after incubation. The side wall of a well is denoted with reference numeral 10 (only in FIG. 1A ). The well is filled with incubation buffer having a surface 12 . In the well, there is a round blood sample disk 14 . The situation of FIG. 1A , the disk is submerged in liquid, is normally the situation that one ends in when dispensing incubation buffer into a well containing a punched disk. However, as can be seen in FIGS. 1B and 1C , the disk can be submerged only partially, for example, when it sticks to the wall of the well or starts to float for some reason. In the situation of FIG. 1C , there is a risk that the analysis fails due to the fact that the floating disk interferes with the measurement of the assay outcome.
[0051] The present method is based on distinguishing between optical signals that are given by a well with a floating disk and optical signals that are given by a well with a non-floating disk. The most common ways of achieving this goal are discussed below.
1. Measurement of the well using a time-resolved fluorescence mode in order to detect a unique time-resolved property of a floating sample disk. This embodiment is suitable in particular for homogeneous neonatal screening assays (e.g. GALT) where analytes are measured using prompt fluorescence. It has been noted that when analyses are based only on one prompt fluorescence response, negative screening results and results originating from a floating disk can not be reliably distinguished from each other at least at the emission wavelength used (in the case of GALT assay at 460 nm). However, the time-resolved fluorescence responses of the disk and the buffer are significantly different. As an example, the disk may have a time-resolved emission at 615 nm which the incubation buffer or the eluted components do not have. In addition, temporal (time-resolved) detection of floating disks can be used even if the actual measurement of the assay outcome is carried out using time-resolved fluorescence, provided that the disk has at least one time-resolved property which is unique with respect to the incubation buffer and the eluted components. As an example, the disk may have a time-resolved emission at 545 nm whereas the analyte is measured using a europium-labelled reagent in the incubation buffer giving an emission at 612-620 nm and no emission at 545 nm. 2. Measurement of the well using prompt fluorescence in order to detect a unique prompt fluorescence property of a floating sample disk. This embodiment is suitable in particular when distinguishing time-resolved properties don't exist between the disk and the incubation buffer. Thus, the detection of a floating disk is based on the differences in the spectral properties of the signals originating from a floating disk, incubation buffer and sample.
[0057] FIG. 2A shows an 8×12 array of wells arranged in a matrix, such as in a microtiter plate (96-well plate). Each well contains a disk punched from blood samples dried on paper-like fibrous cards and incubation buffer doesn't contain any component giving TRF signal. Wells, containing a disk, not interfering measurement and thus giving a reliable measurement outcome, are denoted as 22 . There are also wells, shaded and denoted as 24 , which contain a floating disk interfering measurement. FIG. 2B shows a 3D graph of a time-resolved fluorescence measurement results from the plate of FIG. 2A at the wavelength of 615 nm, indicating that TRF measurement at 615 nm clearly distinguishes the wells containing a floating disk from the wells having no floating disk.
[0058] According to one embodiment, the measurement method used in the detection of floating disks is time-resolved fluorescence, which is adapted for the detection of a known long-lived fluorescence of the sample substrate material. For example, a standard europium fluorescence measurement protocol suits well for this purpose at least in the case of fibrous filter papers used in neonatal screening. If blood samples are measured, it is not necessary that the incubation buffer as such would absorb the excitation or emission light, but eluted haemoglobin will serve as the absorbent. However, it is not excluded that the incubation buffer itself would contain an absorbing component other than haemoglobin. In addition to neonatal screening, time-resolved fluorescence suits other assays taking advantage of similar sample delivery and elution processes.
[0059] FIG. 3 shows the effect of a floating disk on signal. Time-resolved fluorescence signal measured from a well having a floating disk is shown on the x-axis of the graph. On the y-axis, prompt fluorescence signal of a floating disk is shown. Prompt fluorescence of a floating disk was determined by first measuring prompt fluorescence signal when the disk was floating (correct GALT signal+fluorescence of disk) and then subtracting from that signal the prompt fluorescence signal obtained when the disk was manually submerged to the incubation buffer (correct GALT signal). The graph shows that if a disk is floating in the optical measurement path, the amount of time-resolved fluorescence signal is high. However, also the amount of prompt fluorescence signal is high, which may give a faulty screening result. In summary, the higher the time-resolved signal measured, the higher the probability that the GALT prompt fluorescence measurement is faulty. Low time-resolved counts are obtained for example if the disk is tilted, partly submerged, or in horizontal orientation. In these cases, the probability of erroneous GALT results is decreased too.
[0060] The fluorescence measurements are typically performed by using a specific excitation and emission wavelengths selected by means of optical filtering, for example. The excitation and emission wavelengths are chosen based on the fluorescent characteristics of the sample substrate (in the detection of a floating disk) or the analyte measured/label molecules used (in the measurement of analysis outcome). However, the present method can be implemented also by measuring a broad fluorescence excitation and/or emission spectrum and analysing the characteristics of the spectrum for determining if the sample substrate floats or not.
[0061] Main functional units of an automated measuring apparatus in which the present detection method can be used are described shortly below. A more detailed description of these units, as well as their possible uses in one type of measurement apparatus is contained in the patent application PCT/FI2008/050350, the relevant contents of which are incorporated herein by reference.
[0062] The dispensing unit is used for aspirating reagents from reagent containers and dispensing them to microtiter plate wells. The dispensing unit has functionalities for aspirating reagents and buffers from vials and bottles, diluting reagents in a dilution vessel, dispensing reagents to wells, and optionally handling evaporation caps of vials/bottles where the liquids are contained in. The dispensing unit may also monitor the liquid levels of the reagents in the vials and bottles, and detect presence of evaporation caps and dispensing tips in the reagent storage module. The reagents may include buffers, tracer antibodies for immunoassays, reagents for enzyme assays and/or reagents for possible other assays/chemistries. There may also be provided one or several dilution vessels which can be used for diluting the reagents with buffer. There may also be a flush basin for flushing tips.
[0063] The present apparatus has the capability of performing optical measurements of samples with at least one measurement mode, but may have the capability of measuring in two or more measurement modes. It is useful if the instrument has the capability of performing optical measurements of samples with at least three measurement modes. The measurements using different modes may be provided in a single measurement unit or separate measurement units. An exemplary instrument has at least the capability to perform prompt (FI) and time-resolved fluorescence (TRF) measurements, and optionally is capable of measuring absorbance (ABS). Additionally, the exemplary instrument could have luminescence mode capability.
[0064] An exemplary set of main steps in a homogeneous assay that can be used in neonatal screening is described below:
[0000] 1. Punching of sample disks from sample cards and placing the disks into the wells of a microtiter plate.
2. Placing the microtiter plate into an input stack of an automated screening apparatus.
3. Dispensing incubation buffer to the wells of the plate.
4. Detection of whether a disk is floating, and if a floating disk is detected, flagging the measurement result in respect of that well as unreliable or as unsuitable for further analysis
5. Measuring optically the amount of the analyte of interest.
[0065] It is noteworthy that there may be additional steps, such as storage, incubation, shaking and/or heating/cooling steps in the process, as well as transportation steps where the plate is moved between the units responsible for performing the above steps. Furthermore, order of the steps, especially steps 4 and 5 may be different from the example above.
EXAMPLES
Lifetime of Time-Resolved Fluorescence Response of Sample Substrate
[0066] Filter-paper based sample substrate from Schleicher & Schuell (No. 903) without blood sample was cut to give a 6 mm disk. The disk was placed in a black 96-well microtiter plate and 200 μL of water was dispensed on the disk in a well and, for comparison, to an empty well. The disk was submerged in water. Then time-resolved fluorescence decay time measurements were performed by exciting at 337 nm using a laser and measuring emission at different wavelengths as a function of elapsed time from excitation. The well containing just water and no disk didn't give any appreciable time-resolved fluorescence at any of the wavelengths tested. On the other hand, the disk in water gave a strong time-resolved emission at all the wavelengths tested and the calculated decay times were following: at 535 nm 933 μs, 545 nm 880 μs, 572 nm 814 μs, 615 nm 680 μs, and at 642 nm 641 μs.
[0067] The above results show that sample substrate tested gives, upon excitation at 337 nm, time-resolved fluorescence with a long lifetime and with a broad emission spectrum.
Time-Resolved Fluorescence Measurements of Disks
[0068] Two blood spots were eluted in 400 μL water and subsequently 200 μL of eluted blood was dispensed to two wells in a clear 96-well plate. Next a 6 mm disk of Scleicher & Schuell filter paper (No. 903) without blood sample was placed to one of the wells containing eluted blood so that the disk remained floating. Both wells were measured in Victor Multilabel reader (PerkinElmer) using time-resolved mode with factory-set protocols. Next the floating disk was submerged to eluted blood and measurements were repeated. Results are in the table below.
[0000]
Eluted blood,
Emission wave-
Eluted blood, no
Eluted blood,
disk floating
length (nm)
disk (counts)
disk (counts)
(counts)
545
254
2276
167717
572
229
611
12946
615
94
698
28245
642
40
86
3416
[0069] Results in the above table show that all the tested time-resolved fluorescence emission wavelengths can be used in the detection of floating disks.
[0070] Separately a well with water and a well with a disk submerged in water were measured in black 96-well plate using excitation at 340 nm and time-resolved fluorescence emission was measured at 460 nm. There was no blood in the disk. The well with just water gave 90 counts whereas the well with a disk gave 9924 counts. This result indicates that the detection of disks using time-resolved fluorescence can potentially be performed using emission at or close to the blue region of the spectrum.
Prompt Fluorescence Measurement of Disks
[0071] Suitability of prompt fluorescence measurement in the detection of disks was tested by measuring fluorescence (excitation 488 nm, emission 535 nm) of one well with water and the other with disk submerged in water (no blood in the disk, clear 96-well plate). The well with water gave 7627 counts and the well with a disk gave 44071 counts in Victor Multilabel reader. This result shows that a disk in a well can be detected and suggests that the detection of floating disks in an actual assay should be possible using prompt fluorescence measurement.
GALT Assay
[0072] In the Neonatal GALT assay (PerkinElmer), the GALT incubation buffer contains all the necessary components for the detection of GALT activity except enzymes. GALT (galactose-1-phosphate uridyl transferase) itself and other enzymes involved in the enzyme cascade reaction generating NADPH from NADP, namely PGM (phosphoglucomutase), G-6-PD (glucose-6-phosphate dehydrogenase) and 6-PGD (6-phosphogluconate dehydrogenase), come from a sample, a punched blood disk. Components of GALT incubation buffer includes, among other things, NADP which is reduced to NADPH as a result of a reaction cascade started by GALT. GALT incubation buffer with eluted components of a blood disk has no response in a time-resolved fluorescence measurement. On the other hand, the filter paper used to collect blood spots (the substrate) has a long-lived fluorescence which can be measured in the time-resolved mode. If the disk is submerged, the components of the eluted blood, mainly haemoglobin, and also components of the incubation buffer, principally NADP, will prevent most of the time-resolved fluorescence photons from being detected (the so-called quenching effect). On the other hand, a floating disk will provide a time-resolved fluorescence response (e.g. at 615 nm) which is not quenched by the liquid below the floating disk.
[0073] The present method was tested using a standard europium measurement protocol and applied to 3617 wells, 263 of which contained a floating blood disk. All wells having a properly submerged disk provided a TRF signal of 50-300 counts, whereas all wells having a floating disk provided a TRF signal of 350-8000 counts.
[0074] The above detailed description, the attached drawings and examples are given for exemplifying purposes only and are not intended to limit the scope of the invention, which is defined in the appended claims. | The invention relates to a method and apparatus for detecting undesired measurement conditions in a sample container. The method comprises measuring a fluorescent property of the sample container comprising a sample substrate with impregnated blood sample and incubation buffer to which the blood sample is to be eluted, and determining, based on temporal and/or spectral characteristics of the fluorescent property, whether the fluorescent property is characteristic to a sample container comprising a sample substrate and incubation buffer under said undesired measurement conditions or to a sample container suitable for optical measurement of analyte contained in the sample. Thus undesired measurement condition can be a floating sample substrate or a foreign body in the sample container. By means of the invention, reliability of neonatal screening, for example, can be increased. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims the benefit of priority of Japanese Patent Application No. 2004-127930 filed on Apr. 23, 2004, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a portable device for an automotive device control system and, more specifically, to a portable device for controlling access to automobile and automotive devices based on communication between the portable device and the automotive device control system.
BACKGROUND OF THE INVENTION
[0003] In recent years, remote access control systems for automobile such as SMARTKEY SYSTEM (registered trademark) is known and used for controlling access to an automotive device control system. This type of system controls access to an automobile by locking and unlocking doors, starting an engine, unlocking a steering wheel and opening a trunk lid through a radio communication between a portable device carried by a user and a main part of the system disposed in an automobile.
[0004] The portable device generally uses a battery for electrical power supply. Therefore, portable device continuously monitors voltage potential of the battery by using a voltage monitor circuit and initializes its internal setting in order to prevent malfunction of the portable device because of a low voltage potential. An operation scheme described above for a conventional portable device is disclosed in Japanese Patent Document JP-A-2002-247656.
[0005] However, the operation scheme for the conventional portable device suffers from decreased battery life because the conventional portable device continuously consumes electricity of the battery to operate the voltage monitor circuit.
SUMMARY OF THE INVENTION
[0006] In view of the above-described problems, it is an object of the present invention to provide a portable device for an automotive device control system that has an extended battery life by reducing electricity consumption.
[0007] The portable device for the automotive device control system of the present invention includes a communication means for sending and receiving a signal from a main body of the automotive device control system, a control means for controlling the communication means, a potential detection means for detecting electrical potential of a battery used to energize the communication means and the control means, and a detection control means for controlling operation of the potential detection means. Operation mode of the potential detection means is chosen from a continuous monitor mode and an intermittent monitor mode, based on a detected electrical potential of the battery. The detection control means chooses the intermittent monitor mode when the electrical potential of the battery is equal to or higher than a predetermined electrical potential, and it chooses the continuous monitor mode when the battery potential is lower than the predetermined electrical potential.
[0008] The potential detection means operated in the above described manner consumes less electricity of the battery in the intermittent monitor mode than in the continuous monitor mode for the operation of the potential detection means because the potential detection means uses electrical power intermittently in the intermittent monitor mode while the battery potential is higher than the predetermined electrical potential. Therefore, electricity consumption for detecting electrical potential decreases and the battery of the portable device has an extended life.
[0009] The potential detection means operates in the continuous monitor mode when the electrical potential of the battery is lower than the predetermined electrical potential. In this manner, the portable device can prevent malfunction caused by an insufficient electrical potential.
[0010] The detection control means puts the portable device in a sleep state that stops monitoring of a battery potential while the portable device is waiting for a transmission signal from the main body of the automotive device control system in the intermittent monitor mode. The detection control means switches to a resume state for detecting the battery potential when the portable device has received the transmission signal from the main body of the automotive control system. The detection control means returns to the sleep state when the portable device has sent a response signal to the transmission signal.
[0011] The detection control means detects battery potential of the portable device after sending the response signal to the main body of the automotive device control system when potential detection means operates in the intermittent monitor mode. This is because sending the response signal consumes electrical power of the battery and lowers the battery potential. In this manner, the battery potential is detected appropriately in the intermittent monitor mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other objects, features and advantages of the present invention will become more apparent from the following detailed description made with reference to the accompanying drawings, in which:
[0013] FIG. 1 is a block diagram of a portable device and a main body of an automotive device control system according to an embodiment of the present invention;
[0014] FIG. 2 is a flowchart of a battery potential detection method used in the portable device; and
[0015] FIG. 3 is a time chart that illustrates the battery potential detection method in relation to a series of changes in the battery potential.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] An embodiment of the present invention is described with reference to FIGS. 1 to 3 .
[0017] FIG. 1 shows a block diagram of an automotive device control system having a portable device. The automotive device control system includes an automotive device control apparatus 10 installed on an automobile, a door lock controller 20 and a portable device 30 . The automotive device control apparatus 10 and the portable device 30 communicates with each other.
[0018] The automotive device control apparatus 10 includes a transmitter 11 , a receiver 12 , and a control ECU 13 . The transmitter 11 and the receiver 12 are disposed in a compartment of the automobile or on the outside of the compartment. For example, the transmitter 11 and the receiver 12 are disposed in a part close to a door handle. The transmitter 11 transmits a transmission signal to the outside of the compartment upon receiving a transmission control signal from the control ECU 13 . The receiver 12 receives an ID code signal from the portable device 30 and outputs the ID code signal to the control ECU 13 .
[0019] The control ECU 13 is installed on the automobile and controls the transmitter 11 and the receiver 12 . The control ECU 13 has a memory for storing a transmitter control program, an ID code of the portable device 30 and the like. The control ECU 13 compares the ID code transmitted from the portable device 30 with the ID code stored in the memory, and determines if those two codes are the same. The control ECU 13 re-transmits a transmission signal based on the comparison result and outputs an operation signal to the door lock controller 20 . The door lock controller 20 locks or unlocks doors upon receiving the operation signal from the control ECU 13 .
[0020] The portable device 30 includes a receive portion 31 , a transmit portion 32 , a controller 33 , and a battery 34 . The receive portion 31 , the transmit portion 32 and the controller 33 in this embodiment are implemented as an IC chip respectively. The receive portion 31 receives the transmission signal from the transmitter 11 of the automobile device control apparatus 10 and the transmit portion 32 transmits a signal back to the receiver 12 of the automobile device control apparatus 10 . The controller 33 is implemented as a microcomputer of well-known type including a CPU, a memory and the like. The portable device 30 has its own ID code and the ID code is stored in the memory of the controller 33 . The controller 33 is programmed to transmit an ID code signal including the ID code to the receiver 12 on the apparatus 10 through the transmit portion 32 when it receives the transmission signal from the transmitter 11 of the apparatus 10 through the receive portion 31 .
[0021] The battery 34 supplies electricity to the receive portion 31 , the transmit portion 32 and the controller 33 . The controller 33 has an electrical potential monitor circuit 33 a to detect an electrical potential of the battery 34 . In this embodiment, a source potential Vdd of the battery 34 is specified as 3 volt, and a reset potential Vret is specified as 1.8 volt. The reset potential is used as a threshold for initializing the portable device 30 in order to avoid malfunction of the portable device 30 .
[0022] The portable device 30 monitors the potential of the battery 34 in an intermittent monitor mode or in a continuous monitor mode. The intermittent monitor mode is further defined as an alternating operation of a sleep state and a resume state, that is, the sleep state for stopping operation of potential detection and the resume state for resuming operation of potential detection. The continuous monitor mode continuously monitors the electrical potential of the battery 34 . The two modes of potential detection are switched based on a switch potential Vdet. In this embodiment, the switch potential Vdet is determined as a higher potential, i.e., 1.9 volt, than the reset potential Vret.
[0023] Potential monitor operation of the portable device 30 is described with reference to FIGS. 2 and 3 .
[0024] FIG. 2 shows a flowchart of potential monitor operation controlled by the controller 33 based on a program stored therein. The operation starts with step S 10 where the potential monitor mode is set to the intermittent monitor mode. In the intermittent monitor mode, an initial state of monitoring is the sleep state that stops potential detection of the battery 34 . Then, the portable device 30 waits for a reception of the transmission signal transmitted from the transmitter 11 of the apparatus 10 on the automobile (step S 11 ). The state of monitor operation is changed to the resume state upon receiving (step S 11 : yes) the transmission signal (step S 12 ) and the potential detection circuit 33 a detects the potential of the battery 34 (step S 13 ). Step 11 repeats itself (step S 11 : no) until the transmission signal is received.
[0025] The detected potential is compared with the switch potential Vdet in step S 14 . When the detected potential is lower than the switch potential Vdet (step S 14 : yes), the ID code signal including low potential warning (step S 15 ) is transmitted to the receiver 12 on the automobile (step S 16 ). When the detected potential is not lower than the switch potential Vdet (step S 14 : no), the ID code signal transmitted to the receiver 12 does not include low potential warning (step S 15 skipped).
[0026] The potential of battery 34 is detected again by the potential detection circuit 33 a after the ID code signal is transmitted to the receiver 12 (step S 17 ). The detected potential is compared with the switch potential Vdet (step S 18 ). When the detected potential is equal to or higher than the switch potential Vdet (step S 18 : no), the resume state of the intermittent monitor mode is switched to the sleep state (step S 19 ). When the detected potential is lower than the switch potential Vdet (step S 18 : yes), the intermittent monitor mode is switched to the continuous monitor mode (step S 20 ).
[0027] FIG. 3 shows a time chart that illustrates battery potential detection method in relation to a series of changes in the potential of the battery 34 along the time parameter t. The initial state of the monitor operation is the sleep state as shown in FIG. 3 .
[0028] The potential of the battery 34 lowers because of the ID code signal transmission operation after the portable device 30 receives the transmission signal from the transmitter 11 of the apparatus 10 on the automobile (time t 1 ). The potential of the battery 34 is detected upon receiving the transmission signal. The monitor operation is switched from the sleep state to the resume state according to the program. The ID code signal does not include low potential warning at this point, because the potential is not lower than the switch potential Vdet.
[0029] The potential of the battery 34 gradually regains after transmission of the ID code signal (time t 2 ). The potential of the battery 34 is detected just before the monitor operation is switched from the resume state to the sleep state (time t 3 ). The monitor operation is switched from the resume state to the sleep state because the detected potential is not lower than the switch potential Vdet at time t 3 .
[0030] Next, the potential of the battery 34 is detected upon receiving the transmission signal from the transmitter 11 . The monitor operation is switched from the sleep state to the resume state according to the program (time t 4 ). The ID code signal includes low potential warning, because the potential is lower than the switch potential Vdet at time t 4 .
[0031] The ID code transmission ends at time t 5 . The potential of the battery 34 is detected just before the monitor operation is switched from the resume state to the sleep state (time t 6 ). The monitor operation is switched from the resume state to the sleep state because the detected potential is not lower than the switch potential Vdet at time t 6 .
[0032] Next, the potential of the battery 34 is detected upon receiving the transmission signal from the transmitter 11 . The monitor operation is switched from the sleep state to the resume state according to the program (time t 7 ). The ID code signal includes low potential warning, because the potential is lower than the switch potential Vdet at time t 7 .
[0033] The ID code transmission ends at time t 8 . The potential of the battery 34 is detected just before the monitor operation is switched from the resume state to the sleep state (time t 9 ). The monitor operation is changed from the intermittent monitor mode to the continuous monitor mode because the detected potential is lower than the switch potential Vdet at time t 9 .
[0034] The above-described scheme of the potential detection saves battery energy used by potential detection because operation of the detection circuit stops intermittently in the intermittent monitor mode while the detected potential of the battery 34 is equal to or higher than the switch potential Vdet. Therefore, the battery life of the portable device 30 is extended.
[0035] The monitor operation is changed from the intermittent monitor mode to the continuous monitor mode when the detected potential of the battery 34 is lower than the switch potential Vdet. The change of the monitor modes serves as a preparation for further decrease of the battery potential. In this manner, malfunction of the portable device 30 can be prevented because detection circuit is operated continuously for potential detection.
[0036] The battery potential of the portable device decreases when it transmits the ID code signal to the automotive device control apparatus 10 . Therefore, the battery potential is preferably monitored when the ID code signal is transmitted.
[0037] Although the present invention has been fully described in connection with the preferred embodiment thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art.
[0038] For example, though the present invention is applied to the portable device 30 of the automotive device control system, the invention can also be applied to a portable device for two-way communication between a system and a portable device that requires extended battery life for continuous operation.
[0039] Such changes and modifications are to be understood as being within the scope of the present invention as defined by the appended claims. | A portable device for receiving and sending a signal to an automotive device control system includes a communication means for receiving and sending the signal to the automotive device control system, a control means for controlling the communication means, a potential detection means for detecting electrical potential of a battery used to energize the communication means and the control means, and a detection control means for controlling detection operation of the potential detection means. The detection control means operates the potential detection means either in a continuous monitor mode or in an intermittent monitor mode in order to detect potential of the battery. The intermittent monitor mode is used when potential of the battery is equal to or higher than a predetermined potential, and the continuous monitor mode is used when potential of the battery is lower than a predetermined potential. | 1 |
FIELD OF THE INVENTION
The present invention relates to a motor drive for a shaftless spinning rotor of an open end spinning machine embodied as the rotor of an axial field motor, wherein a combined magnetic/gas bearing having a concentric disposition of magnets produces magnetic driving and guiding fields and maintains a bearing or support surface facing outwardly from the rotor and an oppositely located bearing or support surface on the stator spaced apart by an air gap, with means being provided for guiding or conducting the magnetic flux for the magnetic drive and guide fields.
BACKGROUND OF THE INVENTION
As development of rotor spinning machines progresses, the goal is not only to improve the quality of the yarns produced, but above all to increase production capacity. A key factor in increasing production capacity is the rotary speed of the spinning rotor. For this reason, varied kinds of drives and bearings for spinning rotors have been developed, in order to reach rotary speeds of markedly over 100,000 rpm. Reducing the rotor diameter and mass and lowering friction losses enables not only greater rotary speed but also reduced energy consumption when driven.
In this respect, a shaftless spinning rotor, which is embodied as the rotor of an axial field motor, can be considered especially advantageous by providing a combined magnetic and gas bearing which assures relatively low friction losses.
A shaftless open-end spinning rotor of the above-described type having a combined magnetic and gas bearing is known from International PCT Patent Reference WO 92/01096, which discloses a rotor having a bearing face, remote from the spinning chamber of the spinning rotor, and means for conducting the magnetic flux for the driving and guiding magnetic field. By means of the guiding magnetic field, the rotational axis of the open-end spinning rotor is to be rigidly defined and maintained during rotation. However, it has been found impossible to achieve significant suppression of impermissible vibratory, wobbling and oscillating motions that occur particularly in critical rpm ranges.
Permanent magnets located opposite each other in the rotor and the stator and having facing magnetic poles of reversed polarity are provided for generating the magnetic guide field. However, irregularities in the dimensions and in the magnetization of these magnets often occur in the stator and the rotor, which lead to deviations in magnetic induction and inhomogeneities in magnetic flux distribution and thereby can cause a radial mismatch between the magnetic axis of symmetry and the axis of rotation through the center of gravity of the rotor. Further, it is also possible that opposite actions of two concentric magnetic systems in the rotor and stator can cause radial oscillations of the rotor and output losses. Further disadvantages of the known construction lie in the production expense caused by the necessity of extremely accurate dimensioning and exact positioning required of the magnets in the stator and rotor, typically performed by means of an elaborate gluing process. Furthermore, the disposition of permanent magnets in the rotor causes problems in that on the one hand the bearing face of the rotor should have very little roughness, but on the other hand, when permanent magnets are disposed in the bearing face, mechanical finishing of this surface in the form of grinding and polishing is made very difficult without mechanical destruction or demagnetization of the magnets because of the resulting effects of temperature.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to improve the known motor drive of a shaftless spinning rotor for an open end spinning machine by providing a simplified construction and an improved running smoothness and quietness.
Briefly summarized, the foregoing objective may be accomplished in accordance with the present invention in a rotor assembly for an open end spinning machine of the type comprising an axial field motor having a rotor and a stator wherein the rotor includes a body defining an interior spinning chamber and an outward bearing face and the stator includes a bearing face disposed opposite the bearing face of the rotor, by providing the present improved means for producing a combined magnetic and gas bearing for supporting the rotor at a spacing relative to the stator defined by an intervening air gap. Under the present invention, the bearing means includes means for producing a first field of magnetic flux for guiding or orienting and maintaining a rotational axis of the rotor in a stationary disposition, means for producing a second field of magnetic flux for driving rotation of the rotor about the axis, first means for conducting the magnetic flux for the guiding or orienting magnetic field, and second means for conducting the magnetic flux for the driving magnetic field. In accordance with the present invention, the means for producing a first field of magnetic flux comprises a magnet disposed on one of the rotor and the stator concentrically to the axis and the first magnetic flux conducting means comprises a yoke-forming, magnetically conductive element disposed on the other of the rotor and the stator in axially opposed facing relation to the magnet.
Because of the disposition of one or more magnets for the magnetic guide field opposite a magnetically conductive element forming a yoke, instead of the conventional use of a further magnet of opposite polarity, a point-symmetrical field is generated which, in operation, forms a sort of a magnetic potential depression which acts in a self-adjusting manner. In particular, it is no longer necessary to exactly align the magnets to be facing each other in the stator and rotor nor to magnetize them evenly. In this connection, it will be understood that an absolutely homogeneous magnetization is technically difficult or nearly impossible, at least not without extremely great expense.
In the preferred embodiment, a generally non-magnetic means is disposed between the first and second magnetic flux conducting means for decoupling of the respective magnetic fluxes. This is of importance mainly because the magnetic drive field typically located outwardly of the guide field will have a chronologically and spatially changing magnetic force component which disturbs the constant magnetic guide field, whereby the superimposition of the drive field on the guide field could result in an asymmetric field strength distribution at the center of the spinning rotor. For example, while the magnetic field lines between the drive magnets of a brushless DC-motor extend in the same direction over the central area in which the guide magnets are disposed, the direction of the magnetic guide field lines is opposite on opposite sides of the axis of rotation. As a result, a jam in the magnetic flux occurs on the one side, possibly even magnetic satiation, while an oppositely-directed mutual weakening of the magnetic field occurs on the opposite side. Without a separation of the magnetic flux of the magnetic drive and guide fields the effect of the stator current leads to a constant magnetic reversal in the area of the guide magnet(s) or the yoke-forming magnetically conductive elements.
The embodiment of the yoke-forming magnetically conductive element to be of a soft magnetic material has the advantage that this material has a high degree of permeability. If the soft magnetic material additionally has a large hysteresis loop, it is possible to provide yoke-forming elements which, on the one hand, have good adaptability to the field of the oppositely located permanent magnet and, on the other hand, have a storage capacity for magnetic energy resulting in an increase of the effect of the oppositely located magnetic field. Further, the formation of the yoke-forming magnetically conductive element with an annular recess concentric to the rotor axis and opening to the respective rotor or stator bearing face permits the direction of formation of the magnetic guide field to be targeted, especially if yoke-forming magnetically conductive elements are provided on both the stator and the rotor with respective recesses which are axially aligned with each other, with the result of very good centering of the rotor.
Several alternative embodiments are contemplated under the present invention, all of which assure the essential advantages of the invention. In one embodiment, the magnet is inserted within one of the recesses at an inward spacing from the location at which it opens at the respective bearing face. In this case, this placement of the magnet away from the outer surface of the respective yoke-forming element offers the advantage that the magnet is no longer located at the bearing surface of the rotor or stator whereby mechanical finishing of these bearing faces is easily possible.
In some embodiments, a plurality of magnets may be employed, either disposed respectively on the rotor or the stator or both. In such cases, an improved centering of the rotor may be achieved by arranging the magnets in respect to their associated yoke-forming magnetically conductive elements to cause the respective magnetic fields to mutually reinforce each other.
It is also advantageous to arrange the magnet(s) for the magnetic guide field on the stator where they need not perform any rotary movements. A lessened need therefore exists for the secure fastening of the magnets. Furthermore, the magnetic field emanating from the magnets, which in actuality is not completely homogeneous as already mentioned above, does not move.
The magnet(s) may be permanent magnets or electromagnets and various considerations play a role in the decision whether to use permanent or electromagnets. A system with a large soft magnetic volume and electromagnetic coils has higher damping, while the employment of permanent magnets shows an increased resilience of the bearing. In comparison to the use of permanent magnets, the employment of electromagnetic coils permits a control of the magnetic centering force at critical rpm by means of a controlled current supply.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross-sectional view through an assembly of a shaftless open-end spinning rotor embodied as the rotor of an axial field motor, with a center-disposed permanent magnet of axial polarization on the stator side for generating a magnetic guide field, in accordance with one preferred embodiment of the present invention;
FIG. 2 shows an alternative arrangement of permanent magnets for generating a magnetic guide field with ring-shaped permanent magnets of axial polarization recessed in relation to the bearing face;
FIG. 3 shows another magnet arrangement as in FIG. 2, but with radial polarization of the ring-shaped permanent magnets;
FIG. 4 shows another arrangement for generating a magnetic guide field with magnets of respectively axial polarization disposed on both the stator and rotor sides of the assembly;
FIG. 5 shows an arrangement for generating a magnetic guide field having several ring-shaped recesses and an electromagnetic coil for generating the magnetic field; and
FIG. 6 shows an arrangement for generating magnetic guide field having several ring-shaped recesses and several annular magnets of radial polarization inserted into these ring-shaped recesses.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the accompanying drawings and initially to FIG. 1, a shaftless spinning rotor 1 according to the present invention is embodied as the rotor of an axial field motor in assembly with a stator 2 of the motor. The main body of the spinning rotor i forms a spinning cup 3 open at its top with a circular disk-like base 3' from which an annular outer wall extends to define a spinning chamber therewithin with an annular fiber collecting groove 3" extending circumferentially at the juncture of the base 3' and the annular wall, this structure of the rotor 3 being concentric about and defining an axis of rotation 11. As is known in open-end spinning, opened individualized fibers are fed into the chamber to collect centrifugally in the groove 3" as a result of driven rotation of the rotor 3 and the collected fibers are progressively drawn from the spinning chamber to form a yarn or thread. The means by which fibers are delivered into the chamber and the means by which the yarn is withdrawn from the chamber are known but are not shown for the sake of simplicity in that elements do not have any influence on the subject of the present invention.
The underside of the rotor 1 and the opposing upper side of the stator 2 form respective bearing faces of a combined magnetic and gas bearing of the present invention. The bearing face of the rotor 1 includes a supporting and insulating carrier 5 which forms the main portion of the bearing face of the rotor 1 and serves to fasten a yoke 6 (for reasons of simplicity, the term "yoke" will be used in all exemplary embodiments to identify yoke-forming, magnetically conductive elements) coaxially to the underside of the spinning rotor 1 as a dynamically balanced unit by means of a central annular hub portion 19 of the carrier 5 projecting from the rotor 1 concentrically about its axis and encircling the yoke 6 to extend the hub 19 and the yoke 6 supported thereby into a correspondingly centered depression in the stator 2, forming an axial air gap 14 and a radial air gap 15 therebetween. The yoke 6 has a concentric, ring-shaped recess 8 in the form of a circumferential groove, whereby only a central portion 6' of the yoke radially inwardly of the recess 8 and an annular portion 6" located radially outwardly of the recess 8 form a part of the overall bearing face of the rotor in the motor drive assembly. As known from WO 92/01096, the carrier 5, including its hub portion 19, can be formed by rigid laminates which accomplish the function of a solid, and resilient support layer as well as the function of magnetic insulation.
A yoke 23 formed with a recess 21 similarly to the recess 8 in the yoke 6 is supported by the stator 2 axially adjacent the air gap 14 in facing relation to the yoke 6. However, instead of a central portion like the portion 6' of the yoke 6, an axially polarized permanent magnet 22 is provided at the center of the yoke element 23. As with the yoke 6 in the rotor 1, the yoke 23 is embedded in a support and insulating carrier 20. The yoke 23 and the yoke 6 function together to provide magnetic guidance for the rotor 1 as hereinafter described.
In addition to supporting the magnetic guide yoke 6 on the spinning cup 3 of the rotor 1, the above mentioned support and insulating carrier 5 also fastens to the base 3' of the cup 3 a plurality of drive magnets 4 and 4' which for example, consist of segment-shaped magnetic plates of alternating polarity arranged symmetrically about the axis of the rotor 1. Two drive magnets 4, 4' are sufficient in the simplest case and are magnetically insulated from each other in the plane of the bearing face by the carrier 5. However, since this magnet arrangement is already described in WO 92/01096, which is incorporated herein by reference, it need not be addressed in detail herein.
The base 3' of the spinning cup 3 directly serves as the yoke for the soft magnetic ground connection of the drive magnets 4, 4' and therefore the base 3' is made of a ferromagnetic material. The drive magnets 4 and 4' are affixed, e.g., by gluing, to the base 3'. The yoke 6 is axially spaced from the base 3' by an appropriately wide air gap 9 forming a barrier layer which is sufficient for decoupling the magnetic drive and guide fields from each other so that the yoke 6 is unaffected by the functioning of the base 3' as a yoke for the drive magnets 4 and 4'. As a result, the alternating component of the rotating magnetic drive field has no significant influence on the magnetic guide field.
The main component of the stator 2 is a stator winding 25 with an annular soft iron core 24. As already mentioned, the assembly of the yoke 23 and the magnet 22 to form the guide magnet field is mounted on the stator inside this annular assembly of the soft iron core 24 and stator winding 25. Air nozzles 16 open axially through the carrier 20 into the air gap 14 to inject air thereinto. The air nozzles 16 are supplied with air through an annular conduit 17 which communicates with a source of compressed air, not shown, via a connecting line 18. As a result of the outflowing air, the air gaps 14, 15 and an air gap 10 are always maintained appropriately between the spinning rotor 1 and stator 2 counter to the magnetic force of attraction of the magnets for averting direct contact between their opposed bearing faces. The air emerging from the air nozzles 16 flows from the axial gap 14 annularly into the radial gap 15 and outwardly therefrom radially through the air gap 10 between the rotor 1 and the stator 2, thereby achieving a uniform air cushion over the entire bearing face 5 of the rotor 1. The air pressure and air quantity should be adapted to the magnetic force so that, in the main bearing region, i.e., between the annular arrangement of the stator winding 25 and the opposite face 5 of the spinning rotor 3, the air gap 10 is maintained at a sufficient width. In this manner, the air consumption can be kept within feasible limits, and the magnetic interaction between the spinning rotor 1 and the stator 2 can be maximized, while achieving adequate security against direct contact of the bearing faces.
The air gap 14, which is somewhat wider than the air gap 10, prevents dimensional deviations in the magnet arrangements for the guide magnet field, resulting for instance from heating due to eddy currents induced by way of harmonics, from having any negative consequences on the operation of the rotor 1. Above all, however, it can be assured that the vulnerable nozzle arrangement of the air nozzles 16 is protected in the area of their outlet openings 16' in every case.
The radial air gap 15 is defined by two security faces 12,13 formed respectively as wearproof surfaces on the radially outward surface of the carrier 19 and the radially inward surface of the stator 2, to be operative to serve the purpose of radially securing the position of the spinning rotor 1 both upon startup of the rotor 1 and particularly in case of suddenly occurring radial forces during operation, but not during trouble- free operation. These security faces 12, 13, advantageously consist of a sufficiently solid material, e.g., a ceramic material, to assure above all that the start-up security ring forming the face 12 is at least sufficiently strong and stable to prevent damage to the windings 25 of the stator. For example, the ring can be fastened by means of a laminate.
As seen in FIG. 1, the recesses 8 and 21 of the yokes 6 and 23 are axially aligned with and face one another, which serves to locate the portions of the yokes laterally adjacent these recesses directly opposite each other at a spacing defined by the relatively small air gap 14. In the embodiment of FIG. 1, the centered permanent magnet 22 of the yoke 23 and the centered portion of the yoke 6 are located opposite each other essentially along the axis of rotation of the rotor 1. Because of the specific configuration of the yokes 6 and 23, as well as the arrangement of the centered permanent magnet 22, a magnetic guide field results with magnetic flux lines 7 as represented by broken directional arrows in-FIG. 1. As a result, the rotor assembly is magnetically maintained in a centered position at its rotational axis as soon as a minimum of potential energy of the described magnetic centering/guide field has been attained. This magnetic centering/guide system is therefore self-adjusting. Above all, the requirement existing in the prior art of accurately aligning respective guide magnets located opposite each other on the rotor and stator and the requirement of magnetizing the magnets evenly are avoided.
Since only one magnet is used in the present invention in contrast to the arrangement of several magnets in the prior art, this magnet should be correspondingly stronger in comparison with the known system to achieve an appropriate centering force. It is further preferred that a hysteresis material with a large proportion of cobalt be used as the material for the yokes. Also, it is contemplated that a hysteresis motor can be used in place of the illustrated motor with a drive magnet on the rotor side, without affecting the basic operation of the present invention.
For reasons of simplification, the further embodiments of the present invention are illustrated in FIGS. 2 to 6 only insofar as their particular arrangements for the design of the magnetic guide field, i.e., a magnetic field as generated by the guide magnet 22 and the yokes 6, 23 of FIG. 1, which accomplishes the combined functions of retaining the rotor 1 in assembly with the stator 2 and centering the rotor 1 coaxially with the stator 2. Furthermore, it is to be understood that the various embodiments of the present invention are not limited to a stepped bearing face, as shown by way of example in FIG. 1, but also relate to completely flat bearing faces, i.e., the invention can basically be employed independently of the design of the bearing faces.
In accordance with FIG. 2, a yoke 26 on the rotor and a yoke 29 on the stator face each other coaxially with one another and with the center rotational axis of the motor drive. The respective yokes 26, 29 have ring-shaped recesses 27, 30 axially aligned with each other. The annular recess 30 of the stator is bordered at its center by an assembly of a permanent magnet 31 and a disk 29" made of the same material as the yoke 29, which is affixed coaxially with the centered permanent magnet 31. A step results between the disk 29" and the magnet 31 because of the larger diameter of the permanent magnet 31 in respect to the disk 29". However, it is also possible to bevel the upper edge of the permanent magnet 31, so that the step is reduced. The ring-shaped recess 30 is outwardly bordered by a circular wall of the yoke 29 itself.
The permanent magnet 31 is connected adhesively with the yoke 29 and is centered by means of an annular bead 29'" of the yoke 29. The disk 29" can be connected adhesively in the same way with the permanent magnet 31. However, it is also conceivable to fasten the parts by means of a screw connection.
Magnetic flux lines having a magnetic flux direction as indicated at 28 are formed by this arrangement and essentially form a ring around the axis of rotation 11. The air gap 32 of the bearing between the respective yokes of the rotor and the stator, represented for purposes of clarity to be larger than the actual spacing in the range of a few hundredths of a millimeter which would exist in actual practice, only represents a small magnetic resistance for the portions of the yokes 26 and 29 radially adjacent the opposite lateral sides of the recesses 27 and 30. As a result, a relatively strong magnetic flux can be formed, guided by and conforming to the shape of the yokes as indicated by the magnetic flux lines 28 in FIG. 2. In this connection, it is particularly advantageous that the permanent magnet 31 is spaced apart from the edge 29' of the disk 29" at the bearing face on the stator, whereby both outward faces of the yokes 26 and 29 may be worked by means of grinding or polishing without affecting the permanent magnet 31 which can advantageously be inserted later.
The embodiment in accordance with FIG. 3 differs from the embodiment represented in FIG. 2 essentially in that the annular guide magnet 38 employed therein is radially magnetized. A yoke 33 on the rotor is disposed in opposed facing relation to a yoke 36 on the stator, with respective recesses 34 and 37 thereof being axially aligned with each other in an analogous manner. The magnetic flux lines 35 of this arrangement form in the shape illustrated. Advantageously, the annular magnet 38 in this embodiment can also be dimensioned in such a way that it is spaced from the bearing face on the stator to permit working thereof. The portion of the yoke 36 facing away from the bearing face is formed of a lesser thickness adjacent the underside of the annular magnet 38 to prevent the formation of a portion of the magnetic flux in this area which would be unusable for the magnetic guide field.
In the embodiment represented in FIG. 4, guide magnets are disposed on the rotor as well as on the stator. The yoke 39 on the rotor supports an axially magnetized annular magnet 41 which, together with a central cylindrical portion of the yoke 39, defines a recess 40. The yoke 43 on the stator has a centered permanent magnet 45 which is also axially magnetized, with an annularly-shaped recess 44 being defined between an annular axially-projecting wall of the yoke 43 and the centered permanent magnet 45. Hereagain, magnetic flux lines 42 indicate the magnetic flux direction. It is essential in this case that the arrangement of the magnets is selected such that the magnetic guide fields of the respective magnets reinforce each other. As in the embodiment of FIG. 2, annular beads 39' and 43' are applied to the two yokes 29 and 43 for centering the fastened disposition of the magnets 41 and 45 on the respective yokes.
The arrangement illustrated in FIG. 5 differs from the embodiments represented in FIGS. 1-4 in that the yoke 46 on the rotor has two concentric outer and inner annular recesses 47 and 48 and the yoke 50 on the stator is similarly provided with two outer and inner annular recesses 51 and 52. An electromagnetic coil 53 is inserted into the inner recess 52 of the yoke 50 on the stator and is supplied with DC current for excitation of the yokes 46, 50 to generate the appropriate magnetic field in an analogous manner to that of the permanent magnets of FIGS. 1-4. Because of the arrangement of several ring-shaped recesses on both the rotor and the stator, primary and secondary magnetic fields are generated as are represented by primary magnetic flux lines 49 and secondary magnetic flux lines 49'. As will be understood, the same effect can be achieved with a permanent magnet in place of the electromagnetic coil 53.
A further embodiment is represented in FIG. 6 in which, similarly to that of FIG. 5, both a yoke 54 on the rotor and a yoke 55 on the stator have outer and inner recesses 60, 61 and 58, 59, respectively, with each of the recesses 58, 59 in the stator yoke 55 being fitted with annularly-shaped radially polarized permanent magnets 56, 57 in order to increase the number of focused beams of axially extending magnetic fluxes in order to amplify the centering effect of the magnets. As in the other embodiments, the annular magnets 56 and 57 are inserted into the recesses 58 and 59 on the stator at a spacing from its bearing face. Separate magnetic guide fields having magnetic flux lines 62 and 63 are formed by means of this arrangement. As can be seen from the flux directions represented, the magnetic fields generated by the annular magnets 56 and 57 amplify each other.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | A drive for a shaftless spinning rotor wherein the spinning rotor is embodied as the rotor of an axial field motor utilizes axially opposed yoke-forming, magnetically conductive elements disposed respectively on the opposite sides of an air gap formed between the spinning rotor and the stator in combination with at least one magnet (preferably either permanent magnets or electromagnets) on one or both the rotor and stator arranged concentrically to one another and to the rotor axis. The present magnet/yoke arrangement does not require exact mutual alignment of oppositely located magnets nor their homogeneous polarization. The present arrangement is self-adjusting because of the generation of a point-symmetrical field which in operation forms a sort of magnetic potential depression. Magnetic drive and guide fields are advantageously decoupled in order to reduce their mutual interference. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a device transfer method of transferring light emitting devices such as light emitting diodes, which have been formed on a substrate, for example, a sapphire substrate, to a device transfer body such as a display panel, and to a panel on which the transferred devices are arrayed.
[0002] A known method of producing an LED (Light Emitting Diode) display using LEDs includes the steps of cutting an LED wafer, which is obtained by stacking semiconductor layers on a device formation substrate, into chips by a diamond blade or the like, and transferring the LED chips to a display panel or the like with a pitch larger than an array pitch of the LED chips on the device formation substrate.
[0003] The above-described cutting method, however, has problems. For example, blue light emitting diodes are produced by stacking gallium nitride based semiconductor layers on a sapphire substrate as a device formation substrate. In this case, sapphire used as the material of the substrate is as very hard, about 9 in Mohs' hardness. As a result, if the sapphire substrate is full cut into chips by a dicer such as a diamond blade, problems such as cracking and/or chipping tend to occur in the cut planes of the sapphire substrate which prevent the sapphire substrate from being smoothly cut into chips of desired shapes and sizes, the dicer itself may also be broken, and that since sapphire has no cleavage characteristic, it is difficult to cut the sapphire substrate into chips by forming scribing lines on the sapphire substrate and forcibly cutting the sapphire substrate along the scribing lines by an external force.
[0004] To solve the above problems, a method of cutting a sapphire substrate has been disclosed, for example, in Japanese Patent Laid-open No. Hei 5-315646. According to this method, as shown in FIG. 12, a gallium nitride semiconductor layer 61 formed on a sapphire substrate 60 is cut by a dicer to form grooves 62 deeper than a thickness of the gallium nitride semiconductor layer 61 . The sapphire substrate 60 is thinned by polishing a back surface of the sapphire substrate 60 . Scribing lines 63 are formed on the sapphire substrate 60 via the grooves 62 by a scriber. The sapphire substrate 60 is then forcibly cut into chips by an external force. This document describes how the sapphire substrate can be smoothly cut into chips without occurrence of cracking and/or chipping in the cut planes of the sapphire substrate 50 . However, such a cutting method, requires several steps including the labor intensive step of polishing the sapphire substrate 60 . In other words, the above method of cutting a sapphire substrate 60 is expensive and time consuming.
[0005] If a larger number of LED devices are obtained from one device formation substrate, the cost of one LED device can be reduced and the cost of a display unit using such LED devices can be also reduced. In the method disclosed in the above document, Japanese Patent Laid-open No. Hei 5-315646, LED devices each having a size of 350 m per side are obtained from the sapphire substrate having a diameter of two inches. If LED devices each having a size of several tens m per side are obtained from the sapphire substrate having a diameter of two inches and a display unit is produced by transferring the LED devices on a display panel, it is possible to reduce the cost of a display unit.
[0006] However, if the size of each LED device becomes as small as several tens of m per side, it becomes difficult to handle the LED device in the transfer step. Further, since an electrode of each device to be connected to a wiring layer of a base body of a display panel becomes small, the connection work becomes difficult and also a connection failure may often occur.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide a device transfer method capable of easily, smoothly separating devices from each other, and facilitating handling of devices in a transfer step and ensuring good electrical connection between the devices and external wiring, although the devices are fine devices, and to provide a panel on which the transferred devices are arrayed.
[0008] To achieve the above object, according to a first aspect of the present invention, a device transfer method is provided, the method includes covering a plurality of devices, formed on a substrate, with a layer of resin; the resin layer is then cut, to obtain resin buried devices each of which contains at least one of the devices. The resin buried devices are then peeled from the substrate and transferred to a device transfer body.
[0009] With this configuration, the resin buried device being handled has a size larger than the device itself. The larger size of the resin buried device facilitates the handling of the devices in the transfer step. Since respective resin buried devices are obtained by cutting only the resin layer without the need of cutting the substrate, it is possible to easily obtain the resin buried devices because the resin layer can be easily, smoothly cut. Further, the substrate, which is not cut, can be reused.
[0010] According to a second aspect of the present invention, a device transfer method is provided which includes a step of covering a plurality of devices, which have been formed on a substrate, with a resin layer. Electrodes are formed in the resin layer in a manner such that the electrodes are connected to the devices. The method further includes cutting the resin layer to obtain resin buried devices, each containing at least one of the devices. The resin buried devices are then peeled from the substrate and transferred to a device transfer body.
[0011] With this configuration, the resin buried device being handled has a size larger than that of the device itself. The larger size of the resin buried device facilitates the handling of the devices in the transfer step. Since the electrode is formed in the resin layer in such a manner as to be connected to the device, it is possible to easily form the electrode, and to prevent connection failures between the electrode and an external electrode by increasing the area of the electrode. Since respective resin buried devices are obtained by cutting only the resin layer without the need of cutting the substrate, it is possible to easily obtain the resin buried devices because the resin layer can be easily, smoothly cut. Further, the substrate, which is not cut, can be reused.
[0012] According to a third aspect of the present invention, a device transfer method is provided which includes the step of covering a plurality of devices, which have been formed on a device formation substrate, with a first resin layer. The method further includes collectively peeling the devices, together with the first resin layer, from the device formation substrate, and transferring them to a first supporting board. Next, the first resin layer is cut on the first supporting board, to make the devices separable from each other. The devices covered with the first resin layer are then peeled from the first supporting board, and transferred to a second supporting board. The devices thus transferred to the second supporting board are then with a second resin layer. Electrodes are formed in the first and second resin layers in such a manner that the electrodes are connected to the devices. The method then involves cutting the second resin layer to obtain resin buried devices each containing at least one of the devices. The resin buried devices are peeled from the second supporting board, and transferred to a device transfer body.
[0013] With this configuration, the resin buried device being handled has a size larger than that of the device itself. The larger size of the resin buried device facilitates the handling of the devices in the transfer step. Since the electrode is formed in the first and second resin layers in such a manner as to be connected to the device, it is possible to easily form the electrode and to prevent occurrence of connection failures between the electrode and an external electrode by increasing the area of the electrode. Since respective resin buried devices are obtained by cutting only the first and second resin layers without the need of cutting the substrate, it is possible to easily obtain the resin buried devices because the first and second resin layers can be easily, smoothly cut. Further, the substrate, which is not cut, can be reused.
[0014] According to a fourth aspect of the present invention, a panel including an array of resin buried devices is provided. Resin buried device contains at least one device. A plurality of the devices are formed on a substrate and are covered with a resin layer. The resin layer is cut to obtain the resin buried devices each containing at least one of the devices. Furthermore, the resin buried devices are peeled from the substrate and are transferred to the panel.
[0015] With this configuration, it is possible to provide an inexpensive panel.
[0016] In the above device transfer method, preferably, connection holes are formed in the resin layer in a manner such as to reach the devices by laser beams, and the electrodes are connected to the devices via the connection holes. With this configuration it is possible to prevent the resin layer covering the device from being thinned and hence to improve the strength of the resin buried device.
[0017] In the device transfer method, preferably, the electrodes are each formed with their planar dimension substantially corresponding to a planar dimension of each of the resin buried devices, and the resin layer is cut by laser beams with the electrodes taken as a mask, to obtain the resin buried devices. With this configuration, it is possible to eliminate the need of use of a laser system having a high accurate positioning function and hence to reduce the production cost of the devices.
[0018] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the figures.
BRIEF DESCRIPTION OF THE FIGURES
[0019] [0019]FIGS. 1A to 1 C are sectional views showing steps of a device transfer method according to a first embodiment of the present invention, wherein FIG. 1A shows a state in which a sapphire substrate, on which each device has been formed, is coated with a resin, FIG. 1B shows a state in which the resin is hardened, and FIG. 1C shows a state in which an interface between the device and the sapphire substrate is irradiated with laser beams having come from a back surface side of the sapphire substrate;
[0020] [0020]FIGS. 2A to 2 C are sectional views showing steps continued from the step shown in FIG. 1C, wherein FIG. 2A shows a state in which the device is peeled from the sapphire substrate and is transferred to a first supporting board, FIG. 2B shows a state in which gallium remaining on the device is etched, and FIG. 2C shows a state in which device separation grooves are formed by oxygen plasma;
[0021] [0021]FIGS. 3A to 3 C are sectional views showing steps continued from the step shown in FIG. 2C, wherein FIG. 3A shows a state in which the first supporting board is coated with a resin, FIG. 3B shows a state in which the resin is selectively irradiated with ultraviolet rays and a polyimide layer is selectively irradiated with laser beams, and FIG. 3C shows a state in which the devices are selectively transferred to a second supporting board;
[0022] [0022]FIGS. 4A to 4 C are sectional views showing steps continued from FIG. 3C, wherein FIG. 4A shows a state in which each device is covered with a second resin layer, FIG. 4B shows a state in which the first and second resin layers are etched, and FIG. 4C shows a state in which an electrode connected to the device is formed;
[0023] [0023]FIGS. 5A to 5 C are sectional views showing steps continued from FIG. 4C, wherein FIG. 5A shows a state in which a polyimide layer formed on the second supporting board is irradiated with laser beams, FIG. 5B shows a state in which the devices are transferred to the third supporting board, and FIG. 5C shows a state in which the resin layers are etched;
[0024] [0024]FIGS. 6A to 6 C are sectional views showing steps continued from FIG. 5C, wherein FIG. 6A shows a state in which an electrode connected to each device is formed, FIG. 6B shows a state in which the resin layers are cut by laser beams, and FIG. 6C shows a state in which resin buried devices are peeled from the third supporting board;
[0025] [0025]FIGS. 7A and 7B are sectional views showing steps continued from FIG. 6C, wherein FIG. 7A shows a state in which each resin buried body is bonded to a device transfer body, and FIG. 7B shows a state in which a resin buried device of another kind is bonded to the same device transfer body;
[0026] [0026]FIGS. 8A and 8B are sectional views showing steps continued from FIG. 7B, wherein FIG. 8A shows a state in which an interlayer insulating film is formed, and FIG. 8B shows a state in which wiring is formed;
[0027] [0027]FIGS. 9A to 9 D are sectional views showing steps continued from the step shown in FIG. 3C, according to a second embodiment of the present invention, wherein a connection hole is formed in the resin layers by laser beams;
[0028] [0028]FIGS. 10A and 10B are sectional views showing steps continued from the step shown in FIG. 5C, according to a third embodiment, wherein the resin layers are cut by laser means with the electrode taken as a mask;
[0029] [0029]FIGS. 11A and 11B are views showing a light emitting device used in the embodiments of the present invention, wherein FIG. 11A is a sectional view and FIG. 11B is a plan view; and
[0030] [0030]FIG. 12 is a sectional view showing a related art method of cutting a gallium nitride based semiconductor wafer.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0032] First, there will be described devices used for carrying out the present invention with reference to FIGS. 11A and 11B, which devices are exemplified by light emitting diodes representative of light emitting devices in the following embodiments. FIG. 11A is a sectional view of such a light emitting diode and FIG. 11B is a plan view of the light emitting diode. As shown in these figures, a light emitting diode 2 is made from a gallium nitride (GaN) based semiconductor and is formed by crystal growth on a device formation substrate, for example, a sapphire substrate 1 .
[0033] An under growth layer 51 made from a GaN based semiconductor is formed on the sapphire substrate 1 , and a hexagonal pyramid shaped GaN layer 52 doped with silicon is formed on the under growth layer 51 as follows: namely, an insulating film 53 is formed on the under growth layer 51 , and a GaN layer 52 for one device is selectively grown, by an MOCVD (Metal-organic Chemical Vapor Deposition) process, from one of openings formed in the insulating film 53 in such a manner as to be separated from a GaN layer 52 for another device. In the case of taking a C-plane of sapphire as a principal plane of the sapphire substrate 1 , the GaN layer 52 becomes a hexagonal pyramid shaped growth layer surrounded by an S-plane, that is, a ( 1 - 101 ) plane 52 a.
[0034] A portion of the inclined S-plane 52 a of the GaN layer 52 functions as a cladding of a double-hetero structure. An InGaN layer 54 is formed as an active layer on the GaN layer 52 in such a manner as to cover the S-plane 52 a . A GaN layer 55 doped with magnesium is formed on the InGaN layer 54 . The GaN layer 55 functions as a cladding.
[0035] A metal material such as Ni, Pt, Au, or Pb is vapor-deposited on the GaN layer 55 , to form a p-electrode 56 . An n-electrode will be formed on a back surface side of the under growth layer 51 during a transfer step to be described later.
[0036] The above described light emitting diode 2 is configured, for example, as a light emitting diode of blue (B). The structure of the light emitting diode 2 is not limited to that described above but may be a structure in which an active layer is formed into a flat plate or band shape, or be a pyramid structure with a C-plane formed on its upper end portion. The material of the light emitting diode 2 is not limited to a GaN based material, either, but may be any other nitride based material or any other compound semiconductor.
[0037] A device transfer method according to a first embodiment of the present invention will be described below with reference to FIGS. 1 to 8 . The light emitting diodes 2 shown in FIGS. 11A and 11B are used as devices to be transferred by the device transfer method according to the first embodiment.
[0038] Referring to FIG. 1A, a plurality of light emitting diodes 2 , each having the same structure as that shown in FIGS. 11A and 11B, are densely formed on a principal plane of a sapphire substrate 1 having a diameter of, for example, two inches in such a manner as to be arrayed in rows and columns, that is, into a matrix. Each light emitting diode 2 has a size about 20 m square. The light emitting diodes 2 are in a state being separable from each other by device separation grooves 4 formed by reactive ion etching or the like.
[0039] The sapphire substrate 1 is coated with an ultraviolet curing type resin 3 , and a polyimide layer 6 formed on a surface of a quartz glass board 5 as a first supporting board is brought into press-contact with the ultraviolet curing type resin 3 .
[0040] Referring to FIG. 1B, the ultraviolet curing type resin 3 is irradiated with ultraviolet rays having come from a back surface side of the quartz glass board 5 side, to be hardened, whereby a first resin layer 3 ′ is formed. The light emitting diodes 2 are thus collectively covered with the first resin layer 3 ′.
[0041] Referring to FIG. 1C, interfaces between the GaN based under growth layers 51 of the light emitting diodes 2 and the sapphire substrate 1 are irradiated with laser beams having come from a back surface side of the sapphire substrate 1 . At this time, GaN at each interface is decomposed into nitrogen and gallium and the gaseous nitrogen is released therefrom, so that the bond of each light emitting diode 2 to the sapphire substrate 1 is released. Consequently, as shown in FIG. 2A, the light emitting diodes 2 are collectively peeled from the sapphire substrate 1 . With respect to the first resin layer 3 ′ covering the light emitting diodes 2 , bonds of molecules constituting the resin layer 3 ′ are cut at the interfaces by the same laser abrasion effect. As a result, the resin layer 3 ′ is peeled, together with the light emitting diodes 2 , from the sapphire substrate 1 .
[0042] As shown in FIG. 2A, only gallium (Ga) 7 remains on the peeling surface on the light emitting diode 2 side, which gallium is then removed by wet etching or the like as shown in FIG. 2B.
[0043] Referring to FIG. 2C, device separation grooves 8 , each extending from the device separation groove 4 to the quartz glass board 5 , are formed by etching the first resin layer 3 ′ by using oxygen plasma. The formation of the device separation grooves 8 makes the light emitting diodes 2 separable from each other. In this plasma etching, since an erosion effect of oxygen plasma to the under growth layer 51 is significantly smaller than that to the first resin layer 3 ′, the device separation grooves 8 are formed with the under growth layer 51 taken as a mask.
[0044] Referring to FIG. 3A, the light emitting diodes 2 covered with the first resin layer 3 ′ are coated with an ultraviolet curing type resin 9 , and a polyimide layer 11 formed on a surface of a quartz glass board 10 as a second supporting board is brought into press-contact with the ultraviolet curing type resin 9 .
[0045] Referring to FIG. 3B, the ultraviolet curing type resin 9 is selectively irradiated with ultraviolet rays having come from a back surface of the quartz glass board 10 . It is to be noted that only one position of the ultraviolet curing type resin 9 , which corresponds to a position of the central light emitting diode 2 , is irradiated with ultraviolet rays in FIG. 3B; however, in actual, positions of the ultraviolet curing type resin 9 , which correspond to positions of the light emitting diodes 2 spaced from each other at intervals of, for example, ten pieces, are selectively irradiated with ultraviolet rays. The portion, irradiated with ultraviolet rays, of the ultraviolet curing type resin 9 is hardened, whereby a resin layer 9 ′, which bonds the light emitting diode 2 covered with the first resin layer 3 ′ to the polyimide layer 11 formed on the quartz glass board 10 , is formed.
[0046] An interface between the polyimide layer 6 and the quartz glass board 5 is irradiated with laser beams having come from a back surface side of the quartz glass board 5 . At this time, the polyimide layer 6 is peeled from the quartz glass board 5 or internally peeled by the laser abrasion effect. In this way, as shown in FIG. 3C, although the light emitting diodes 2 , each having the size of about 20 m square, are densely arrayed on the quartz glass board 5 as the first supporting board, those spaced from each other at the intervals of ten pieces are transferred to the quartz glass board 10 as the second supporting board while being arrayed with an enlarged pitch of about 200 m. It is to be noted that only one light emitting diode 2 is shown in FIG. 3C; however, in actual, the light emitting diodes 2 covered with the first resin layer 3 ′ on the quartz glass board 5 , which are spaced from each other at the intervals of 10 pieces, are simultaneously transferred to the quartz glass substrate 10 . In addition, the light emitting diodes 2 , which are adjacent to those having been transferred, remain on the quartz glass substrate 5 ; however, they will be all transferred to other quartz glass boards 10 .
[0047] Referring to FIG. 4A, all of the light emitting diodes 2 (covered with the first resin layer 3 ′) having been transferred to the quartz glass substrate 10 are collectively covered with a second resin layer 12 . The second resin layer 12 is formed, for example, by hardening an ultraviolet curing type resin by ultraviolet rays.
[0048] As shown in FIG. 4B, the second resin layer 12 , the polyimide layer 6 , and the first resin layer 3 ′ are etched back by using oxygen plasma, to expose the p-electrode 56 of the light emitting diode 2 , and then the surfaces of the p-electrode 56 and the first and second resin layers 3 ′ and 12 , on which an extraction electrode to be described later is to be formed, are cleaned.
[0049] Referring to FIG. 4C, an extraction electrode 13 is formed on the first and second resin layers 3 ′ and 12 in such a manner as to be connected to the p-electrode 56 of the light emitting diode 2 . The extraction electrode 13 is formed by depositing a transparent material made from a metal or ITO (Indium Tin Oxide) by vapor-deposition or sputtering and patterning the deposited material into a specific planar shape having a specific size by photolithography and wet etching.
[0050] Referring to FIG. 5A, a quartz glass board 14 as a third supporting board is fixed to a surface side, on which the extraction electrode 13 has been formed, of the second resin layer 12 via a polyimide layer 15 formed on a surface of the quartz glass board 14 . An interface between the polyimide layer 11 and the quartz glass board 10 is irradiated with laser beams having come from a back surface side of the quartz glass board 10 , so that the polyimide layer 11 is peeled from the quartz glass board 10 or internally peeled by the laser abrasion effect (see FIG. 5B). In this way, the light emitting diodes 2 on the quartz glass board 10 as the second supporting board are collectively transferred, together with the resin layers 3 ′ and 12 covering the light emitting diodes 2 , to the quartz glass board 14 as the third supporting board. As will be described below, this transfer step is carried out for forming an extraction electrode on the n-electrode side opposite to the extraction electrode 13 on the p-electrode side.
[0051] Referring to FIG. 5C, the polyimide layer 11 and the second resin layer 12 are etched back by oxygen plasma, to expose the under growth layer 51 of the light emitting diode 2 , and then surfaces of the under growth layer 51 and the second resin layer 12 , on which an extraction electrode on the n-electrode side is to be formed as described below, are cleaned.
[0052] Referring to FIG. 6A, an extraction electrode 16 is formed on the second resin layer 12 in such a manner as to be connected to the under growth layer 51 of the light emitting diode 2 . The extraction electrode 16 is formed by depositing a transparent material such a metal or ITO by vapor-deposition or sputtering and patterning the deposited material into a specific planar shape having a specific size by lithography and wet etching.
[0053] Referring to FIG. 6B, device separation grooves 17 are formed by cutting the second resin layer 12 and the polyimide layer 15 by laser beams L emitted from an excimer laser system or a third harmonic YAG laser system, to obtain each resin buried device 20 in which the light emitting diode 2 is covered with the resin layer. In accordance with this embodiment, each resin buried device 20 containing one light emitting diode 2 has a planar size of about 160 m square and has a thickness of several tens m.
[0054] Referring to FIG. 6C, an interface between the quartz glass board 14 and the polyimide layer 15 is irradiated with laser beams having come from a back surface of the quartz glass board 14 . It is to be noted that only one resin buried device 20 is irradiated with laser beams in FIG. 6C; however, in actual, the resin buried devices 20 spaced from each other at intervals of, for example, three pieces are selectively irradiated with laser beams, and portions, irradiated with laser beams, of the polyimide layer 15 are peeled from the interface with the quartz glass board 14 or internally peeled by the laser abrasion effect.
[0055] The resin buried device 20 is then attracted by a vacuum chuck 21 having a suction hole 21 a , and is transferred, as shown in FIG. 7A, to a panel 50 of a display unit as a device transfer body. The suction holes 21 a are arrayed in rows and columns with pitches corresponding to those of pixels of a display unit, that is, arrayed into a matrix corresponding to that of the pixels, to collectively attract the peeled resin buried devices 20 spaced from each other at the intervals of three pieces from the quartz glass board 14 . Concretely, the suction holes 21 a are arrayed into a matrix with a pitch of 600 m, which can simultaneously attract about 300 pieces of the resin buried devices 20 .
[0056] That is to say, of the resin buried devices 20 arrayed with a pitch of about 200 m on the quartz glass board 14 as the third supporting board, those spaced from each other at the intervals of three pieces are transferred to the device transfer body or panel 50 in such a manner as to be arrayed with an enlarged pitch of about 600 m. It is to be noted that the other resin buried devices 20 remaining on the quartz glass board 14 will be all transferred to other positions of the same device transfer body 50 or other device transferred bodies.
[0057] The device transfer body 50 includes an insulating substrate 29 , wiring layers 30 a to 30 c , an insulating layer 28 formed on the insulating substrate 29 in such a manner as to cover the wiring layers 30 a to 30 c , a wiring layer 27 formed on the insulating layer 28 , and a thermoplastic resin layer 26 formed on the wiring layer 27 . The resin buried device 20 is brought into press-contact with the thermoplastic resin layer 26 . A portion, being in press-contact with the resin buried device 20 , of the thermoplastic resin layer 26 is softened by irradiating it with infrared rays having come from a back surface side of the insulating substrate 29 , whereby the resin buried device 20 is fixed to the thermoplastic resin layer 26 .
[0058] After that, as shown in FIG. 7B, resin buried devices 31 containing, for example, light emitting diodes 22 of red (R) are transferred, in accordance with the same manner as that described above, to the device transfer body 50 in such a manner as to be arrayed in a matrix with a pitch of about 600 m. Subsequently, while not shown, resin buried devices containing light emitting diodes of green (G), control transistors, and the like are similarly transferred to the device transfer body 50 .
[0059] Referring to FIG. 8A, an insulating resin layer 33 is formed in such a manner as to cover the resin buried devices, the control transistors, and the like. Then, as shown in FIG. 8B, connection holes 34 , 35 , 36 , 37 , 38 , and 39 are formed in the insulating resin layer 33 . By use of these connection holes, an extraction electrode 32 a of the resin buried device 31 is connected to the wiring layer 27 by means of wiring 40 ; an extraction electrode 32 b , formed on the same surface side as that on which the extraction electrode 32 a is formed, of the resin buried device 31 is connected to the extraction electrode 13 of the resin buried device 20 by means of wiring 41 ; and the extraction electrode 16 of the resin buried device 20 is connected to the wiring layer 30 c by means of wiring 42 . A protective layer and the like are finally formed, to obtain a display panel in which the light emitting diodes of red (R), green (G), and blue (B) covered with the resin are arrayed in rows and columns with pitches corresponding to pixel pitches, that is, arrayed into a matrix corresponding that of pixels.
[0060] As described above, according to this embodiment, since the light emitting diodes 2 , each having the very small size about 20 m square, are densely formed on the sapphire substrate 1 as the device formation substrate, the number of the light emitting diodes 2 per one substrate can be made large. This makes it possible to reduce the product cost of one light emitting diode and hence to reduce the cost of a display unit using the light emitting diodes. Since the light emitting diode is transferred to the device transfer body 50 in the form of the resin buried device having the size about 160 m square, it is possible to easily handle the light emitting diodes in the transfer step. The resin layer covering the light emitting diode 2 serves to protect the light emitting diode. The enlargement of the size of the light emitting diode 2 by covering the diode 2 with the resin layer is advantageous in that the extraction electrodes 13 and 16 can be easily formed, and that the planar sizes of the extraction electrodes 13 and 16 can be enlarged enough to prevent occurrence of any wiring failure at the time of wiring the extraction electrodes 13 and 16 to the device transfer body 50 side, to improve the reliability of wiring thereof to the device transfer body 50 side.
[0061] In the above embodiment, in place of cutting the hard sapphire substrate 1 , the first and second resin layers 3 and 12 are cut by laser beams, to separate an array of the light emitting diodes 2 into individual devices to be transferred (resin buried devices). With this configuration, since the resin layer can be easily and accurately cut by the laser abrasion effect, it is possible to separate an array of the light emitting diodes 2 into individual devices having accurate shapes and sizes without a lot of labor and time paid for cutting.
[0062] A second embodiment of the present invention will be described with reference to FIGS. 9A to 9 D. It is to be noted that parts corresponding to those described in the first embodiment are designated by the same reference numerals and the overlapped description thereof is omitted.
[0063] [0063]FIG. 9A shows a step equivalent to the step shown in FIG. 4A according to the first embodiment. According to this embodiment, however, the process goes on from the step shown in FIG. 9A to a step shown in FIG. 9B, in which the second resin layer 12 , the polyimide layer 6 and the first resin layer 3 ′ are etched back by oxygen plasma to an extent that the p-electrode 56 of the light emitting diode 2 is not exposed, and then the surfaces of the first and second resin layers 3 ′ and 12 , on which an extraction electrode to be described later is to be formed, are cleaned.
[0064] Referring to FIG. 9C, a connection hole 23 is formed in the first resin layer 3 ′ by laser beams emitted by an excimer laser system or a third harmonic YAG laser system, to expose the p-electrode 56 of the light emitting diode 2 . Referring to FIG. 9 D, an extraction electrode 13 ′ is formed on the first and second resin layers 3 ′ and 12 in such a manner as to be connected to the p-electrode 56 via the connection hole 23 . The material of the extraction electrode 13 ′ and the formation method thereof are the same as those described in the first embodiment. Subsequent steps are also the same as those described in the first embodiment.
[0065] According to the first embodiment, as shown in FIG. 4B, the first and second resin layers 3 ′ and 12 are etched back until the p-electrode 56 is exposed, and correspondingly, the thicknesses of the first and second resin layers 3 ′ and 12 for covering and protecting the light emitting diode 2 become thin, so that the rigidity of the resin buried device 20 obtained in the subsequent step becomes weak. This may often cause a difficulty in handling the resin buried device 20 at the time of picking up the resin buried device 20 by the vacuum chuck 21 for transferring it to the device transfer body 50 .
[0066] To cope with such an inconvenience, according to the second embodiment, as described above, the connection hole 23 for exposing the p-electrode 56 therethrough is locally formed in the first and second resin layers 3 ′ and 12 , with a result that as compared with the first embodiment, the thickness of the first and second resin layers 3 ′ and 12 become thicker and thereby the strengths thereof become larger. Another advantage of formation of the connection hole 23 is as follows. Since an etching rate of the ultraviolet curing resin forming each of the first and second resin layers 3 ′ and 12 by oxygen plasma is small, it takes a lot of time to etch back the first and second resin layers 3 ′ and 12 . Meanwhile, the use of laser beams can form the connection hole in a resin layer for a short time irrespective of a material forming the resin layer. Accordingly, as compared with the manner in the first embodiment that the first and second resin layers 3 ′ and 12 are etched back by oxygen plasma until the p-electrode 56 is exposed, the manner in the second embodiment that the first and second resin layers 3 ′ and 12 are etched back by oxygen plasma to an extent that the p-electrode 56 is not exposed and then the connection hole 23 is formed in the first and second resin layers 3 ′ and 12 by laser beams so as to expose the p-electrode 56 therethrough is advantageous in that the time required to expose the p-electrode 56 can be shorten, and that the degree of freedom in selection of materials for forming the first and second resin layers 3 ′ and 12 can be increased, leading to the reduced material cost.
[0067] It to be noted that the step shown in FIG. 9B may be replaced with a step in which the connection hole 23 is directly formed in the second resin layer 12 , the polyimide layer 6 , and the first resin layer 3 ′ in the state shown in FIG. 9A. However, the cleaning of the surfaces, on which the extraction electrode 13 ′ is to be formed, by oxygen plasma as in the step shown in FIG. 9B is advantageous in increasing the adhesive strength of the extraction electrode 13 ′ to the resin layers.
[0068] A third embodiment of the present invention will be described below with reference to FIGS. 10A and 10B. It is to be noted that parts corresponding to those described in the first embodiment are designated by the same reference numerals and the overlapped description thereof is omitted.
[0069] According to the third embodiment, the process goes on from the step shown in FIG. 5C in the first embodiment to a step shown in FIG. 10A, in which an extraction electrode 16 ′ to be connected to the under growth layer 51 of the light emitting diode 2 is formed on the second resin layer 12 , wherein a planar size of the extraction electrode 16 ′ is set to be equal to that of a resin buried device 20 ′ obtained in the next step, that is, set to a square shape having a size 160 m square. Like the first embodiment, the extraction electrode 16 ′ is formed by depositing a transparent material such as a metal or ITO by sputtering and patterning the deposited material into a planar shape having the above-described specific size by photolithography and wet etching.
[0070] In the next step shown in FIG. 10B, device separation grooves 17 are formed by cutting the second resin layer 12 and the polyimide layer 15 by laser beams L emitted from an excimer laser system or a third harmonic YAG laser system with the extraction electrode 16 ′ taken as a mask, to obtain each resin buried device 20 ′ in which the light emitting diode 2 is covered with the resin layer. Subsequent steps are the same as those described in the first embodiment.
[0071] In the step shown in FIG. 6B according to the first embodiment, the device separation grooves 17 are formed by identifying alignment marks formed, for example, at diagonal positions on the laser system side and performing accurate NC control of the laser system on the basis of the identified alignment marks. In this case, the laser system side must be operated at a high positioning accuracy in the order of 1 m. On the contrary, according to the third embodiment, since the extraction electrode 16 ′ formed so as to have the same planar shape and planar size as those of the resin buried device 20 ′ to be separated is used as the mask, the laser system side does not require a high positioning accuracy and a cross-sectional diameter of a laser beam may be relatively large. For example, the laser system side may be operated at a positioning accuracy in the order of 10 m. According to this embodiment, therefore, it is possible to eliminate the need of use of an expensive, accurate laser system and hence to reduce the production cost. Further, the third embodiment can be carried out without addition of any step to the first embodiment.
[0072] While the embodiments of the present invention have been described, the present invention is not limited thereto, and it is to be understood that many changes may be made without departing from the technical thought of the present invention.
[0073] The device used for carrying out the present invention is not limited to the light emitting diode described in the embodiments, but may be a laser diode, a thin film transistor device, an photoelectric conversion device, a piezoelectric device, a resistance device, a switching device, a micro-magnetic device, or a micro-optical device.
[0074] In the light emitting diode described in the embodiments of the present invention, the substrate, on which a crystal growth layer is to be grown, is not particularly limited insofar as an active layer having good crystallinity can be formed thereon. Examples of materials for forming the substrates may include sapphire (Al 2 O 3 ; containing an A-plane, R-plane, and C-plane), SiC (including 6H, 4 H, and 3 C), GaN, Si, ZnS, ZnO, AlN, LiMgO, GaAs, MgAl 2 O 4 , and InAlGaN. The above material having a hexagonal or cubic system is preferably used, and a substrate made from the above material having a hexagonal system is more preferably used. For example, in the case of using a sapphire substrate, the C-plane of sapphire, which has been often used for growing a gallium nitride (GaN) based compound semiconductor thereon, may be used as a principal plane of the substrate. The C-plane as the principal plane of the substrate may contain a plane orientation tilted in a range of 5 to 6°. The substrate may not be contained in a light emitting device as a final product. For example, the substrate may be used for holding a device portion in the course of production and be removed before accomplishment of the device.
[0075] In the light emitting diode described in the embodiments of the present invention, the crystal growth layer formed by selective growth on the substrate preferably has a crystal plane tilted to the principal plane of the substrate. The crystal growth layer may be a material layer containing a light emission region composed of a first conductive layer, an active layer, and a second conductive layer. In particular, the crystal growth layer, preferably and thereby not limited thereto, has a wurtzite crystal structure. Such a crystal layer can be made from, for example, a group III based compound semiconductor, a BeMgZnCdS based compound semiconductor, a BeMgZnCdO based compound semiconductor, a gallium nitride based compound semiconductor, an aluminum nitride (AIN) based compound semiconductor, indium nitride (InN) based compound semiconductor, an indium gallium nitride (InGaN) based compound semiconductor, or aluminum gallium nitride (AlGaN) based compound semiconductor. In particular, a nitride based semiconductor such as a gallium nitride based compound semiconductor is preferably used as the material for forming the above crystal layer. It is to be noted that InGaN or AlGaN, or GaN does not necessarily mean only a nitride based semiconductor of ternary mixed crystal or binary mixed, but may be a nitride based semiconductor containing other impurities in amounts not to affect the nitride based semiconductor. For example, InGaN may contain Al and another impurity in slight amounts not to affect InGaN.
[0076] In the light emitting diode described in the embodiments, the peeling layer to be interposed between the substrate and the device is made from polyimide; however, it may be made from another resin, particularly, a high molecular resin. Examples of the high molecular resins may include polyacetylene, polyamide, polyether sulphone, polycarbonate, polyethylene, polyethyleneterephthalate, polymethyl methacrylate, polystyrene, polyvinyl chloride, polyester, polyether, epoxy resin, polyolefin, and polyacrylate. These materials may be used singly or in combination of two or more kinds.
[0077] Although each of the first and second resin layers 3 ′ and 12 is made from an ultraviolet curing type resin in the embodiments, it may be made from a thermoplastic resin or a thermosetting resin. The use of an ultraviolet curing type resin, however, is advantageous in that since an ultraviolet curing type resin does not require any heat at the hardening stage, it is not thermally contracted or expanded. As a result, the device is not affected by a stress caused by hardening the resins forming the first and second resin layers 3 ′ and 12 , and can be produced at a high dimensional accuracy.
[0078] Each of the first, second, and third supporting boards 5 , 10 and 14 is not limited to the quartz glass board described in the embodiments, but may be a board of another type, for example, a plastic board.
[0079] The transfer of the resin buried devices 20 to the device transfer body 50 may be performed in accordance with a manner different from that described in the embodiment. Specifically, the resin buried devices 20 may be individually peeled from the third supporting board 14 once, and then transferred to the device transfer body 50 one by one.
[0080] It is to be noted that the third embodiment may be combined with the second embodiment.
[0081] While a preferred embodiment of the present invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
[0082] It should be understood that various changes and modifications to the presently preferred embodiments 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 intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. | A device transfer method includes the steps of: covering a plurality of devices, which have been formed on a substrate, with a resin layer; forming electrodes in the resin layer in such a manner that the electrodes are connected to the devices; cutting the resin layer, to obtain resin buried devices each containing at least one of the devices; and peeling the resin buried devices from the substrate and transferring them to a device transfer body. This device transfer method is advantageous in easily, smoothly separating devices from each other, and facilitating handling of the devices in a transfer step and ensuring good electric connection between the devices and external wiring, even if the devices are fine devices. | 7 |
CROSS-REFERENCE TO RELATED LITERATURE
BOSCH Technical Instruction: MOTRONIC Combined Ignition and Fuel-Injection System, pages 1-43, pub. 1983 by Automotive Equipment Div., Robert Bosch GmbH, Stuttgart.
FIELD OF THE INVENTION
The invention relates generally to a method of damping or reducing bucking or abnormal vibrations of spark-ignition engines and, more particularly, to a method of damping abnormal engine vibrations by adjustment of the ignition advance angle to reduce engine torque in the case of increasing engine speed and to increase engine torque in the case of decreasing engine speed.
BACKGROUND
A method of damping abnormal vibrations, also known as "bucking", which may occur in internal combustion einges of the spark-ignition kind, has been proposed in commonly assigned URBANEK German Paent DE 42 01 861 Cl, filed Jan. 24, 1992, to be published Feb. 4, 1993. In accordance with that disclosure, in the event of increasing engine speed, engine torque is reduced by retarding the ignition angle, and in the event of decreasing engine speed, engine torque is increased by advancing the ignition angle.
Engine speed fluctuations are detected by measuring any deviation in speed per unit of time, with a distinction being made simultaneously between bucking vibrations and acceleration intended by an operator. Where the change in speed is caused by bucking, the change in speed is quantified or weighted, and a corrective ignition angle of appropriate sign is added to the effective, normal ignition angle, i.e. ignition timing is either advanced or retarded.
In certain circumstances, damping of bucking or of abnormal vibrations upon detection of deviations in engine rotation may not be achieved sufficiently quickly since the anti-bucking control will not be effective until after the occurrence of initial deviations in speed. That may, however, adversely affect the performance of an internal combustion engine.
THE INVENTION
Briefly, in one advantageous embodiment, the method in accordance with the invention provides for measuring engine speed, reducing or increasing the torque of the engine at increases and decreases in engine speed, respectively. A first value representative of the load of the engine is measured, temporarily stored, and compared against a subsequently measured load value. The difference between the first and subsequent load values is determined. The ignition angle is then adjusted as a function of this difference and of engine speed, with the adjustment being lomited to avoid excessive changes in engine speed.
The method in accordance with the invention provides for an anti-bucking control which is effective substantially earlier, i.e. immediately upon detection of a change in engine load. Further advantages are derived from the degree or extent of ignition angle adjustment being determined by the change in load and by resetting of the ignition angle taking place in dependence of the rate of engine speed. As compared to prior anti-bucking controls, operating solely on the basis of engine speed dynamics, the method in accordance with the invention provides for significantly improved drivability.
The method provides, advantageously, for incrementally resetting the ignition angle to a predetermined effective ignition angle as a function of changes in engine speed, so that the change in engine rotations will occur gradually and in accordance with a predetermined function, see the referenced MOTRONIC publication (figure on page 10).
It is particularly advantageous when the readjustment of the ignition angle toward the predetermined ignition angle as determined by engine characteristics, and which are provided by a characteristic field or table based on these characteristics, is carried out in predetermined steps or increments, using an ignition counter, after each ignition event. This assures that the readjustment of the ignition angle is achieved without a surge in engine speed.
Advantageously, the method may also provide for resetting the ignition angle in dependence of changes in engine rotation as well as on the basis of the ignition counter.
DRAWINGS
FIG. 1 schematically depicts an internal combustion engine and a circuit for detecting engine rotations and load; and
FIG. 2 is a flowchart depicting the steps of the method in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic representation of an internal combustion engine including its ignition system. The engine speed n of engine 11 is detected by a tachometer 12 from an encoded wheel 10 or transducer, and is fed to a microprocessor 13. Another input variable fed to microprocessor 13 is a load p. Microprocessor 13 specifies an adjustment of the ignition angle by a correction angle ALPHA corr (α corr ) in order to avoid the occurrence of abnormal engine vibrations or bucking. In an adder stage 14, the corrective ignition angle α corr is added to a characteristics field ignition angle α z' . Ignition is triggered by an ignition stage 15. The normal or characteristic ignition angle α z is established by the microprocessor 13 as a function of engine speed n, temperature T, and further input values 17, in a manner well known in the art; see Bosch MOTRONIC brochures. Suitable microprocessors include INTEL Model No. 80C537.
FIG. 2 is a flowchart for cyclically executing the method in accordance with the invention. In a first step, i.e. step 20, an ignition event is detected. Following each ignition, a load p is detected in a processing step 21, and the difference Δp, between the load p and a previously detected and temporarily stored load value, is calculated.
Following this, a decision step 22 determines whether the detected load difference Δp os greater than or equal to a predetermined threshold value Δp thr . If this is the case, an active bit is set to 1 or "HIGH" in a processing step 23. This simply means that the method for damping abnormal vibrations or bucking is being activated.
In a following processing step 24, an ignition adjustment angle Δα 1 is calculated on the basis of the operating parameters of the combustion engine, such as, in particular, the load difference Δp and engine speed n. A comparison and decision step 25 thereafter determines whether an adjusted ignition angle Δα z Σ, after the addition of that portion constituting the ignition adjustment angle Δα 1 , is greater than or equal to a maximum permitted adjusted ignition angle Δα z Σmax.
If this is the case, the Y, or YES-output of decisionstep 25 leads to a processing step 26, where the adjusted ignition angle Δα z Σ is set to the maximum ignition adjustment angle Δα z Σmax. The N, or NO-output of the comparison and decision step 25 leads to a processing step 27 where the actual ignition adjustment angle portion Δα 1 is added to the total ignition angle. The output of processing step 26 and the output of processing step 27 lead to a decision step 28.
A determination is made by the decision step 28 as to whether the actual ignition adjustment angle portion Δα 1 is greater than or equal to the adjusted ignition angle α z Σ. If this is the case, the YES-output of the decision step 28 leads to a processing step 29 where the active bit for the ignition angle adjustment for damping abnormal vibrations is reset to zero. In this manner, the resetting of the adjusted ignition angle α z Σ and or α corr is made possible, or is initiated. A NO-output of the decision step 28 would lead to actuation of a processing step 30. In a processing step 30, the corrective ignition angle α corr is incremented in small steps so that adjustment of the ignition will proceed in small steps along a ramp. In this manner, excessive jumps in ignition angles are prevented and drivability is improved.
Parallel to the method described thus far, further operational steps are required. Thus, if the output of the decision step 22 is negative, i.e. if theload difference Δp is less than a predetermined threshold value, a decision step 31 determines whether the active bit has already been set for adjusting the ignition angle. If this is the case, the YES-output of decision step 31 leads to a decision step 32 where a determination is made as to whether the load difference Δp is greater than or equal to zero (Δp≧0).
If this is the case, the YES-output of decision step 32 leads to the input of a processing step 24 which determines the ignition adjustment angle Δα 1 on the basis of actual or instantaneous operating parameters. The NO-output of the decision step 32 leads to a processing step 33 which, at a load difference Δp<0, will issue an igntion adjustment angle portion Δα 1 of zero value; in other words, any positive load difference Δp will result in an increase of Δα z Σ, and any negative load difference Δp will add nothing to Δα z Σ. The output of processing step 33 leads to the input of the decision step 25. The NO-output of decision step 31 leads to a decision step 34. A determination is made by decision step 34 as to whether a first ignition counter IC1 is set at zero. If this is the case, a processing step 35 will cause the correction ignition angles α corr and Δα z Σ to be reset incrementally, that is to say, as long as the ignition counter IC1 is set at a value of IC1=0, the corrective ignition angle α corr remains unchanged.
The NO-output of decision step 34 leads to a processing step 36 where an ignition counter IC1 is incremented to IC1 inc in predetermined steps or gradients of engine rotation.
The outputs of processing steps 29 and 30 lead to a processing step 37. The processing step 37 sets the ignition counter IC1 to a predeterminable initial value IC1 start , the initial value being such that the instant at which it will be applied is definable, and that, on the one hand, it constitutes an emergency escape from the ignition adjustment angle and that, on the other hand, it prevents resetting of the adjustment α corr prior to the local maximum engine speed. The output of processing step 37, like the outputs of processing steps 35 and 36, leads to a processing step 38.
A second ignition counter IC2 . . . IC2 inc is incremented in processing step 38. Following this, a decision step 39 determines whether there has been a change from a given throttle setting or a transition from engine braking operation SAS to the part-load range TL. If not, the NO-output of the decision step 39 connects to a decision step 40 which determines whether the combustion engine is idling. If it is not, a succeeding decision step 41 determines whether the contents of the ignition counter IC2 equals zero. If the engine is idling (LL), the ignition angle correction α corr is not added to the ignition angle. If the determination of decision step 41 is positive, its YES-output connects to a processing step 42 in which the actual ignition angle α zact is defined by adding the ignition correction angle to the effective ignition angle α zact =α z +α corr ).
The YES-output of the decision step 39 leads to a processing step 43 where a second ignition counter IC2 is set to an initial value IC2 start . Where the system is operated under engine braking SAS, fuel injection is turned off or discontinued. In the transition from engine braking SAS to partial load TL, care must be taken not to commence with excessively retarded ignition angles as this may lead to slow combustion because of the poor state of the fuel mixture. These, in turn, cause ignitions in the intake pipe.
The second ignition counter IC2 thus serves to render the retarding adjustment α corr of the anti-bucking function effective only after the state of the fuel mixture reliably permits more retarded ignition angles as effective ignition angles. The second ignition counter IC2 thus provides for a delay in the correction of the ignition angle under certain operating conditions, such as during transition from engine braking to part load TL. The output of processing step 43, the YES-output of the decision step 40 and the NO-output of decision step 41 lead to a processing step 44 in which the effective ignition angle is commanded as the actual ignition angle α z . The outputs of the processing steps 42 and 44, in turn, lead to a processing step 45 in which the next cycle of ignition angle adjustment or correction is initiated. | The invention relates to a method of damping abnormal vibrations or bucking of spark ignition engines by adjustment of the ignition angle, including simultaneous detection and temporary storage of a value representative of the effective or instantaneous load and, by comparing the load value against successive load values, establishing changes in the load, whereby such change in load, in case a predetermined threshold is exceeded, affects an adjustment of the effective ignition angle, with resetting of the ignition angle to the effective or characteristic field angle taking place as a function of the gradient of engine rotations. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a method of monitoring a partial tightness on movable members, such as for example window panes or movable roof. These components of motor vehicles are provided in increased numbers in the electrical drive which are operatable remotely. Tightness occurs when, for example, wind deflectors which are arranged before the movable roofs are subjected to increased air resistance while traveling with increased traveling speed. In these situations an actuation of removable roof occurs.
Manual bridging functions are provided for electrical drives utilized for actuation of window panes or movable roofs, so that the driven displaceable members at the location of a tightness can be moved by hand over the tightness location. A manual engagement of the operator during driving of a vehicle distracts it and can lead to critical traveling situations, in which the driver may not pay undivided attention to the traffic.
In other embodiments of the window panes or movable roofs, reference runs are provided in the movable systems. The reference runs load not insignificantly the electrical drive, since they have a calibration function. Reference runs moreover are time consuming, and during the reference runs not all operations occur, which later during operation of the window panes or movable roofs can occur.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method of bridging of partial tightness of movable members, which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a method of bridging partial tightness of a movable members, in accordance with which an automatic monitoring function is provided, and within a tightness region a releasing force is varied in one or several steps.
With the inventive solution, an automatic bridging function is utilized, which corresponds to the rotary speed course. An automatically operating control operates so that only in the small limited region of the bridging location which is identified as such, the releasing force is increased by a certain amount. When a one-time increase of the releasing force is not sufficient for a certain amount to overcome the tightness location, then it is increased by automatic bridging function in a stepped manner in several starting routines to a maximum value. When with a releasing force below the maximum releasing force, the overcoming of the tightness location is performed, then the releasing force required for overcoming the obstacle is stored in an adaptive storage unit. The maximum value of the releasing force can be preset on the automatic bridging function, so that depending on the application, predetermined maximum releasing forces are provided or can be allowed. Also the step widths at which the reducing force is raised within the starting routine in a stepped manner can be preselected variably for the automatic bridging function.
The stepped increase of the releasing force can be embedded for example in a first run to an obstacle with subsequent reversing of the drive. If the obstacle is located outside of the region in which the tightless location is localized, the drive is reversed. If the tightness location is inside the back window, the releasing force is increased only in the region in which the tightness location is provided. After several starts and runs on the obstacle, a stepped increase of the releasing force in the region of the back window is provided, until the maximum fixed releasing force is achieved.
When the obstacle representing the tightness location is finally overcome without reversing of the electrical drive, the rotary speed adaptation can be adjusted to the changed obstacle. The releasing force which directly overcomes the obstacle or the rotary speed adaptation can be stored in a storage which is associated with the automatic bridging function.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, 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
FIG. 1 is a view showing a rotary speed course of an electric drive with a tightness location to be overcome; and
FIG. 2 is a view showing a bridging function as a status automating system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a rotary speed course of an electric drive with a tightness location to be overcome.
FIG. 1 shows both the adjusting rotary speed break on the electrical drive, and also the releasing force increase released by the passage of a tightness region 4 . 1 . The rotary speed course 1 over the path 2 is plotted above in FIG. 1 in the rotary speed/path diagram. In the tightness region 4 . 1 to be overcome a rotary speed break is provided. It extends not on a discrete location of a traveling path 2 , but instead over a traveling path region 4 . 1 . With the inventive proposed procedure, the force which is required for overcoming the tightness region 4 . 1 is increased in stepped fashion, until the driven member to be moved, for example a window pane or a movable roof, smoothly passes the tightness region 4 . 1 without reversing the electrical drive.
In the lower region of the diagram of FIG. 1, the releasing force 3 is plotted over the path 2 . In the upper diagram of FIG. 1 the tightness region 4 . 1 is transmitted to the lower diagram. Within the tightness region 4 . 1 which releases an automatic bridging function, a stepped increase of the releasing force is provided. After this, a new start of the tightness region 4 . 1 with increased releasing force takes place. The increased releasing force has its limit in the preset maximum permissible value of the releasing force which is predetermined on the automatic bridging function. The maximum value for the releasing force is identified in the lower diagram of FIG. 1 with reference numeral 9 . Depending on the predetermined releasing force increase steps, the starting routines 15 , 19 shown in FIG. 2 are performed so often, until n required releasing force increase steps are worked off. In an adaptive storage system the predetermined releasing force value 5 can be overwritten by such value for the releasing force, which allows to overcome directly the tightness region 4 . 1 for the movable member.
The rotary speed of an electric drive can be adapted to a partial tightness, such as for example the one which can occur with wind deflectors on removable roofs. The rotary speed values adapted to the actual conditions can be stored in the storage system.
From the consideration of the bridging function as a condition automated system of FIG. 2, it can be seen that, starting from the start and an aim, or an end point of the processing of the automatic bridging function routine, a first clamping inquiry 13 and performed. When this condition of the movable member is recognized, the position of the region 4 . 1 is stored, the time limiter is set and the electrical drive is reversed. This is performed by a clamping parameter storage 14 , from which the monitoring block 12 which contains in the condition automatic system 10 is branched. There a first clamping force increase 16 is performed, which is transmitted then by the control of the electrical drive in the first starting routine 15 to the movable member. It is monitored whether inside the first run starting routine 15 the course of the electrical drive is ended normally, or the new clamping situation occurs. If the motor running ends normally, the increase of the clamping force which is performed in the position 16 in the monitoring block is again retaken.
When to the contrary, within the first running routine 15 to be performed the running of the electrical drive ends not normally, a new clamping situation occurs. The new clamping situation is verified by an additional inquiry 19 in the monitoring block 12 . The second clamping inquiry 13 with a positive result activates a new clamping increase at the position 18 , so that now after the resulting processing of the first starting routine 15 , the second starting routine 19 can be performed with an increased value for the clamping force to be applied. After the increase of the releasing force and performing of the second starting routine 19 , a testing 21 is performed of the condition, whether the electrical drive ends its running normally or it comes again to the clamping situation. Thereafter, the new clamping force increase 18 is taken, before the starting or aiming point 11 is branched.
In addition to the starting routines 15 , 19 which can be performed with different releasing forces, the monitoring block 12 monitors whether for example a previously set motor stoppage time of for example 10 seconds is exceeded or not. If it is exceeded, the starting or aiming inquiry point 11 is branched, and the automatic bridging function is set back. A setting back of the automatic bridging function can be performed when during the inquiry 25 of the control of the electrical drive, a rotary speed reverse on the electrical drive occurs. During the occurrence of a rotary direction reverse, the movable member, whether a window pane or a movable roof, is moved back to its open position. Also, in the closed position of the corresponding movable member, the automatic bridging function 10 is set back.
The diagram of FIG. 2 shows a course of the automatic bridging function.
First a first start on an obstacle which produces a tightness is performed. The electrical drive for driving the member to be moved is reversed and the member moves out of the tightness region if the obstacle must lie outside of the tightness region 4 . 1 .
If the obstacle is located in the tightness region 4 . 1 , the electrical drive is reversed. By means of the automatic bridging function, an increase of the releasing force is performed for example as F>100 N. Thereafter a new start of the member to be moved is performed in the tightness region by running of the first starting routine 15 . If it comes again to a clamping situation, by running of the second starting routine 19 , a second run with a stepped increase of the releasing force is performed, to overcome the obstacle represented by the tightness region 4 . 1 . These starts are performed with a corresponding stepped increase of the releasing force until the stepped increase releasing force assumes the predetermined maximum value of the releasing force 9 (compare FIG. 1 ). If the obstacle can be finally overcome, the releasing force can be stored and associated with the corresponding path region 4 . 1 on which the tightness region 4 . 1 was found. In this way a force threshold adapted to the movement path to be overcome is adjusted for the releasing force, so that the electrical drive which drives the member to be moved is adapted to the tightness region 4 . 1 in the sense of the rotary speed and the releasing force. The path portion 2 to be covered is driven with a predetermined releasing force 5 , and during detection of the previously stored tightness region 4 . 1 the electrical drive is operated with a stepped increased releasing force.
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 constructions differing from the types described above.
While the invention has been illustrated and described as embodied in method of bridging partial tightness on movable members, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
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.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims: | A method of bridging partial tightnesses of moveable members received in guides and driven by electric drive motors provides an automatic monitoring function. Within a tightness region, a releasing force is varied in one or several steps. An automatic bridging function is utilized, which corresponds to the rotary speed course, and an automatically operating control operates so that the releasing force is increased only in a limited region of the identified bridging location. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage filing under 35 U.S.C. 371 of PCT/US2009/064173, filed Nov. 12, 2009, which claims priority to U.S. Provisional Application No. 61/113,741, filed Nov. 12, 2008, the disclosures of which are incorporated by reference in their entirety herein.
BACKGROUND
The present disclosure relates to a nonwoven cleaning article and methods of making. In particular, the present disclosure relates to an open and lofty nonwoven cleaning article that comprises natural fibers.
Nonwoven articles are used extensively in cleaning, abrading, finishing and polishing applications on a variety of surfaces. An example of an open, lofty, three dimensional nonwoven is described in U.S. Pat. No. 2,958,593 to Hoover et al. Such nonwoven webs comprise a plurality of synthetic fibers randomly arranged and secured together by an adhesive binder. Examples of scouring pads comprising non-woven fibrous materials are described in U.S. Pat. No. 2,327,199 (Loeffler), U.S. Pat. No. 2,375,585 (Rimer), and U.S. Pat. No. 3,175,331 (Klein). Nonwoven fibrous hand pads for domestic use and for more general abrasive applications are available, under the trademark “Scotch-Brite,” from 3M Company of St. Paul, Minn., USA, and nonwoven fibrous hand pads that provide mild scouring for skin cleansing are available, under the trademark “Buf-Puf,” also from 3M Company. Nonwoven fibrous scouring materials are also used outside the domestic environment, for example in floor pads such as those available, also under the trademark “Scotch-Brite”, from 3M Company.
A nonwoven fibrous scouring material is preferably a relatively open material (i.e. it has a comparatively high void volume, typically of at least 50%) so that it can retain debris removed from the surface that is being cleaned. Such a material can also be cleaned very easily by rinsing in water or another suitable liquid, so that it can be re-used.
Known processes for manufacturing nonwoven fibrous materials having a comparatively high void volume involve forming an open, three-dimensional nonwoven web of synthetic fibers, applying a liquid binder resin to the web, and then curing the binder resin to bond the fibers together. A preferred method of applying the binder resin is roll coating, which coats the fibers with the resin substantially continuously throughout the web. Abrasive particles can be adhered to the bonded web to enhance the abrasive characteristics of the web.
The use of a substantial amount of natural vegetable fibers in place of synthetic fibers in a conventional manufacturing process of the type described above has not been seen as an option for mass-producing nonwoven fibrous scouring materials having a comparatively high void volume because of the risk that the vegetable fibers will be crushed during the web forming process, when the liquid binder resin is applied, or both. A crushed web with a void volume of substantially less that 50% is too compact to function effectively as a scouring material. The risk of the fibers being crushed is considered to be particularly high if the binder resin is applied by roll coating. With that mind, EP-A-1 618 239 (3M Innovative Properties (Company) describes a method of making a scouring material comprising the steps of: forming a three-dimensional nonwoven web of natural fibers contacted with dry particulate material that includes fusible binder particles; exposing the web to conditions that cause the binder particles to form a flowable liquid binder; and then solidifying the liquid binder to form bonds between the fibers of the web and thereby provide a bonded web. Abrasive particles are then adhered to the pre-bonded web by at least a make-coat resin.
Although the method described in EP-A-1 618 239 is effective, it requires the use of an apparatus that is less widely available than that used to carry out the conventional type of manufacturing process referred to above. It would be advantageous to be able to continue to use the conventional type of process to produce nonwoven fibrous scouring materials comprising of natural vegetable fibers, and the present invention is based on the surprising discovery that this can be achieved through an appropriate selection of the fibers employed.
SUMMARY
Disclosed is a scouring material that comprises an open, lofty, three-dimensional nonwoven web of fibers, including natural fibers, and methods of making. The terms “open” and “lofty” indicate that the bonded web is of comparatively low density, having a network of many, relatively large, intercommunicated voids. These terms indicate that the bonded web has a density no greater than 60 kg/m 3 .
It has been found that an open and lofty scouring material can be made that is capable of providing an effective scouring action despite the fact that natural fibers from which it is composes are traditionally associated with nonwoven materials having a low void-volume and/or a low abrasive action.
In one embodiment, the scouring material comprises a three dimensional nonwoven web of entangled fibers comprising natural fibers and synthetic fibers. Natural vegetable fibers comprise 20 to 80% wt. of the fibers of the web. The synthetic fibers comprise at least first synthetic fibers having a first melting point and second synthetic fibers having a second melting point that is higher than the first melting point. The first synthetic fibers entirely melt and coalesce at mutual contact point of the natural fibers and second synthetic fibers to bond the fibers together and to create voids. The bonded web has a maximum density of 60 kg/m 3 .
In one embodiment, a method of making the scouring material comprises providing a plurality of fibers comprising natural fibers and synthetic fibers, wherein 20 to 80% wt. of the fibers are natural vegetable fibers, and wherein the synthetic fibers comprise at least first synthetic fibers having a first melting point and second synthetic fibers having a second melting point that is higher than the first melting point, mixing the fibers to form a mat, melting the entire first synthetic fibers to create voids in the mat, coalescing the melted first synthetic fibers to bond the natural fibers and second synthetic fibers together, wherein the bonded web has a maximum density of 60 kg/m 3 .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of a nonwoven article;
FIG. 2 is an exploded view a nonwoven article of FIG. 1 following formation, but prior to melting of the meltable fiber;
FIG. 3 is an exploded view of the nonwoven article of FIGS. 1 and 2 , following melting of the meltable fiber;
FIG. 4 is an exploded view of a nonwoven article, such as shown in FIG. 1 , a binder coating and abrasive particles;
FIG. 5 is a side view of one embodiment of a process of making a nonwoven article.
While the above-identified drawings and figures set forth embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of this invention. The figures may not be drawn to scale.
DETAILED DESCRIPTION
FIG. 1 is a perspective view of one embodiment of a nonwoven article 100 . FIG. 2 is an exploded view the nonwoven article 100 of FIG. 1 following formation of the nonwoven article. As shown in FIG. 2 , the nonwoven article 100 comprises natural fibers 110 and synthetic fibers, wherein the synthetic fibers comprise at least a first synthetic fiber 120 , and a second synthetic fiber 130 . During formation, the fibers are all randomly arranged to form a mat of fibers.
The nonwoven article 100 comprises from 20 to 80% wt. natural fibers 110 . In one embodiment, the nonwoven article 100 comprises from 40 to 70% wt. natural fibers 110 . Therefore, in one embodiment 20 to 80% of the nonwoven article 100 comprises synthetic fibers. In another embodiment, from 30 to 60% wt. of the nonwoven article 100 comprises synthetic fibers. Of the synthetic fibers included in the nonwoven article 100 , from 20 to 60% wt. are first synthetic fibers 120 (discussed in more detail below). In another embodiment, 30 to 40% wt. of the synthetic fibers are first synthetic fibers 120 .
The first synthetic fiber 120 has a first melting temperature. The second synthetic fiber 130 has a second melting temperature. The second melting temperature is higher that the first melting temperature. During formation of the nonwoven article 100 , the fibers are exposed to heat to melt the first synthetic fiber 120 entirely.
During heating, the first synthetic fiber 120 will melt, while the second synthetic fiber 130 , having a higher melting point, will at least partially or will completely remain intact. During melting, the first synthetic fiber 120 tends to collect at junction points where fibers contact one another. Then, upon cooling, the material of the first synthetic fiber 120 will coalesce and resolidify at the junction points of the natural fiber 110 and second synthetic fiber 130 to secure the web together.
FIG. 3 shows the nonwoven article 100 of FIGS. 1 and 2 following melting and resolidifying of the first synthetic fiber 120 . Following melting and resolidifying, the space occupied by the first synthetic fiber (see FIG. 2 ), is now open (see FIG. 3 ). Therefore, there are now more openings in the nonwoven article 100 . A large amount of sizable openings in a nonwoven article make the nonwoven suitable for scouring and cleaning because the dirt and debris scraped away by the fibers then becomes trapped in the openings until the nonwoven article is rinsed.
Natural fibers tend to crush or break under stressed imposed during textile or web formation processing. However, synthetic fibers are much more resilient and tend to have a “memory” such that under the pressures imposed during processing, the synthetic fiber will tend to return to its original shape. This tendency to return to its original shape makes the presence of the second synthetic fiber, that does not entirely melt, useful in retaining a lofty, springy web.
Further, it is believed that the material of the first synthetic fiber that melts and coalesces at junction points of the second synthetic 130 and natural fiber 110 , gives strength to the second synthetic 130 and natural fiber 110 and aids in retaining the original lofty shape of the web even under subsequent processing.
The first synthetic fiber 120 and second synthetic fiber 130 may be single component or multicomponent synthetic fibers. The component(s) of the first synthetic fiber 120 must be capable of melting, either partially or entirely, while a portion of the second synthetic fiber 130 remains at least partially intact. In one embodiment, the first synthetic fiber 120 entirely melts, while a portion of the second synthetic fiber 130 remains at least partially intact.
If the first synthetic fiber 120 is a single component fiber, then the melting point of the single component must be lower than the melting point of the highest melting point component of the second synthetic fiber 130 . Therefore, the second synthetic fiber 130 may be a multicomponent fiber wherein one portion may or may not melt, but another portion has a melting point higher than the component of the first synthetic fiber such that it remains intact.
If the first synthetic fiber 120 is a multicomponent fiber, then the melting point of each of the components of the first synthetic fiber 120 is lower than the melting point of the highest melting point component of the second synthetic fiber 130 . Therefore, the second synthetic fiber 130 may be a multicomponent fiber wherein one portion may or may not melt, but another portion has a melting point higher than each of the components of the first synthetic fiber such that it remains intact.
Examples of materials of the first synthetic fiber and/or synthetic synthetic fiber include polyester and copolyester (e.g., polyethylene terephthalate), nylon (e.g., hexamethylene adipamide, polycaprolactam), polypropylene, acrylic (formed from a polymer of acrylonitrile), cellulose acetate, vinyls such as poly vinyl chloride and vinyl chloride-vinyl acetate polymer, polyvinyl butyral, polyvinylidene chloride-vinyl chloride copolymers, vinyl chloride-acrylonitrile copolymers, acrylics including polyacrylic and acrylic copolymers such as acrylonitrile styrene copolymers and polyamides such as hexamethylene adipamide, polycaprolactum and copolyamides, PLA, and other meltable, natural based polymers. Multicomponent fibers may be bicomponent fibers. One example of a bicomponent fiber is a sheath/core fiber. Other multicomponent polymeric fibers are within the scope of the present inventions. Other multi-component fibers may consist of a layered structure where one layer has a first melting point and another layer has a second melting point lower than the first melting point. In such an arrangement, the layer with the second melting point will melt and resolidify to secure the web together.
The first and/or second synthetic fibers used may be virgin fibers or waste fibers reclaimed from garment cuttings, carpet manufacturing, filter manufacturing, fiber manufacturing, or textile processing, or from post-consumer use. The first and/or second synthetic fibers may be linear or crimped. A crimped fiber may aid in providing more loft to the nonwoven article.
The first and/or second synthetic fibers can be in any number of lengths and sizes. For example, these fibers may range in length from 2 to 250 mm and from 1.5 to 200 denier. They may be linear, crimped, or surface modified that imparts texture. The first and/or second synthetic fibers may be approximately the same length and size or may be different lengths and sizes. However, it is understood that the fibers can be as small as the lowest length of fiber that are capable of being cut.
Suitable natural fibers include vegetable fibers such as banana, flax, cotton, jute, agave, sisal, coconut, soybean, and hemp. For a nonwoven article that will be used for scouring, preferably the natural fiber is stiff and relatively rigid. For example, fibers such as, but not limited to, jute, agave, sisal, coconut and hemp may be preferred natural fibers for making a nonwoven article for scouring. In one example, coconut fibers are particularly suitable as a fiber for making a nonwoven article for scouring. The coconut fibers are stiff and abrasive in part due to it high lignin content. The natural fibers used may be virgin fibers or waste fibers reclaimed from other manufacturing processing or post-consumer use.
The natural fibers may include a surface treatment. Generally, the surface treatment makes the natural fiber softer, more non-linear, and more absorbent. The natural fibers may be treated with surface treatments to aid in adhering the polymer resin of the melted first synthetic fiber 120 or to aid in adhering any subsequent binder coatings (discussed below), because following surface treatment the natural fiber is more absorbent. The surface treatment may include a chemical surface treatment such as exposure to mild acid treatment such as acetic acid, or exposure to basic conditions such as sodium hydroxide. The surface treatment may be application of superheated steam, plasma treatment, e-beam or gamma ray treatment. The natural fibers may be treated with a fire retardant to aid in safe processing or for providing a nonwoven web with fire resistance. The surface treatment may be conducted to the pure natural fibers or following formation of the web the surface of the web may be treated.
Following formation of a web comprising the natural fibers 110 , melted first synthetic fiber 120 , and second synthetic fiber 130 , the web may be coated with a binder 200 . The binder 200 may provide further mechanical strength to the nonwoven article and/or may provide additional stiffness for an abrasive or scouring article. FIG. 4 is an exploded view of a nonwoven article 100 , such as shown in FIG. 1 , with a binder coating 200 and benefiting particles 300 , such as abrasive particles. The benefiting particles 300 may be included with the binder 200 or separately applied following application of the binder 200 .
The binder 200 may be applied by known processing means such as roll coating, spray coating, immersion coating, or foam coating. The binder may be a resin. Suitable resins include phenolic resins, polyurethane resins, polyureas, styrene-butadiene rubbers, nitrile rubbers, epoxies, acrylics, and polyisoprene. The binder may be water soluble. Examples of water soluble binders include water-soluble binders include surfactants, polyethylene glycol, polyvinylpyrrolidones, polylactic acid (PLA), polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, carboxymethyl celluloses, hydroxypropyl cellulose starches, polyethylene oxides, polyacrylamides, polyacrylic acids, cellulose ether polymers, polyethyl oxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, and urethanes of polyethylene oxide and polypropylene oxide copolymers.
The benefiting particles 300 can be any discrete particle, which is a solid at room temperature, added to the nonwoven article 100 to provide a cleaning, scouring, polishing, wiping, absorbing, adsorbing, or sensory benefit to the nonwoven article. In one embodiment, the benefiting particles 300 have size of less than 1 cm. In other embodiments, the benefiting particles have a size of less than 1 mm.
In one embodiment, the benefiting particles 300 are abrasive particles. Abrasive particles are used to create an abrasive nonwoven article 100 that can scour and abrade difficult to remove material during cleaning. Abrasive particles may be mineral particle, synthetic particles, natural abrasive particles or a combination thereof. Examples of mineral particles include aluminum oxide including ceramic aluminum oxide, heat-treated aluminum oxide and white-fused aluminum oxide; as well as silicon carbide, alumina zirconia, diamond, ceria, cubic boron nitride, garnet, flint, silica, pumice, and calcium carbonate. Synthetic particles include polymeric materials such as polyester, polyvinylchloride, methacrylate, methylmethacrylate, polycarbonate, melamine, and polystyrene. Natural abrasive particles include nutshells such as walnut shell, or fruit seeds such as apricot, peach, and avocado seeds.
Various sizes, hardness, and amounts of abrasive particles may be used to create an abrasive nonwoven article 100 ranging from very strong abrasiveness to very light abrasiveness. In one embodiment, the abrasive particles have a size greater than 1 mm. In another embodiment, the abrasive particles have a size less than 1 cm.
In one embodiment, the benefiting particles 300 are metal. The metal particles may be used to create a polishing nonwoven article 100 . The metal particles may be in the form of short sections or may be in the form of grain-like particles. The metal particles can include any type of metal such as but not limited to steel, stainless steel, copper, brass, gold, silver (which has antibacterial/antimicrobial properties), platinum, bronze or blends of one or more of various metals.
In one embodiment, the benefiting particles 300 are solid materials typically found in detergent compositions, such as surfactants and bleaching agents. Examples of solid surfactants include sodium lauryl sulfate and dodecyl benzene sulfonate. Examples of solid bleaching agents include inorganic perhydrate salts such as sodium perborate mono- and tetrahydrates and sodium percarbonate, organic peroxyacids derivatives and calcium hypochlorite.
In one embodiment, the benefiting particles 300 are solid biocides or antimicrobial agents. Examples of solid biocide and antimicrobial agents include halogen containing compounds such as sodium dichloroisocyanurate dihydrate, benzylkoniumchloride, halogenated dialkylhydantoins, and triclosan.
In one embodiment, the benefiting particles 300 are microcapsules. Microcapsules are described in U.S. Pat. No. 3,516,941 to Matson and include examples of the microcapsules that can be used as the benefiting particles 300 . The microcapsules may be loaded with solid or liquid fragrance, perfume, oil, surfactant, detergent, biocide, or antimicrobial agents. One of the main qualities of a microcapsule is that by means of mechanical stress the particles can be broken in order to release the material contained within them. Therefore, during use of the nonwoven article 100 , the microcapsules will be broken due to the pressure exerted on the nonwoven article 100 , which will release the material contained within the microcapsule.
It is understood that any combination of one or more of the above described benefiting particles 300 may be used within the nonwoven article 100 .
As discussed, the benefiting particle 300 may be included with the binder 200 and applied to the nonwoven article 100 during application of the binder 200 . In such an application, typically a slurry is formed with the binder 200 and benefiting particles 300 . In another embodiment, the benefiting particles 300 may be separately sprayed, dropped or otherwise adhered to the already applied binder 200 .
FIG. 5 is a side view showing one embodiment of the process 400 of making the nonwoven article 100 discussed above. A fiber input stream 405 comprises natural fibers 110 , first synthetic fibers 120 , and second synthetic fibers 130 that proceed to the web forming apparatus 410 . The fiber input stream 405 may be a single input stream comprising all of the input fibers, or a variety of fiber input streams may be included to enter into the web forming apparatus 410 . Fibers can be fed unopened, processed, individualized or preopended form, fiber lap form, or sliver form.
Prior to entering the web forming apparatus 410 , the input fibers may be processed through a shredder to chop fibers or create fibers from recycled material, an opener to open, comb, or blend the fibers, or a surface treatment such as a chemical solution treatment, superheated steam, gamma ray, e-bean treatment.
The web forming apparatus 410 may include any know web forming apparatus. The web forming apparatus 410 randomly mixes the input stream 405 of fibers to form a loose web 415 that exits the web forming apparatus 410 . One example of a web forming apparatus is shown and described in US Patent Application Publication 2005/0098910 titled “Fiber distribution device for dry forming a fibrous product and method,” the disclosure of which is herein incorporated by reference. This web forming apparatus is a type of air-laying fiber processing equipment. In this type of equipment, within a forming box are spike rollers that blend and mix the fibers while gravity allows the fibers to fall down through an endless belt screen and form the loose web 415 of interengaged fibers.
Another type of air-laid equipment that may be used for form a loose web 415 is described in U.S. Pat. No. 2,958,593. A commercially available web forming apparatus is a “RandoWebber” web forming machine, available from Rando Machine Corporation, Macedon, N.Y. This type of air-laying equipment uses circulating, forced air to randomize and interengaged the input fibers 405 to make a loose web 415 . A conventional mechanical arrangement of opening, carding and crosslapping may also be used. In addition, an arrangement having a combination or mechanical and airlaid forming may be used.
Following formation of the loose web 415 , the web may proceed to processing to strengthen or further interconnect the fibers. For example the loose web 415 may proceed to needling.
The loose web 415 exits the web forming apparatus 410 and proceeds to a heating unit 420 , such as an oven, to heat and melt the first synthetic fiber 120 . The temperature and time within the heating unit 420 must be controlled such that the first synthetic fiber 120 entirely melts while the second synthetic fiber 120 at least partially remains intact. The melted first synthetic fiber 120 tends to migrate and collect at points of intersection of the natural fibers 110 and second synthetic fibers 130 . Then, upon cooling, the melted first synthetic fiber 120 coalesces and solidifies to create a secured, interconnected pre-bond web 425 .
At this point, the pre-bond web 425 is held together by the melted first synthetic fiber 120 . However, to add mechanical strength or abrasiveness to the pre-bond web 425 , a binder 200 may be coated on the pre-bond web 425 . After the heating unit 420 , the pre-bond web 425 may proceed to a coater 430 where a liquid or dry binder could be applied. The coater 430 could be a roller coater, spray coater, immersion coater, powder coater or other known coating mechanism. The coater 430 could apply the binder to a single surface of the pre-bond web 425 or to both surfaces. It is possible that another coater (not shown) may be necessary to coat any remaining uncoated surface. For example, a roll coater may apply a binder to both surfaces of the prebond web 425 . A spray coater may apply a binder to a single surface or two spray coating stations may be needed to coat bother surfaces of the pre-bond web 425 . Further, depending on the binder 200 separate curing equipment (not shown), such as an oven, may be needed after the coating stations 430 . A curing oven may be heated air circulation, infrared or ultraviolet. The heated air circulation oven may use steam, heated oil or electricity heated coils to generate heated air.
The benefiting particle 300 may be included with the binder 200 of the coating. For example, a slurry can be created with the binder 200 and benefiting particle and the slurry can be coated onto the web. Alternatively, the binder 200 may be applied followed by the benefiting particles being dropped, sprinkled, or sprayed on to the binder 200 . Depending on the binder 200 , following coating, the nonwoven article 100 may be cured. For example, an oven (not shown) may be included following the coating to cure the binder 200 .
Although specific embodiments of this invention have been shown and described herein, it is understood that these embodiments are merely illustrative of the many possible specific arrangements that can be devised in application of the principles of the invention. Numerous and varied other arrangements can be devised in accordance with these principles by those of ordinary skill in the art without departing from the spirit and scope of the invention. Thus, the scope of the present invention should not be limited to the structures described in this application, but only by the structures described by the language of the claims and the equivalents of those structures. | An open, lofty nonwoven scouring material comprising natural fibers and a method of making the scouring material is disclosed. The scouring material comprises a three dimensional nonwoven web of entangled fibers comprising natural vegetable fibers and synthetic fibers. Natural vegetable fibers comprise 20 to 80% wt. of the fibers of the web. The synthetic fibers comprise at least first synthetic fibers having a first melting point and second synthetic fibers having a second melting point that is higher than the first melting point. The first synthetic fibers entirely melt and coalesce at mutual contact point of the natural fibers and second synthetic fibers to bond the fibers together and to create voids. The bonded web has a maximum density of 60 kg/m 3 . | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
Valve arrangements described herein are more particularly described and claimed in U.S. patent application Ser. No. 086,392, filed Oct. 18, 1979 by the present inventor, and entitled "Pinch Tube Valve", now abandoned in favor of continuation application Ser. No. 279,954, filed July 1, 1981. The use of such valve arrangements are further detailed in U.S. applications "Jet Pattern Dyeing of Material, Particularly Carpet", Ser. No. 085,943, filed Oct. 18, 1979 by the present inventor, now abandoned in favor of Ser. No. 237,577, filed Feb. 24, 1981, now U.S. Pat. No. 4,341,098, and "Pattern Dyeing of Textile Materials Such as Carpet", Ser. No. 156,624, filed June 6, 1980, now abandoned, by the present inventor and Alfred Clifford. These aforementioned applications are assigned to the assignee of the present invention and are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
This invention relates to the treating of textile material. More specifically, this invention relates to the spray dyeing of textile material, such as carpets.
Numerous techniques have been used for treating or dyeing textile material such as carpet. A common technique is the well known and popular "TAK" process wherein dye is dropped or splattered onto the carpet web previously flooded with gum. This is disadvantageous in that it requires a great amount of gum, which in turn produces a large amount of effluent and necessitates a great amount of energy for steam setting the dye and for drying the carpet. Additionally, the use of a roller and doctor blade or similar types of dye applicating arrangements for applying dye and the period for drying are limiting factors in terms of the speed at which the carpet is conveyed through the system and consequently limit the rate of carpet production.
Foam dyeing represents an attempt to overcome several of the above-mentioned disadvantages common to most dyeing processes. Foam dyeing generally uses foam generators and foam stabilizers mixed with the dye. The dye and any ancillary additives are mechanically foamed in a conventional foamer. The prepared foam may then be metered onto the face of a carpet after which vacuuming and/or padding may be used to collapse the foam causing the dye to be uniformly distributed on the carpet pile.
Although such prior art techniques have been generally useful in avoiding several of the disadvantages associated with conventional dyeing techniques, they are often limited to the production of patterns having random dyeing affects. Generally, such techniques have been unsuitable for patterns requiring sharp resolution for intricate or detailed patterns. Further, the requirement for adding foam generators and foam stabilizers adds to the production costs of such techniques.
OBJECTS
It is a general object of the present invention to provide a new and improved method and apparatus for treating textile material.
Another object of the present invention is to provide for the dyeing of textile material with a relatively low amount of water and energy consumption.
A further object of the present invention is to provide for the dyeing of textile materials with only a minimal amount of effluent produced.
A still further object of the present invention is to provide for the dyeing of textile materials with sharp patterns having a high degree of resolution.
Yet another object of the present invention is to provide for the dyeing of textile materials wherein the dye is used in a highly efficient manner with very little of the dye wasted as effluent.
Another object of the present invention is to minimize the drying time of a dyeing process so as to allow increased rate of production.
Yet another object of the present invention is to provide for the dyeing of textile materials with patterns which may be changed very quickly.
SUMMARY OF THE INVENTION
These and other objects of the present invention which will become apparent as the description proceeds are realized by a method and apparatus for treating textile web wherein liquid and air are applied at preselected pressures into a mixing chamber. Depending on the relative pressures of the liquid and air, the mixture is caused to be atomized or foamed through an exit nozzle onto the face of the textile web. A plurality of nozzles, each with its own mixing chamber, are spaced above and across the face of the web so that the entire width of the web is treated as the web is conveyed past the nozzles. Each chamber is independently valved such that high pattern resolution may be achieved and a plurality of such treating stations may be successively arranged along the path of travel of the carpet web.
More specifically, the method of the present invention comprises mixing gas and a treating fluid in a plurality of mixing zones, each mixing zone receiving its gas and treating fluid respectively by means of a corresponding one of a selectively controlled gas valve and a corresponding one of a selectively controlled liquid valve spraying the mixed gas and treating fluid from a plurality of spray nozzles onto a moving textile web; and selectively controlling the valves to control application of the spray from the spray nozzles such that the minimum amount of material is applied onto the textile web to complete the desired treatment. The method further includes the step of supplying control signals to a plurality of control valves, each control valve supplying control fluid to a corresponding one of the gas valves and a corresponding one of the liquid valves, and wherein the control fluid opens and closes the gas and liquid valves to control the spray applied from the spray nozzles. The closing of the gas valves and dye valves is accomplished by having the valve pinch a flexible tube running through the valve. Controlling the relative pressures of the air and liquid applied controls the extent of atomization or foaming of the applied spray.
The apparatus for treating a continuously moving textile material according to the present invention comprises:
a plurality of gas valves; a plurality of treating fluid or dye valves, each dye valve corresponding on a one-to-one basis with one of the gas valves; a plurality of mixing zones, each mixing zone being connected to receive and mix gas and treating fluid or dye, as the case may be, respectively, from a corresponding one of the gas valves and a corresponding one of the treating fluid valves; a plurality of spray nozzles, each spray nozzle being connected for receiving the mixed gas and fluid from a corresponding one of the mixing zones; and control means for selectively opening and closing the gas valves and treating fluid valves to turn on and off spray from the spray nozzles such that a pattern may be dyed onto the textile material. The control means comprises a plurality of control valves, each control valve supplying control fluid to a corresponding one of the gas valves and to a corresponding one of the treating fluid valves, and wherein the control fluid opens and closes the gas valves and treating fluid valves to turn on and off spray from the spray nozzles. Each of the gas valves and treating fluid valves is a pinch valve which cuts off flow by pinching a flexible tube carrying gas or treating fluid to one of the mixing zones. Each of the gas valves and treating fluid valves further includes a spring-biased piston and a freely rotatable ball moveable by movement of the piston to cut off fluid flow by pinching the flexible tube. A plurality of support members, each support member supporting a plurality of gas valves and a plurality of corresponding treating fluid valves, is provided. Each support member includes control fluid passages for allowing control fluid flow from a control valve to the corresponding gas valve and corresponding treating fluid valve. The spray nozzles are stationary, and disposed in a spray line transverse to the direction of movement of the textile web, and all spray nozzles spray in the same direction. The mixing zones are chambers with the gas entering the chamber in the same direction as mixed gas and treating fluid exists from the chamber to the spray nozzles and with the treating fluid entering the chamber perpendicular to the gas. In a preferred embodiment, the treating fluid is a dye.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will be best understood when considered in conjunction with the accompanying drawings wherein like characters represent like parts throughout and:
FIG. 1 shows a side view of a first embodiment of the present invention with several parts shown in cross section.
FIG. 2 shows a cross section view along lines 2--2 of FIG. 1.
FIG. 3 shows an alternate embodiment of the present invention with several parts shown in cross section.
FIG. 4 shows a view along lines 4--4 of FIG. 3, but with a slight modification to parts of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIGS. 1 and 2, a first embodiment of the present invention will be discussed. FIG. 1 shows a side view of the present invention with several parts shown in cross section, whereas FIG. 2 shows a cross section view taken along lines 2--2 of FIG. 1 to illustrate operation of various valves used with the present invention.
A carpet 10 moves in the direction shown below a dyeing station 12 according to the present invention. It will be readily appreciated that a dyeing station similar to 12 may be located either upstream or downstream from 12 to dye the carpet with a different color, thereby attaining multi-color effects. Since such other dye stations will be identical in construction to dye station 12 except that it will be supplied with a different color dye, it obviously need not be discussed in detail.
More generally, dye station 12 could be a treating station in which case spray liquids other than dye could be used. For example, gums or other substances used for treating textiles may be employed in place of, or in addition to, dye. Since the present invention is especially well-suited to dyeing the discussion which follows will emphasize the use of dye as the spray liquid.
It will also be appreciated, that dyeing station 12 extends transversely of the width of a carpet web driven continuously through several treating stations of a conventional carpet dyeing system. Web 10 may, for example, be fifteen feet in width and is subjected to several treating steps during the process all of which are well known.
The dye station 12 according to the present invention includes an applicator head having upper, lower, front, and back walls labled 14U, 14D, 14F and 14B respectively. Corner blocks 13 as shown and bolts (not shown) may be used to hold the walls together and provide additional rigidity to the structure. Additionally, a lower wall 14L and lower hinged wall or skirt 14H are situated as shown to define a closed area 15 between the carpet and application head. If desired side skirts, not shown, may also be included to completely enclose the area over the carpet 10 just below the head. Support 16 is attached to wall 14B for supporting a pressurized air source reservoir 18A and pressurized dye source reservoir 18D, each of which is generally cylindrical extending perpendicular to the plane of the view of FIG. 1, i.e. transverse to the direction of travel of the carpet web 10.
A spray nozzle support block 20, which is rectangular in cross section as shown and extends across the width of the carpet web is mounted to the underside of lower wall 14D and supports spray nozzles 22. Although only one spray nozzle is shown in FIG. 1, it is to be understood that a number of identical spray nozzles 22 will extend in a line perpendicular to the plane of the view of FIG. 1 and transverse to the direction of travel of the carpet web. Preferably, the center-to-center distance between adjacent spray nozzles 22 threaded into block 20 is one-half inch. Each of the spray nozzles 22 is connected to a mixing zone or chamber 24 by a connector tube 23 and each chamber 24 is in turn connected to a flexible gas supply tube 26 and a flexible dye supply tube 28. The interior of mixing chamber 24 may be a simple parallelepiped with exterior access holes, or nipples allowing connection of tubes 23,26 and 28 dye and air in and the mixture of dye and air out. The chamber could, for example, be about a 1/2" cube. For simplicity's sake, the gas or air supply tube 26 and the dye supply tube 28 are broken away. All of the mixing chambers 24, air supply tubes 26, and dye tubes 28 will be disposed within the applicator head 11. For a 15 foot width head one can readily appreciate that interconnecting 260 mixing chambers 26 requires an enormous amount of tubing to be confined within the walls defining the head. As shown, the air tubes 26 are connected to the air reservoir 18A, whereas the dye tubes 28 are connected to the dye reservoirs 18D.
Each of the air tubes 26, which is associated with a corresponding one of mixing zone 24 and a corresponding one of spray nozzle 22, also is associated with a corresponding one of air or gas valves 30. Likewise, each of the dye tubes 28, is associated on a one-to-one basis with a mixing zone 24 and a corresponding spray nozzle 22, and also corresponds on a one-to-one basis with a control valve 34. Thus, each associated gas valve 30, dye valve 32 and control valve 34 forms a valve control set and as shown in FIG. 1, five such control sets of corresponding gas valves 30, dye valves 32, and control valves 34 are mounted to an individual support member block 36 forming a modular unit. A number of such identically constructed modular support member blocks 36 are supported interiorly on applicator head 17 on cross bracket 46. Each of the support member blocks 36 have interior fluid channels adapted to be connected to a control fluid source or reservoir 40 by way of tube 38. The control fluid may be air at 60 p.s.i. pressure for example. If the air reservoir 18A which is used for spraying the dye is of the same pressure, then the tube 38 may simply connect to cylinder 18A. Alternately, a compressor or other source of pressurized air for control fluid tube 40 may simply be the same source of pressurized air which supplies 18A.
Each of the support member blocks 36 is mounted to a support bracket 46 which is connected by hinge 44 to mounting piece 42. Each of the numerous support member blocks 36 may have a separate support bracket 46 or, alternately, as shown in FIG. 2, two adjacent support member blocks 36 may be supported by the same bracket 46. The mounting piece 42 may simply extend along the full axial length of the applicator head 11 parallel adjacent the line of spray nozzles 22. The actual location is selected to minimize the length of connecting tubes.
As best shown in FIG. 2, the control fluid air which enters the support member block 36 through tube 38 is distributed to the associated five control valves 34 by a control fluid passage 48. Depending upon whether the solenoid of control valve 34 is actuated, control fluid may either be blocked or flow through a particular control valve 34 into the corresponding gas valve 30 and corresponding dye valve 32 by way of control fluid passage 50. There would, of course, be five control fluid passages 50 in each support member 36 corresponding to each set of a a gas valve 30, a dye valve 32, and a control valve 34.
The operation of the valves such as the gas valves and each dye valve 32 is discussed in detail in the above-identified and incorporated by reference patent application Ser. No. 279,954. However, the operation of a gas valve 30 will be briefly discussed herein, it being understood that each of the dye valves 32 functions in the same manner. When the solenoid valve 34 is actuated, control fluid such as pressurized air is allowed to flow from passage 48 into passage 50 and into valve chambers 30C and 32C. The piston 30P will be displaced against the bias of spring 30S. This will cause the freely rotating ball 30B to squeeze the flexible gas tube 26, thereby cutting off flow of gas into the corresponding mixing chamber 24. In similar fashion, the presence of pressurized control fluid in chamber 32C will act on piston 32P simultaneously cutting off the flow of dye to the corresponding mixing chamber 24 by pinching the flexible dye tube 28. Obviously, this will in turn cut off the spray output of the corresponding spray nozzle 22.
Each of the solenoid control valves 34 is turned on and off by electrical signals on lines 52 connected to an external control via plug 54 mounted in front wall 14F. A single plug 54 may be used to interconnect all five of the solenoid control valves 34 on a particular modular support member block 36. Alternately, a plug 54 may be wired to control solenoid control valves 34 on two or more adjacent support member blocks 36.
Turning now to FIGS. 3 and 4, an alternate embodiment of the present invention will be discussed. FIG. 3 shows a side view of an alternate embodiment of the present invention, whereas FIG. 4 shows a view taken along lines 4--4 of FIG. 3 with a slight modification to support member block 36'. This alternate embodiment of a dyeing station 12' and applicator head 11' according to the present invention includes numerous components which function in exactly the same fashion as with the embodiment of FIGS. 1 and 2 and which, therefore, need not be described again. The dyeing station 12' and applicator head 11' are identical to the dyeing station 12 and head 11 except for the placement and support for gas valves 30, dye valves 32 and control valves 34.
In the embodiment of FIG. 3 the solenoid control valves 34 are disposed side-by-side in two rows upon a support plate 56 which is bolted to a support wall 58 as shown. The support wall 58 may be bolted or otherwise affixed to front and back walls 14F and 14B. A control fluid tube 60 extends from each of the solenoids 34 to support member block 36'.
The support member block 36' is mounted upon a support plate 62 which is bolted to the wall 14D by upstanding cornerposts 37. Support member block 36', which may extend substantially along the full span of the spray nozzles 22 or alternately constructed to comprise a number of similar modular blocks arranged in a line extending the length of applicator head 11', includes a number of control fluid passages 50'. The control fluid passages 50' operate in the same manner as the control fluid passages 50 for the embodiment of FIGS. 1 and 2. In particular, control fluid from the solenoid 34 flows to the corresponding gas valve 30 and dye valve 32 by way of control fluid tube 60 and control fluid passage 50'.
As shown in FIG. 3, a particular gas valve 30 may be situated directly below the corresponding dye valve 32. In that case, the control fluid passage 50' extends vertically downward and horizontal to the right to provide the pressurized control fluid air to the valves 30 and 32. The valve 30 and 32 mounted on the left side (as seen in FIG. 3) of the support member block 36' may be supplied with air by a passage similar to 50' except that it leads off to the left as shown in phantom lines in the view of FIG. 3. By mounting valves 30 and 32 on both sides of the support member block 36', a large number of the valves may be accomodated to correspond to each of the spray nozzles 22 extending across the width of the travelling carpet web. Thus, if the center to center distance of nozzles 22 were reduced to 1/4 inch, block 36' would readily support the additionally required valves.
A slight modification of the support member block 36' may be seen in FIG. 4 which shows a support member block 56" wherein the gas valves 30 and corresponding dye valves 32 are staggered to accommodate more valves in a given amount of space. In this case, the control fluid passages 50" may lead vertically down to a particular dye valve 32 and then slant to supply control fluid to the corresponding gas valve 30. For simplicity's sake, the valves 30 and valves 32 are shown in schematic form only. Similarly, only the control fluid passages 50" associated with valves on the back (i.e., the view of FIG. 4) are shown, it being readily understood that similar control fluid passages 50" would be used for valves 30 and 32 mounted to the front of the support member block 36".
OPERATION
The operation of the present invention will presently be discussed. The carpet 10 is driven in the direction of the arrow in a continuous fashion by means which are well known in the art. The spray nozzles 22 stand in a spray line perpendicular to the direction of movement of the carpet 10 about six inches above the base of the carpet web 10. In particular, a pattern controller, digital computer, or similar means well known in the art is used to control actuation of the solenoid control valves 34 which in turn cause the corresponding gas valves 30 and dye valves 32 to be controlled. When the gas valve 30 and dye valve 32 corresponding to a particular spray nozzle 22 are actuated by the control valve 34, gas, which may be air as shown, and dye are mixed together in the particular mixing chamber 24 corresponding to that spray nozzle 22. The air flowing into the mixing zone 24 by way of air or gas tube 26 tends to atomize or break up the dye flowing into the mixing chamber 24 by dye tube 28. As shown in the drawings, the air is supplied into the mixing chamber in the same direction as the mixed air and dye is sprayed out of the spray nozzle. The dye is supplied into mixing chamber 24 perpendicular to the output of the mixture of dye and air. If desired, the mixing chamber 24 and corresponding spray nozzle 22 may be integral.
If the pattern controller indicates that a particular spray nozzle 22 is to be turned off, the corresponding solenoid control valve 34 may be actuated to allow control fluid to pass into the control fluid passage 50 (or 50' or 50") to cause the corresponding flexible tubes 26 and 28 corresponding to a particular spray nozzle 22 will then readily cut off the spray of dye out of that spray nozzle.
In carrying out the method of the present invention, various pressure combinations for the air and dye used in spraying the dye may be used to achieve varying results. A range of 0 p.s.i. to 60 p.s.i. for both air and dye is acceptable with 12 p.s.i. of dye to 24 p.s.i. of air providing a mist or atomized output from the mixing chamber. A ratio of approximately 4:1 in dye pressure to air pressure will cause bubbles to be formed yielding a foam out of the mixing chamber. Most importantly, the present invention does not require the addition of water or organic solvents to the dye to achieve foaming. Further, the present invention does not require the addition of numerous foam generator and/or foam stabilizer chemicals as is common among foam dyeing techniques, although one could add such chemicals if desired.
In the case of producing a fine mist, the side skirts act as a shield to confine the mist from being carried away by local drafts. However, such misting does not cause serious problems as in actual practise users prefer to operate without the skirts since downward application of the atomized mixture or foam, depending on pressures selected, causes direct application of the materials to the pile face of the carpet web in a well controlled fashion to allow selective pattern formation.
Following the application of the dye onto the pile face, the carpet is passed into a steamer (not shown) where the dye may be fixed into the carpet yarns most advantageously and in lessor amounts than heretofore required, because the dye can be applied directly without a gum carrier. A considerable energy saving is effected since less steam is needed than in prior art processes which use gum, resins, or other carriers. Such carriers commonly must be heated to reduce their viscosity and permit them to be washed away. Further, the minimal use of such gums and other substances in the present invention means that less water is used in the washer or washing stage (not shown) which typically follows the steamer. Since less water is used in the washing stage, the amount of heat energy required in the subsequent drying stage (not shown), is also reduced.
An important advantage of the present invention is that a pick up of between 110 and 130% is realized as compared to, for example, a normal TAK dyeing process which has required between 350 and 500% pickup. "Pick up" as used herein refers to the ratio of dye to the weight of carpet in percent to achieve dyeing. For example, if 60 oz. of dye are applied to 30 oz. of carpet, the pick up would be 60/30×100=2×100=200% pick up. A lower pick up is advantageous and is indicative of using less dye for a given weight carpet. The present invention is therefore more efficient in its use of dye in addition to its advantageous minimization of energy consumption.
Although various details have been included in the present discussion, it is to be understood that these details are for illustrative purposes only. Numerous modifications and adaptations will be readily apparent to those of ordinary skill in the art. Accordingly, the scope of the present invention should be determined by reference to the appended claims. | A method of carpet treating and apparatus for the dyeing of intricate patterns is provided wherein a plurality of spray nozzles are disposed in a spray line transverse to the direction of movement of a carpet. Each spray nozzle is connected to a mixing chamber where air and treating liquid preferably dye, are applied at selected pressures between 0 and 60 p.s.i. Depending on the relative pressure of the air and liquid dye, the mixture is caused to be either atomized or foamed through the spray nozzles onto the face of a moving carpet web. Each nozzle is connected to its own separate mixing chamber the input of which are controlled through a corresponding control valve which turns on and off the spray nozzle by opening and closing a corresponding gas valve and corresponding dye valve. | 3 |
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made with Government support under Contract Numbers DMR-9523735 and DMI-0127834 awarded by the National Science Foundation (NSF). The government has certain rights in the invention.
BACKGROUND
[0002] Materials which do not deteriorate mechanically and continue to function in extreme conditions of temperature, friction and wear, are desirable and necessary in a wide range of modern applications. The materials of aircraft brakes experience some of the harshest service conditions seen in any application. The material experiences high friction and temperatures while the aircraft is taxiing and landing. In addition, all aircraft brake materials are required to withstand the extreme conditions of rejected take-off (RTO) trials.
[0003] One class of materials used for aircraft brakes is composites of carbon fibers reinforcing a carbon matrix (C/C composites). These materials are described in J. Economy, H. Jung and T. Gogeva, Carbon, Vol. 30, No. 1, pp 81-85 (1991).
[0004] C/C composites are considerably stronger and lighter than steel. Such materials increase in strength with increasing heat treatment and resist thermal shock caused by rapid temperature changes. However, they suffer from a number of drawbacks including poor oxidation resistance, highly variable wear rate and coefficient of friction, and costly manufacturing. The lack of high temperature stability requires an expensive supplementary processing step to coat the non-frictional surfaces with an oxidation barrier. In addition, fabrication is very time consuming (1-2 months) due to the long periods required for chemical vapor infiltration of the carbon matrix. Thus, the fabrication is a slow, expensive process. The carbon matrix is usually introduced among the carbon fibers by liquid impregnation and charring of organic materials. In some applications, chemical vapor deposition is used as a final step in processing. The steps in the processes are repetitive and can take months to complete. These materials are also only moderately oxidation resistant, thus requiring the addition of an expensive oxidation barrier coating to the non-frictional surfaces. Furthermore, they have a highly variable coefficient of friction, especially in the presence of water, which causes variable brake feel to pilots (nicknamed “morning sickness”).
[0005] Carbon fibers reinforcing a boron nitride matrix (C/BN composites) have the potential to overcome some of the shortcomings of C/C composites. These materials are prepared by first polymerizing borazine (B 3 N 3 H 6 ), to yield an oligomer of appropriate viscosity that is used as a boron nitride precursor for impregnating the carbon fibers. The impregnated fibers are then heated under pressure, yielding a solid boron nitride matrix reinforced by the carbon fibers. The preparation time for such composites requires days, as opposed to the months needed for C/C composites, with concomitant cost savings (U.S. Pat. No. 5,399,377). However, due to low density, the resulting C/BN composites do not have acceptable heat capacity and thermal conductivity values to substitute for C/C composites in aircraft brakes. The preparation typically yields a composite with a density in the range of 1.38 g/cc to 1.43 g/cc, and with multiple impregnations (up to six) the density increases up to 1.61 g/cc. Additional impregnations do not appear to effectively increase the density of the composites.
[0006] Consequently, C/BN composites have higher oxidation resistance than C/C composites, but do not have the desired density of about 1.8 g/cc which is expected to be necessary for the materials to have the heat capacity and thermal conductivity needed for good braking.
[0007] The performance of C/C composites may also be improved by the addition of a boron nitride matrix, yielding carbon fiber composite materials with a boron nitride layer, or C/C/BN composites. These materials are prepared by immersing lower density C/C composites in borazine oligomers and subjecting the system to the same procedure used for C/BN composites (U.S. Pat. No. 5,399,377). The boron nitride coating renders the product more oxidation resistant than C/C composites. Nevertheless, the density of C/C/BN composites is still below the level required for aircraft brakes applications, and their wear rate is too high once the thin BN coating is worn away (Brian Fabio, M. S. Thesis, The University of Illinois at Urbana-Champaign).
SUMMARY
[0008] In a first aspect, the present invention is a method of manufacturing a composite material comprising forming a mixture comprising a plurality of fibers and a borazine oligomer; subjecting the mixture to a first heating, for 12 hours to 56 hours; and subjecting the mixture to a second heating. The temperature of the first heating is 60° C. to 80° C., and the pressure during the first heating is at least 0.5 MPa, the temperature of the second heating is at most 400° C., and the greatest pressure of the second heating is at least 15 MPa.
[0009] In a second aspect, the present invention is a composite material comprising carbon fibers in a boron nitride matrix. The composite material has a density of at least 1.62 g/cc.
[0010] In a third aspect, the present invention is a composite material comprising carbon fibers in a boron nitride matrix. The composite material has a wear rate of at most 0.4 mg/m at an energy level of 100 kJ/kg to 1100 kJ/kg, and a coefficient of friction of at least 0.22 at an energy level of 100 kJ/kg to 1200 kJ/kg.
[0011] In a fourth aspect, the present invention is a method of manufacturing a composite material comprising boron nitride, comprising forming a mixture comprising a preform and a borazine oligomer; subjecting the mixture to a first heating, for 12 hours to 56 hours; and subjecting the mixture to a second heating. The temperature of the first heating is 60° C. to 80° C., and the pressure of the first heating is at least 0.5 MPa, and the temperature of the second heating is at most 400° C., and the greatest pressure of the second heating is at least 15 MPa.
[0012] In a fifth aspect, the present invention is a composite material comprising a 3D needled carbon fiber preform impregnated with boron nitride having a density of at least 1.63 g/cc.
[0013] In a sixth aspect, the present invention is a composite material, comprising CVI-infiltrated carbon fiber preform impregnated with boron nitride having a density of at least 1.62 g/ cc.
[0014] In a seventh aspect, the present invention is a composite material comprising a 3D needled carbon fiber preform impregnated with boron nitride having a wear rate of at most 0.05 mg/m at an energy level of 100 kJ/kg to 1000 kJ/kg, and a coefficient of friction of at least 0.12 at an energy level of 100 kJ/kg to 900 kJ/kg.
BRIEF DESCRIPTION OF FIGURES
[0015] FIG. 1 illustrates a thermogravimetric analysis (TGA) experiment performed on a 1:1 mixture of carbon fibers and borazine.
[0016] FIG. 2 is the X-ray diffraction scan of the C/BN composites of the invention, showing that the d-spacing of BN is 3.36 A.
[0017] FIG. 3 is a plot of the wear rate for traditional C/C composites, traditional C/C/BN composites, and the high density C/BN composites of the invention.
[0018] FIG. 4 is a plot of the coefficient of friction (COF) for traditional C/C composites, traditional C/C/BN composites, and the high density C/BN composites of the invention.
[0019] FIG. 5 is a plot of the wear rate at 160 psi for the high density C/BN material of the invention and for traditional lower density C/BN materials.
[0020] FIG. 6 is a plot of the coefficient of friction (COF) at 160 psi for the high density C/BN material of the invention and for traditional, low density C/BN materials.
[0021] FIG. 7 is the X-ray diffraction scan of the 3D C/C/BN composites of the invention, showing that the d-spacing of BN is 3.38 A.
[0022] FIG. 8 is a plot of the wear rate, at a pressure of 0.25 MPa, of traditional 3D C/C composites, the 3D C/BN composites of the invention, and of the 3D C/C/BN composites of the invention.
[0023] FIG. 9 is a plot of the wear rate, at a pressure of 0.5 MPa, of traditional 3D C/C composites, the 3D C/BN composites of the invention, and of the 3D C/C/BN composites of the invention.
[0024] FIG. 10 is a plot of the coefficient of friction (COF), at a pressure of 0.25 MPa, of traditional 3D C/C composites, the 3D C/BN composites of the invention, and of the 3D C/C/BN composites of the invention.
[0025] FIG. 11 is a plot of the coefficient of friction (COF), at a pressure of 0.5 MPa, of traditional 3D C/C composites, the 3D C/BN composites of the invention, and of the 3D C/C/BN composites of the invention.
DETAILED DESCRIPTION
[0026] The present invention provides a new type of C/BN composites with densities averaging 1.75 g/cc, and methods for their fabrication. These C/BN composites were found to outperform C/C composites in testing, and their density renders them a viable substitute for C/C composites in applications of friction and wear. The invention is based on the discovery that higher density C/BN composites can be formed when carbon fibers impregnated with borazine oligomers are heated under a pressure exceeding 0.5 MPa, and the pressure is applied before the temperature reaches 400° C.
[0027] These high density C/BN composites are prepared by first heating the borazine monomer in a pressure vessel, with occasional venting, at a temperature of 60° C. to 80° C., more preferably 65° C. to 75° C., and, most preferably, 68° C. to 72° C. The borazine reacts with itself to yield oligomers while releasing hydrogen as a primary by-product, and the heating is applied until a viscosity of 500 cP to 2500 cP is attained, usually within 24 to 48 hours. The oligomers are used to impregnate carbon fibers, and the resulting system is heated to 60° C. to 80° C., more preferably 65° C. to 75° C., and most preferably, 68° C. to 72° C., under a pressure ranging from 0.5 to 8 MPa, more preferably 1 to 5 MPa, and most preferably 2.2 to 4.4 MPa, for preferably 12 to 48, hours to induce further oligomerization of the borazine without formation of voids.
[0028] The composite is then subject to increasing temperature and pressure under an inert atmosphere. The heating promotes further borazine polymerization while the pressure is controlled to achieve a high density product. The temperature is increased to 300° C. to 400° C. at a rate of 0.25° C./min to 3° C./min, more preferably to 325° C. to 375° C. at a rate of 0.75° C./min to 1.25° C./min, yet more preferably to between 340° C. to 360° C. at a rate of 0.9° C./min to 1.1° C./min. The pressure is ramped to a final pressure of 14 MPa to 30 MPa, more preferably from 18 MPa to 26 MPa, and most preferably, 21 MPa to 23 MPa. The composite is then preferably held at the final temperature and pressure for an additional 10 to 30 hours, more preferably 16 to 24 hours.
[0029] The resulting composite is preferably heated at 5° C./min to 15° C./min to a final pyrolysis temperature of 1100° C. to 1500° C., for 1 to 3 hours, and then cooled, more preferably heated at 10° C./min to a final pyrolysis temperature of 1150° C. to 1250° C., for about 2 hours. This process is optionally carried out two or three times to maximize the density of the product.
[0030] The process described above was also applied to 3D needled carbon fiber preforms. The hydrogen and other by-products appear to easily escape from the preform, yielding a new type of high density 3D C/BN material with as little as a single impregnation. In addition, it was found that optimal wear properties were obtained when the 3D carbon preform was first subjected to carbon CVI to a density of ˜1.3 g/cc and then impregnated with borazine oligomer and subjected to the process above, yielding a new higher density 3D C/C/BN material.
[0031] Objects of various shapes may be fabricated by using the materials of the invention in resin transfer molding processes (RTM). In RTM, a fiber preform, with the shape of the desired object, is loaded into a mold without the borazine. Alternatively, the preform may be bent into the desired shape by the walls of the mold. The mold is closed, and borazine or the borazine oligomer as described above is injected or transferred into the mold and impregnates the preform. The resulting system is then subjected to the same temperature and pressure treatment as described above, yielding objects with increased densities and complex shapes in faster processing times.
EXAMPLES
[0032] 1) Thermogravimetric Analysis of the C/BN Composite Production Process
[0033] One possible explanation for the higher density of the materials of the invention may be that the pressure prevents the hydrogen evolving from the transformation of the borazine into boron nitride from forming bubbles that would lead to a porous, lower density structure. To investigate this possibility, a series of thermogravimetric analysis (TGA) experiments were done using a 1:1 mixture of carbon fibers and borazine.
[0034] FIG. 1 is a representative TGA showing that the majority of the hydrogen and other by-products evolved from the borazine below 150° C. This indicated that applying pressure would be most effective below this temperature for two reasons: (1) after attaining 150° C. the viscosity would become too high and the sample less compressible; (2) this is the region where most of the hydrogen by-product is being produced, a high pressure at this temperature could help prevent the introduction of pores into the matrix structure. In general, the system should be maintained under pressure at a temperature of at most 150° C. until about 80% of the weight loss due to borazine polymerization has occurred. However, pressure during the higher temperature processing, 150° C. to about 350° C., is still essential in order to keep the evolving hydrogen from creating porosity in the structure.
[0035] 2) Preparation of High Density C/BN Composites
[0036] Borazine monomer was oligomerized in an inert atmosphere at 70° C. for 36 hours, until an oligomer of viscosity of 500 to 2500 cP was attained. In a dry box, chopped carbon fibers were placed into a two inch diameter mold and a measured amount of the borazine oligomer was added. Graphite foil was then placed on top of the sample (as a releasing agent) followed by a tightly fitting disk of TEFLON® (DuPont, Wilmington, Del.) to prevent potential leakage of borazine. To provide extra mechanical support to the TEFLON® a precisely machined brass disk was placed on top of the TEFLON®. A steel plunger was then placed on top of the brass and the entire assembly transferred into a controlled atmosphere hot press. The mold and the sample were then heated to 70° C. and held isothermally for an additional 48 hours under pressure. Pressure was applied while the temperature was increased to 350° C. at a rate of 1° C./min under dry nitrogen. The composite was then held at 350° C. for 20 hours under constant pressure. Following this final oligomerization, the composite was removed from the mold and separated from the graphite foil. The composite was then placed in a mullite tube furnace which was backfilled with dry nitrogen. The furnace was ramped at 10° C./min to a final pyrolisis temperature of 1200° C., held for two hours, and then cooled. The processing schedule, shown in Table 1, describes the temperatures and the pressures applied. From a single impregnation bulk densities in the range of 1.3 to 1.55 g/cc were achieved using 40% V f (fiber volume fraction) chopped pitch based carbon fibers. This process was carried out three times to maximize the density to approximately 1.75 g/cc.
TABLE 1 Temperature ° C. Pressure (MPa) Hold Time (hrs) 70 2.2 48 90 4.4 1° C./min ramp 110 13 130 15 150 22 350 22 20 1200 — 10° C./min ramp, 2 hr hold
[0037] During the reimpregnations a similar temperature-pressure process was used with one additional step prior to hot pressing. This involved placing the composite in a steel pressure vessel and heating under vacuum for 30 minutes, backfilling with nitrogen and then introducing enough borazine oligomer to submerge the composite. The system was then held at 70° C. for 12 hours, with occasional venting to reduce the partial pressure of hydrogen. This allowed for better permeation of the composite and caused the borazine oligomer molecular weight to increase while filling in the porous structure. As an example, one composite exhibited an initial density of 1.46 g/cc and one, two and three impregnations yielded increased densities of 1.62, 1.66 and 1.75 g/cc, respectively.
[0038] 3) X-ray Diffraction Data of C/BN Composites
[0039] The X-ray diffraction data depicted in FIG. 2 shows that the interlayer, or d-spacing, of the BN in the C/BN composites is 3.36 Å. It is known that hexagonal BN with d-spacings below 3.38 Å display greatly increased resistance to hydrolysis (C. G. Cofer and J. Economy, “Oxidative and hydrolytic stability of boron nitride”, Carbon, Vol. 33, No. 4, p. 389). The BN d-spacing is calculated from the sharp peak labeled on the scan, appearing at 26.435°.
[0040] 4) Wear Rate Testing of High Density C/BN Composites
[0041] Once the C/BN composites reached a density of approximately 1.75 g/cc, friction and wear testing was performed on an inertial brake dynamometer. This is the most important parameter since it determines the lifetime and safety of the brake material. The resulting wear rate plotted versus energy level for previously tested C/C, C/C/BN, and the new C/BN composites of the invention appear in FIG. 3 . The shapes of the curves for the C/C and C/C/BN composites are similar, though C/C/BN exhibits a wear rate lower than the C/C at all levels. C/BN exhibits a wear rate significantly lower than the C/C in the two problematic regions, namely low energy levels (taxi conditions) and high energy levels (Rejected Takeoff). A significant amount of wear over the lifetime of a C/C aircraft brake occurs during taxiing. In this region the C/BN displays a four-fold decrease in wear-rate, implying the potential for a significant increase in the number of landings between overhauls. At an energy level of approximately 600 kJ/kg the wear rate of the C/C material begins to increase. This increase in wear rate corresponds to the onset of oxidation of the carbon. In comparison, the C/BN does not display significant oxidation until much higher temperatures (900-1000° C. for short times), which would correspond to energy levels of approximately 1200 kJ/kg. Another advantage of this increased resistance to wear at high temperatures would be that the addition of an expensive oxidative barrier coating (as used with commercial C/C) would not be necessary.
[0042] 5) Comparison with Traditional C/BN Materials.
[0043] The wear rate of the C/BN material of the invention is also markedly better than that of a traditional, lower density C/BN material produced according to the process of U.S. Pat. No. 5,399,377. As illustrated in FIG. 5 , the wear rate of the C/BN of the invention is consistently below 0.5 mg/m, whereas the traditional C/BN material exhibited wear rates reaching above 2 mg/m.
[0044] 6) Friction Testing of High Density C/BN Composites
[0045] The average coefficient of friction (COF) is plotted versus energy levels in FIG. 4 . The resulting COF for the C/BN composites was found to be much less sensitive to energy, and therefore temperature, than C/C composites. Typically, the COF for C/C composites varies widely from 0.1 to 0.5 depending on the temperature. In contrast, the COF for the C/BN composites varied only from 0.22 to 0.32 in the energy range tested. Moreover, as illustrated in FIG. 6 , the material of the invention exhibited a higher COF than traditional, low density, C/BN materials. The stable COF data for the C/BN composites allows for much better predictability in designing the braking system and resolution of issues for variability in the feel of brakes to pilots. It has also been shown that the COF of boron nitride is less sensitive to the presence of water (G. W. Rowe, Wear, vol. 3, page 274, 1960). This will also help in resolving the issue of morning sickness, by decreasing the change in the COF as the brakes dry out, caused by heating, during use.
[0046] 7) Preparation of High Density 3D C/BN Composites.
[0047] The procedure previously described for the C/BN composite of Example 1 was applied on a 3D needled preform instead of the chopped carbon fibers. The preform had a 28% fiber volume and a bulk density of about 0.45 g/cc. The fiber of the preform was polyacrylonitrile-derived, with an average fiber diameter of 9 microns and a density of about 1.78 g/cc. Samples of the preform were provided by the Goodrich Corporation (Brecksville, Ohio) or Albany International Techniweave (Rochester, N.H.). The process was repeated up to three times, yielding final 3D C/BN composites with a density of 1.63 g/cc to 1.72 g/cc.
[0048] 8) Preparation of High Density 3D C/C/BN Composites.
[0049] A sample of 3D needled preform such as that used in Example 7 was carbon vapor infiltrated to increase density to ˜1.3 g/cc, then placed in a steel pressure vessel and heated under roughing vacuum for 12 hours. The pressure vessel was backfilled with dry nitrogen and borazine oligomer was added. The preform and borazine were reacted for an additional 12 hours in the steel pressure vessel. In a dry box, the borazine soaked sample was placed in a mold and an excess of borazine oligomer was added. The rest of the procedure then followed the same steps as previously described for the C/BN composite of Example 1. This process was typically carried out four times, yielding a product with a density of 1.62 g/cc to 1.80 g/cc.
[0050] 9) X-ray Diffraction Data of High Density 3D C/C/BN Composites.
[0051] As seen in FIG. 7 , X-ray diffraction scans of the high density 3D C/C/BN composite material displayed a highly ordered boron nitride phase with an interlayer spacing of 3.38 Å. The more defined shoulder appearing next to the boron nitride peak is due to the vapor deposited carbon matrix that tends to order itself on the surface of the carbon fiber.
[0052] 10) Wear Rate Testing of High Density 3D C/C/BN Composites.
[0053] As seen in FIG. 8 and FIG. 9 , the 3D C/C/BN systems displayed a wear rate so low that it is, at best, very difficult to measure accurately. The change in mass of the samples is very small, on the order of micrograms. The wear rate of the 3D C/C/BN is a full order of magnitude lower than the wear rates of 3D C/C up to an energy level of approximately 600 kJ/kg. At approximately 900 kJ/kg the wear rate of the 3D C/C/BN composites starts to increase gradually due to oxidation but only at higher interfacial pressures. In particular, the wear rate was near zero at low energy levels (<300 kJ/kg) that represent the taxiing condition of aircraft braking. This regime accounts for the majority of wear over the life of the brakes and may be significantly decreased with the 3D C/C/BN composite. For example, the Boeing 777, designed for 3000 landings per overhaul (LPO), only realizes 1500 LPO due to extra taxiing caused by airport congestion. This wear would be essentially eliminated with the use of the 3D C/C/BN material. The samples were tested at interfacial pressures of 0.25 MPa and 0.5 MPa, and the wear rate only marginally increased as the interfacial pressures was raised, as opposed to the more pronounced increases registered with 3D C/C and 3D C/BN materials.
[0054] 11) Friction Testing of High Density 3D C/C/BN Composites.
[0055] At an interfacial pressure of 0.25 MPa, the 3D C/C/BN displays a COF of approximately 0.2 ( FIG. 10 ). However, increased pressure leads to a relative decrease in the COF that is less substantial than that registered on 3D C/C and 3D C/BN materials ( FIG. 11 ). It is interesting to note that at lower interfacial pressures and high energy levels, the COF actually increases. This property would be especially important in the case of an RTO where a higher COF is needed to affect decreased stop time and distance, thus contributing to passenger safety. | A method of manufacturing a composite material comprises forming a mixture comprising a plurality of fibers and a borazine oligomer; subjecting the mixture to a first heating, for 12 hours to 56 hours; and subjecting the mixture to a second heating. The temperature of the first heating is 60° C. to 80° C., and the pressure during the first heating is at least 0.5 MPa, the temperature of the second heating is at most 400° C., and the greatest pressure of the second heating is at least 15 MPa. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a novel process for the production of previously unknown secondary ether fatty acids and secondary ether esters from either their equivalent fatty acids possessing an alcohol in the 4,5 or 6 position or, in the alternative, from their equivalent lactone precursors.
2. Description of the Prior Art
Production of hydroxy fatty acids and lactones utilizable as the starting material for the methods and products of the instant invention has been previously taught in the art.
U.S. patent application 08/534,810 filed Sep. 27, 1995, entitled “Method for Development of δ-Lactones and Hydroxy Acids form Unsaturated Fatty Acids and Their Glycerides”, and herein incorporated by reference, teaches the formation of δ-lactones and 5-hydroxy fatty acids.
U.S. Pat. No. 5,380,894 to Burg et al. teaches the formation of 5-,6- and 7-hydroxy fatty acids from the hydrolysis of estolides which were in turn produced from the reaction of one or a mixture of unsaturated fatty acids in the presence of a catalyst at elevated temperature and pressure.
Showell et al. (1968, J. Org. Chem., 33:2697-2704) disclose the production of γ-lactones from oleic acid, undecylenic acid and erucic acid by perchloric acid isomerization. Hydrolysis of these γ-lactones is subsequently carried out to yield 4-hydroxy fatty acids.
High yields of δ-lactones have been achieved by the acid catalyzed reaction of a 4-hexenoic acid containing a carbocation stabilizing functionality as described by Fujita et al. (1982, J. Chem. Tech. Biotechnol., 32:476-484).
Ballantine et al. (“Organic Reactions Catalysed by Sheet Silicates: Ether Formation by the Intermolecular Dehydration of Alcohols and by the Addition of Alcohols to Alkenes”; J. Mol. Catal., 1984, 26, 37-56) teach that primary alcohols may be converted to ethers through the use of ion-exchanged montmorillonites as heterogenous catalysts in pressure vessels at 200° C. Secondary alcohols, in the presence of acid catalysts, typically undergo dehydration to their corresponding stable alkenes. As shown in Table 2 of Ballantine's article, ether yields from secondary alcohols in this reaction never exceeded 35% and were, except for a singular occurrence, below 10%.
SUMMARY OF THE INVENTION
We have now invented a process for the production of novel fatty ether esters and fatty ether acids, which possess low viscosity and low temperature melting point properties and may be used as viscosity modifiers in the creation of cosmetics and complete vegetable oil based biodegradable fluids such as hydraulic fluids and dielectric fluids. The fatty ethers are of the formula(I):
wherein R is selected from C 7 -C 17 aliphatic hydrocarbons which may be saturated or unsaturated, linear or branched, and may be optionally substituted, such as with one or more hydroxy groups; R 1 is selected from linear or branched C 1 -C 24 hydrocarbons which may be saturated or unsaturated, linear or branched, aliphatic or aromatic, and may be optionally substituted by one or more hydroxyl, halo, or amine groups; with the proviso that when R 1 is aromatic, it is limited to an optionally substituted six member carbon ring; and R 2 is selected from hydrogen or from linear or branched C 1 -C 24 hydrocarbons which may be saturated or unsaturated, linear or branched, aliphatic or aromatic, and may be optionally substituted by one or more hydroxyl, halo, or amine groups; with the proviso that when R 2 is aromatic, it is limited to an optionally substituted six member carbon ring; and x is an integer from 2 to 4.
Formation of these fatty ether compounds is by reaction of the appropriate hydroxy fatty acid or lactone with a nucleophilic alcohol in the presence of an acid catalyst to produce fatty ether esters. Following their formation, the fatty ether esters may be recovered for subsequent use, or in the alternative, they may either be hydrolyzed to produce fatty ether acids or transesterified with a different nucleophilic alcohol in the presence of an acid catalyst to produce alternate ester variants.
In accordance with this discovery, it is an object of the invention to provide novel fatty ether compounds having utility as viscosity modifiers, hydraulic fluids and dielectric fluids.
It is a further object of the invention to provide a method of making these fatty ether compounds.
Other objects and advantages of the invention will become readily apparent from the ensuing description.
DETAILED DESCRIPTION OF THE INVENTION
Starting materials for use in the instant invention include one or a mixture of 4,5 or 6 hydroxy fatty acids of the formula (II):
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups; and x is an integer from 2 to 4; or one or more of a mixture of γ-, δ- or ε-lactones of the formula (III):
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups, and x is an integer from 2 to 4;
The hydroxy fatty acids and lactones of formulas (II) and (III) may be acquired from natural sources or synthesized by means readily known to those of skill in the art. Useable fatty acid source materials, which may be converted by art-disclosed means into the hydroxy fatty acid and lactone starting materials of formulas (II) and (III), include the Δ 5 and Δ 6 unsaturated fatty acids in either the free or glyceryl ester form. These occur naturally in a variety of plant oils and may be conveniently obtained for use therefrom. Meadowfoam oil, having a high content of Δ 5 unsaturated fatty acids is particularly preferred as a source material for preparation of the starting materials of the instant invention. Without being limited thereto, other oils such as pine oils, marsh-marigold oils, or oils of the carrot family (i.e. coriander, dill and fennel) may be used as sources.
Any monounsaturated vegetable oil including soybean oil, rapeseed oil, canola oil, sunflower oil, peanut oil and cottonseed oil may also be converted into its corresponding γ-lactone by means of an acid catalyzed isomerization at 100° C. and thus also be used as a source material for preparation of the starting materials of the instant invention.
As starting materials in the reaction of the invention, the hydroxy fatty acids and/or lactones may be provided in substantially pure form or, in the alternative, as a mixture and/or in an impure form.
The novel fatty ether esters of the invention are prepared by a reaction of one or more of the fatty acids of formula (II)
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups; and x is an integer from 2 to 4; and/or one or more of a mixture of γ-, δ- or ε-lactones of formula (III):
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups, and x is an integer from 2 to 4; with a primary or secondary alcohol in the presence of a suitable acid catalyst under suitable conditions of temperature, pressure, reactant ratios and time to form fatty ether esters of formula (IV):
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups; each R 1 is identical and is selected from linear or branched C 1 -C 24 hydrocarbons which may be saturated or unsaturated, linear or branched, aliphatic or aromatic, and may be optionally substituted by one or more hydroxy, halo, aromatic or amine groups; with the proviso that when R 1 is aromatic, it is limited to an optionally substituted six member carbon ring; and x is an integer from 2 to 4.
Preferred fatty ether esters include those formed by reaction of 4- and 5-hydroxy fatty acids with either straight or branched primary and secondary alcohols possessing 1 to 24 carbon atoms. These compounds are represented by the structure of formula (IV) wherein R, R 1 , and x are as described above except that x is an integer from 2 to 3.
Particularly preferred fatty ether esters include those formed by reaction of 5-hydroxy fatty acids with primary and secondary alcohols possessing 1 to 24 carbon atoms. These compounds are represented by the structure of formula (IV) wherein R, R 1 , and x are as described above except that x is the integer 3.
Conditions for the formation of the fatty ether esters of formula (IV) include reaction temperatures ranging from about 25° C. to about 200° C., preferably from about 80° C. to about 140° C. While the reaction is envisioned as being performed at ambient pressure, this is primarily due to simplicity of operation—with either higher or lower pressures being useable so long as such do not interfere with the reaction (e.g. excessively low pressures would cause a boiling off of one or more reactants). Reactant ratios of nucleophilic alcohol to hydroxy fatty acid and/or lactone range from about 2 to about 40 mole equivalents, with a range of about 10 to about 20 mole equivalents being preferred. Suitable acid catalysts include mineral acids such as perchloric acid and sulfuric acid; Lewis acids such as boron triflouride, tin octoate and zinc chloride; and heterogenous catalysts such as clays and ion-exchange resins. The acid catalysts are present in an amount ranging from about 0.01 to about 6.4 mole equivalents of the hydroxy fatty acid and/or lactone. The nucleophilic alcohols are straight chain or branched and can be primary or secondary in nature. Reaction times are envisioned to run from about 1 to about 100 hours, with a range of about 2 to about 24 hours being preferred. Production of the fatty ether esters by this reaction range from about 70% to about 90% of the theoretical yield; their separation from the reaction mixture may be accomplished by any art-known means such as vacuum distillation under reduced pressure.
The ether fatty esters of formula (IV) thus produced may in turn be hydrolyzed by reaction with a base to produce the ether fatty acids of formula (V):
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups; R 1 is selected from linear or branched C 1 -C 24 hydrocarbons which may be saturated or unsaturated, linear or branched, aliphatic or aromatic, and may be optionally substituted by one or more hydroxy, halo, aromatic or amine groups; with the proviso that when R 1 is aromatic, it is limited to an optionally substituted six member carbon ring; and x is an integer from 2 to 4. This is accomplished by treatment of the ether fatty ester with an alcoholic mixture containing from about 0.1 to about 2.0 M of an alkaline earth or alkaline metal hydroxide such as potassium, sodium, calcium or lithium hydroxide. Reactions were run under the alcohol's reflux temperature, preferably at temperatures ranging from about 60° C. to about 120° C. for 1 hour and then cooled to room temperature and neutralized with dilute mineral acid to a pH of about 5.5. The water layer is then separated from the organic phase and residual solvents are removed under vacuum to afford the ether. One would also expect this hydrolysis to occur with high pressure steam splitting, as currently used in industrial settings.
In the alternative, the ether fatty esters of formula (IV) may be transesterified with a second nucleophilic alcohol in the presence of an acid catalyst using the same protocol as the previously described esterification reaction with the exception that temperatures ranging from about 25° C. to about 120° C., preferably from about 60° C. to about 110° C. are used, and that reactant ratios of from about 0.01 to about 0.1 mole equivalents of acid and from about 1 to about 10 mole equivalents of alcohol per mole equivalent of fatty ester are utilized. The resultant products are ether fatty esters of formula (VI):
wherein R is selected from C 7 -C 17 hydrocarbons which may be saturated or unsaturated, linear or branched, and may contain other substituents, such as one or more hydroxy groups; each of R 1 and R 2 are independently selected from linear or branched C 1 -C 24 hydrocarbons which may be saturated or unsaturated, linear or branched, aliphatic or aromatic, and may be optionally substituted by one or more hydroxy, halo, aromatic or amine groups; with the proviso that when either R 1 or R 2 is aromatic, it is limited to an optionally substituted six member carbon ring; and x is an integer from 2 to 4.
The following examples are intended to further illustrate the invention and are not intended to limit the scope of the invention which is defined by the claims.
EXAMPLE 1
A series of reactions were conducted to examine the production of 5-alkoxy eicosanoates from δ-lactones obtained from meadowfoam oil by the process described in U.S. patent application Ser. No. 08/534,810, filed Sep. 27, 1995, entitled “Method for Development of δ-Lactones and Hydroxy Acids from Unsaturated Fatty Acids and Their Glycerides”, and herein incorporated by reference. δ-lactone was dissolved in the appropriate alcohol and reacted under the conditions listed in Table 1. Mixing was maintained throughout the course of the reaction by magnetic stirring or overhead stirring in larger scale reactions. The reaction vessels were fitted with reflux condensers to recycle volatile alcohols back into the reaction mixture. Temperature was maintained in the reaction via a temperature controller with a thermocouple immersed in the reaction mixture, except those reactions that were conducted at the alcohol's boiling point. Isolation and workup of the reaction are listed below based on the catalyst employed.
BF 3 workup:
After the reaction reached completion, the crude reaction mixture was poured into a separatory funnel and diluted with 50 mL hexane, washed 2×10 mL with saturated NaCl solution, dried over Na 2 SO 4 , gravity filtered through a #1 Whatman filter paper and concentrated in vacuo. Kugelrohr distillation at 160° C.-180° C. (0.2 mm Hg) to remove unsaturated byproducts and excess alcohol provided isolated ethers.
Clay workup:
After the reaction reached completion, the crude reaction mixture was diluted in 50 mL of hexane, filtered through #1 Whatman filter paper using a buchner funnel and vacuum filtration flask and concentrated in vacuo. Kugelrohr distillation at 160° C.-180° C. (0.2 mm Hg) to remove unsaturated byproducts and excess alcohol, provided the isolated ethers.
HClO 4 workup:
After the reaction reached completion, the crude reaction mixture was poured into a separatory funnel and diluted with 50 mL of hexane, washed 2×10 mL with 0.5M Na 2 HPO 4 solution, dried over Na 2 SO 4 , gravity filtered through a #1 Whatman filter paper and concentrated in vacuo. Kugelrohr distillation at 160° C.-180° C. (0.2 mm Hg) to remove unsaturated byproducts and excess alcohol provided the isolated ethers.
H 2 SO 4 workup:
After the reaction reached completion, the crude reaction mixture was poured into a separatory funnel and diluted with 50 mL of hexane, washed 2×10 mL with 0.5M Na 2 HPO 4 solution, dried over Na 2 SO 4 , gravity filtered through a #1 Whatman filter paper and concentrated in vacuo. Kugelrohr distillation at 160° C.-180° C. (0.2 mm Hg) to remove unsaturated byproducts and excess alcohol provided the isolated ethers.
EXAMPLE 2
A series of reactions were conducted the same as in Example 1, except substituting γ-lactone for δ-lactone. γ-lactone was dissolved in the appropriate alcohol and reacted under the conditions listed in Table 2. Workup and isolation of the ether is the same as described above in Example 1, being dependent on the catalyst used.
EXAMPLE 3
A series of reactions conducted in the same manner as that of Example 1, except substituting 5-hydroxy eicosanoic acid for δ-lactone. The 5-hydroxy eicosanoic acid was dissolved in the appropriate alcohol and reacted under the conditions listed in Table 3. Workup and isolation of the ether is the same as described above in Example 1, being dependent on the catalyst used.
TABLE 1
Catalyst
Alcohol
Temp.
Reaction
Percent
Percent
Substrate
Catalyst
Equivalents*
Alcohol
Volume
(° C.)
Time (h)
Ether
Unsaturated
δ-Lactone
BF 3
6.4
Methanol
5
mL
67
24
86
10
δ-Lactone
BF 3
4.5
Butanol
5
mL
85
19
84
13
δ-Lactone
BF 3
4.5
Decanol
5
mL
85
24
93
7
δ-Lactone
BF 3
1.0
2-Ethylhexanol
10
mL
120
1.5
57
36
δ-Lactone
Clay
0.1
g
Methanol
5
mL
67
24
0.1
19
δ-Lactone
Clay
0.1
g
Butanol
5
mL
117
21
70
17
δ-Lactone
Clay
0.1
g
Decanol
5
mL
115
24
82
12
δ-Lactone
Clay
0.1
g
2-Ethylhexanol
5
mL
120
22
84
11
*Equivalents = mole of substrate per mole of catalyst except for clay which is reported as mass of clay.
TABLE 2
Catalyst
Alcohol
Temp.
Reaction
Percent
Percent
Substrate
Catalyst
Equivalents*
Alcohol
Volume
(° C.)
Time (h)
Ether
Unsaturated
y-Lactone
BF 3
4.5
Methanol
5 mL
67
142
44
3
y-Lactone
BF 3
4.5
Butanol
5 mL
85
94
76
8
*Equivalents = mole of substrate per mole of catalyst except for clay which is reported as mass of clay.
TABLE 3
Catalyst
Alcohol
Temp.
Reaction
Percent
Percent
Substrate
Catalyst
Equivalents*
Alcohol
Volume
(° C.)
Time (h)
Ether
Unsaturated
5-Hydroxyeicosanoic acid
BF 3
4.5
Butanol
5
mL
85
22
83
14
5-Hydroxyeicosanoic acid
BF 3
1.0
2-Ethylhexanol
25
mL
120
18
80
14
5-Hydroxyeicosanoic acid
Clay
2.0
g
Butanol
10
mL
98
35
30
12
5-Hydroxyeicosanoic acid
HCIO 4
0.4
Methanol
10
mL
67
25
4
5
5-Hydroxyeicosanoic acid
HCIO 4
0.5
Butanol
10
mL
110
18
74
21
5-Hydroxyeicosanoic acid
HCIO 4
0.5
Decanol
10
mL
100
2
69
8
5-Hydroxyeicosanoic acid
HCIO 4
0.3
2-Ethylhexanol
5
mL
90
19
84
16
5-Hydroxyeicosanoic acid
H 2 SO 4
2.0
Butanol
10
mL
110
18
67
33
*Equivalents = mole of substrate per mole of catalyst except for clay which is reported as mass of clay. | Fatty ether compounds and a process for their production is disclosed. The compounds possess low viscosity and low temperature melting point properties and may be used as viscosity modifiers in the creation of cosmetics and complete vegetable oil based biodegradable fluids such as hydraulic fluids and dielectric fluids. Formation of these fatty ether compounds is by reaction of the appropriate hydroxy fatty acid or lactone with a nucleophilic alcohol in the presence of an acid catalyst to produce fatty ether esters. Following their formation, the fatty ether esters may be recovered for subsequent use, or in the alternative, they may either be hydrolyzed to produce fatty ether acids or transesterified with a different nucleophilic alcohol in the presence of an acid catalyst to produce alternate ester variants. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a versatile fitness kit including apparatus which is particularly beneficial to those who are interested in improving the muscular development of the upper body, hips, lower limbs and more specifically for the arms and shoulders. The versatile fitness apparatus is also particularly helpful in improving the aerobic capacity of the user.
Weight devices such as dumbells have been used previously to condition joggers, runners, and for body development and muscle coordination, as have hand grippers in a more specialized and related use. Typical of such dumbells is the device shown in U.S. Pat. No. 1,577,077.
It will be obvious that hand grippers which are coil tempered to meet the needs of the various training levels by providing increased strenuousness for the exercise through a number of different means have limitations. One improvement of the present invention provides or eliminates the necessity of buying more than one hand gripper to increase the strenuousness of the exercise, as the invention through its adjustability accomplishes this result. The versatile fitness apparatus also eliminates the necessity of buying devices such as aerobic hand weights and dumbells because the versatile gripper members, as will be detailed hereinafter, are detachably connectable to provide this aerobic fitness function.
BRIEF DESCRIPTION OF INVENTION
One aspect of the present invention is to provide a versatile fitness apparatus which consists of a three-in-one device to function as an aerobic hand gripper and therefore eliminate the need to utilize other less versatile hand grippers.
To demonstrate the versatility of my invention and while in the form of a hand gripper, a finger gripping member is slidably mounted on one leg of a U-shaped spring loaded device and a thumb gripping member is mounted on the other leg of said U-shaped device. In this fashion, manipulation of the hand gripper is possible as will be obvious.
Secondly, detachment of the finger gripping member from the leg of the U-shaped device and detachment of the thumb gripping member of the U-shaped device and connection of these gripping members as is shown in FIG. 1, provides a versatile aerobic gripper for a different but necessary fitness function.
Thirdly, a weight, whose measure may be preselected, is shown as detachably connected to the aerobic gripper to make the exercise more or less strenuous as desired, and while one weight is preferred it is within the teachings of the present invention to use plural weights. In the preferred embodiment the weight is either square or octagonally shaped with a flat bottom to faciliate storage when the versatile fitness apparatus is not in use.
The invention disclosed also provides a convenient way to carry the fitness apparatus to provide further versatility, that is, connectors are incorporated into the U-shaped devices so that they can be conveniently joined to a belt with similar connectors to those in the U-shaped devices. The belt then can be carried over the shoulder to free the hands for other uses. In this fashion a versatile multipurpose fitness apparatus can be adjusted to accommodate different uses. In the preferred form the belt is made to size and is padded on the inside to provide a high degree of comfort when worn around the waist. There is also included a localized padded area on the outside of the belt to add comfort to the shoulder area when it serves as a means for carrying the versatile fitness apparatus.
To facilitate the hand gripper function a calibration scale is included on the outside leg of the U bar to permit selection of the strenuousness of the exercise during this function.
Also reflectors may be provided on the belt and/or the finger and thumb gripping portions to provide greater visibility at night.
It also will be realized by one skilled in the art from the description that follows that the belt versatile and fitness apparatus which is preferably sold in kit form, will easily conform to the known methods of manufacture and will be uncomplicated in construction and therefore commercially feasible.
These and other features, objects and advantages will be further understood and appreciated by those skilled in the art by reference to the following description, claims and drawings.
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a versatile fitness apparatus kit which provides a totally new convertible product which after simple adjustment of its parts is intended for use in aerobics, jogging, racewalking, running and walking.
As will be described in detail hereinafter, a belt with suitable padding is also provided which facilitates the carrying of the versatile fitness apparatus so as to free up the hands for other uses when the exercise function is inactive.
While the objectives, purposes and advantages of the invention have been set out generally, other objects will be more clearly understood from the following description and the accompanying drawings in which:
FIG. 1 is an enlarged side view of the versatile aerobic gripper form of the fitness device of the instant invention which may be used as will be described for the development of the aerobic qualities of the user.
FIG. 2A is a cross section taken on the section line 2A--2A of FIG. 1.
FIG. 2B is a cross section taken on the section line 2B--2B of FIG. 1.
FIG. 3 is an exploded perspective view of the aerobic gripper of FIG. 1.
FIG. 4 is a side view showing assembly of the fitness apparatus in the form wherein it is shown as a hand gripper.
FIG. 5 is a sectional view taken on lines 5--5 of FIG. 4.
FIG. 6 is a view of the shoulder and waist belt showing the connecting members and the padding to facilitate carrying of the versatile fitness apparatus shown in FIG. 4.
FIG. 6A is a sectional view taken on lines 6A--6A to show the padding on the belt of FIG. 6.
Referring to the drawings, there is shown in FIG. 4 a view of the versatile fitness apparatus generally designated 10 and assembled to form a jogging gripper comprising a U-shaped device 12 which has, at the periphery, an oversized U portion 14 when compared with the periphery 16 of the leg 17. Stated differently the U-portion 14 is enlarged and slims down at 18 to a smaller dimension for each of the legs 17 and 17'. In this fashion a degree of adjustability of the resistance of the U-shaped device is provided for increased resistance when the fitness apparatus 10 serves the function of a hand gripper. The U-shaped device takes the form of a rectangle or channel as shown in FIG. 5 and a restraining member 22 is mounted on the legs 17 and 17'. The restraining member functions to hold the legs 17 and 17' in optimum position so that the hand gripper function can be performed. Without the restrainer 22, the U-shaped device 12 would open due to the U-shaped device being spring loaded to provide a desired resistance during the hand gripping function.
A thumb gripping unit or portion 30 is slidably mounted on the U-shaped leg 17. This is accomplished by providing a rectangular opening 32 throughout the length of the thumb gripping unit as is best seen in FIG. 3. Similarly a finger gripping unit or portion 40 is mounted on the leg 17' in exactly the same fashion as was described hereinabove for the thumb gripping unit 30. That is, there is also a rectangular opening 42 in the finger gripping unit 40 which is slidably mounted on the leg 17'.
Adjustability to provide for a more strenuous or less strenuous hand gripper exercise is accomplished by arranging for the thumb gripping unit 30 and the finger supporting member 40 to be slidably arranged on the legs 17 and 17' of the fitness apparatus to provide a more severe or less severe resistance as is desired by the user. In this connection if the units 30 and 40 are moved in the direction of the U 14, there will be a more strenuous exercise and if the gripping members 30 and 40 are moved downwardly towards the ends of the legs 17 and 17', there will be a less strenuous exercise.
The specific provisions for the adjustability of the finger and thumb gripping units comprise the combination of the slidability of the finger and thumb grippers along the legs 17 and 17' with the capability of fixing these grippers by means of stops 50 and 50' on the finger gripper 40 and thumb gripper 30. These stops are connected to springs 52 and 52' respectively and said stops may be dislodged from slots 54 and 54' by finger action to permit movement to other slot locations on the legs 17 and 17'. In this manner the desired adjustability is provided.
Attached to each of the legs 17 and 17' respectively are the connecting members 60 and 60'. Note that these connecting members are threaded to the ends of the legs 17 and 17' so that they may be disconnected if desired and they also serve as stops for the thumb gripper 30 and the finger gripper 40 to facilitate carrying these devices when connected to a belt 90 as will be described hereinafter. Any male/female connector well known in the art is suitable for this purpose.
To carry the versatile fitness apparatus, the belt 90 having complimentary connecting members as is shown in FIG. 6 and designated 70 and 70' to those on the versatile jogging grippers are utilized. As will be obvious two of the fitness devices 10 would be used normally for fitness purposes and with the provision of identical connecting members on the end of the second jogging gripper opposite or crisscross connection of the connecting members to identical connectors 70 and 70' formed on the ends of the belt provides for a very simple and efficient manner to carry the apparatus when they are not in use. This permits the utilization of the hands for other purposes.
Preferably the belt 90 includes a full length padded interior 91 shown in FIG. 6A. On the opposite side of the belt there is located a localized padded portion 92 to make shoulder carrying of the apparatus more comfortable.
At the top of the finger gripping portion 40 and the base of the thumb gripping portion 30, there is provided a joining arrangement 80 which comprises a key 81 and a keyway 82. A similar joining or connection arrangement is provided for the add on weight 83.
Additionally an angled end 84 at the bottom end of the finger gripper portion serves to hold the add on weight 83 in cooperation with a wing nut 85 which functions to provide and serves to permit detachable connection of the add on weight 83 to the bottom of the fingers gripping portion 40. Detachability is accomplished in combination with the key and the keyway and wing nut 85.
Additional weights may be added as is shown in FIG. 3. Those added weights serve the purpose of providing a more strenuous exercise and may be connected to the weight 83 as is shown in FIG. 3 in the same fashion as described above for connection to the base or joining arrangement 80.
As was previously described generally the thumb gripping member 30 and finger gripping member 40 may be disconnected by sliding each unit off the legs 17 and 17'. This is accomplished simply by disconnecting the threaded connecting members 60 and 60' and as is shown in FIG. 3. The thumb gripping member 30 and finger supporting member 40 may also be connected in a key and keyway arrangement and maintained in position by a wing nut 86 which is also shown in FIG. 3 of the drawings. In this way an aerobic type of gripper is fashioned and can be utilized for aerobic exercise purposes. This is accomplished by detachable connection of the finger and thumb members as shown in FIG. 1 through a key and keyway arrangement in cooperation with the wing nut 86.
As will be seen in FIG. 1 the finger gripping portion 40 is provided with fingers supporting grooves designated 44 to accommodate the fingers comfortably during use thereof in either the hand gripper or jogging functions.
Additional weights as is shown in FIG. 3 may be added to provide a more vigorus exercise to achieve a greater aerobic benefit.
The specification incorporates preferred embodiments of the invention, however, it will be understood that the invention may be otherwise embodied within the scope of the following claims. | A versatile fitness kit wherein apparatus is provided which is particularly suitable of aerobic, jogging, racewalking, running and walking type exercises. The fitness apparatus comprises a U-shaped member which is capable of selectively resisting pressure which would be applied through the manipulation of the hand through grippers that are movably mounted on the U-shaped device. There is also provided an adjustable member which is mounted on the U-shaped device to adjust the amount of pressure to that desired during the exercise period. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/121,934, filed on Apr. 12, 2002, now abandoned, which is a continuation of application Ser. No. 09/304,934, filed on May 4, 1999, now U.S. Pat. No. 6,371,938, which is a continuation of application Ser. No. 08/911,338, filed on Aug. 14, 1997, now U.S. Pat. No. 5,899,885, which is a division of application Ser. No. 08/519,201, filed on Aug. 25, 1995, now U.S. Pat. No. 5,779,675, the contents of which are incorporated herein by reference.
BACKGROUND OF INVENTION
This invention relates to pressure jacket systems for securing a syringe in an injector head. More specifically, the invention relates to pressure jacket systems which allow front loading and removal of a syringe, and which hold the syringe securely to an injector head during injection procedures.
In the medical field, patients often are injected with fluids in procedures such as angiography. In such procedures, which require controlled injection of a large volume of fluid into a patient, a needle is used as a conduit for the fluid which is connected to the syringe by a connector tube. The syringe is mounted on a motorized injector having an injector head.
For long term compatibility with injectable fluids, syringes may be made of polypropylene with a certain minimum wall thickness. The thickness is critical as typical pressures of up to 1200 p.s.i. are used to inject the fluids into a patient. For safety and sanitary reasons, different disposable syringes are used or different fluids and different patients.
Pressure jackets are known in the art for enclosing and retaining syringes while in use. A pressure jacket serves to limit radial expansion of a syringe which may lead to bursting or to leaks of the pressurized fluid around the seals of the syringe plunger. Another function of a pressure jacket is to prevent forward motion of the syringe. For example, typically a force of 2000 pounds is required to restrain the forward motion of a 200 ml syringe with a cross-section of 1.7 in. 2 at 1200 p.s.i.
Certain present pressure jackets are one piece designs, where the syringe is inserted into the jacket from the rear end of the jacket. An example of such a pressure jacket is found in U.S. Pat. No. 4,677,980, assigned to the common assignee of this application. The neck of the syringe protrudes from the front end of the pressure jacket for connection of fluid lines that lead to the patient. Because the diameter of the syringe neck is much smaller than that of the syringe barrel, it can withstand both radial and forward force.
However such an arrangement causes a problem when the syringe is removed from the pressure jacket. The neck of the syringe must pass through the present pressure jacket configurations. This requires the patient fluid path to be disconnected, which presents a potential biohazard and may result in spilling fluids onto the pressure jacket.
Additionally, fluid spilled during loading and purging air from the syringe may get inside the pressure jacket and require cleaning.
Thus, a pressure jacket system is needed which permits a syringe to be front loaded onto an injector head and removed from the injector head without disconnecting the patient fluid path. Further, a pressure jacket system is needed which reduces the materials required for the manufacture of the syringe.
SUMMARY OF INVENTION
The present invention relates to front loadable pressure jacket systems for use with injectors having an injector head with a housing and a front opening. A syringe is connected to the injector front opening to allow the flow of fluids through the syringe. A pressure jacket holds the syringe to the injector head. A piston extendible through the injector front opening imparts motive force to a plunger in the syringe to cause fluid flow.
One embodiment of the present invention is a pressure jacket having first and second jacket halves each having interior surfaces conformable to the exterior surface of the syringe. A hinge pin extends from the front face of the injector head. The first and second jacket halves are rotatably mounted on the hinge pin. The halves may be placed in an open position allowing insertion and removal of the syringe or a closed position so that the jacket surrounds the syringe.
A second embodiment of the present invention includes a pressure jacket with first and second jacket halves, where each jacket half has a front or distal end and a rear or proximal end. A hinge for rotational connection to the injector's front face allows the first and second jacket halves to be placed in an open position, allowing insertion and removal of the syringe, and a closed position such that the jacket substantially surrounds the syringe. A locking ring is disposed around the first and second jacket halves. The locking ring is placed in a position over the front ends of the first and second jacket halves when in the closed position and the ring is placed in a position near the proximal ends of the jacket halves when in the open position.
A third embodiment of the present invention includes a pressure jacket that has a hollow cylinder portion with an open distal end and a rear end coupled to the injector head. The cylinder has at least one locking finger having front and rear ends, and a pivot axis disposed near the rear end. The pivot axis is connected to the open distal end of the cylinder. The locking finger is pivotable to a closed position such that the front end of the finger acts to hold the syringe within the cylinder. The finger is pivotable to an open position to allow the insertion or removal of the syringe.
A fourth embodiment of the present invention includes a pressure jacket having a jacket cylinder with an open front end and a rear end coupled to the injector head. A first tie rod has a rear end attached to the injector head and a front end that is attached to a first front plate. The first front plate is pivotable between a closed position for holding the syringe within the jacket cylinder and an open position for allowing the insertion or removal of the syringe. A second tie rod likewise has a rear end attached to the injector head and a front end attached to a second front plate. The second front plate is pivotable between a closed position for holding the syringe within the jacket cylinder, and an open position for allowing the insertion or removal of the syringe.
A fifth embodiment of the present invention includes a pressure jacket with a jacket cylinder having an open front end and a rear end coupled to the injector head. A first pivot is coupled to the injector head and a first tie rod is attached to the first pivot. A second pivot is coupled to the injector head and a second tie rod is attached to the second pivot. A front retaining plate joining the front ends of the tie rods allows the retaining plate to be pivotable between a closed position for holding the syringe within the jacket cylinder and an open position to allow the insertion or removal of the syringe from the jacket cylinder.
A sixth embodiment of the present invention includes a pressure jacket which has a jacket cylinder formed around a longitudinal axis and having an open front end and a rear end. The jacket cylinder is transversely pivoted to the front face of the housing to allow the cylinder jacket to be pivoted between a closed position and an open position. An arm having a rear end affixed to the injector head is attached to a retaining member. The retaining member retains the syringe in the jacket cylinder when the jacket cylinder is in a closed position. The jacket permits the loading or removal of the syringe when the jacket cylinder is in an open position.
A seventh embodiment of the present invention includes a pressure jacket that has a slidable canopy retractable within the injector head. An arm having a rear end is coupled to the injector head. The front end of the arm is coupled to a retaining member and retains the syringe. The canopy slides to a closed position to retain the syringe and slides to an open position to allow the insertion or removal of the syringe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an injector head and front loading syringe that may be used with the embodiments of the present invention;
FIG. 2 is a perspective view of a first embodiment of the invention in an open position;
FIG. 3 is a front elevational view of the first embodiment of the invention in an open position;
FIG. 4 is a perspective view of the first embodiment of the present invention in a closed position;
FIG. 5 is a front elevational view of the first embodiment of the present invention in a closed position;
FIG. 6 is a perspective view of a second embodiment of the present invention in an open position;
FIG. 7 is a perspective view of the second embodiment of the present invention in a closed position;
FIG. 8 is an exploded view of a third embodiment of the present invention;
FIG. 9A is an alternate configuration of the locking fingers of the third embodiment of the present invention in an open position;
FIG. 9B is an alternate configuration of the locking fingers of FIG. 9A in a closed position;
FIG. 10 is a front elevational view of a third embodiment of the present invention in an open position;
FIG. 11 is a front elevational view of the third embodiment of the present invention in a closed position;
FIG. 12 is a perspective view of a fourth embodiment of the present invention in an open position;
FIG. 13 is a perspective view of the fourth embodiment of the present invention in a closed position;
FIG. 14 is a perspective view of a fifth embodiment of the present invention in an open position;
FIG. 15 is a perspective view of the fifth embodiment of the present invention in a closed position;
FIG. 16 is a perspective view of a sixth embodiment of the present invention in an open position;
FIG. 17A is a perspective view of the sixth embodiment of the present invention in a closed position;
FIG. 17B is an isolated view of an alternative to the sixth embodiment of the present invention;
FIG. 18 is a perspective view of a seventh embodiment of the present invention in a partially open position; and
FIG. 19 is a front elevational view of the seventh embodiment of the present invention in a closed position.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an injector head indicated generally at 20 and a syringe 22 which may be used in connection with various embodiments of the present invention. The injector head 20 includes a housing 21 and a front face 23 . The injector head 20 is used to actuate syringe 22 , which is mounted on the injector head 20 . The syringe 22 includes a tubular body 24 and a plunger 26 slidably positioned therein. In operation, the rear of the syringe 22 is fixed in or against an opening 30 on the injector front face 23 . Syringe 22 may be affixed to opening 30 by any suitable means, such as mounting flanges (not shown), as described in U.S. Pat. No. 5,383,858, assigned to the common assignee of this application and which is fully incorporated herein by reference. Any of the pressure jacket systems described below may be used to retain syringe 22 when syringe 22 is affixed to the injector front face 23 . The fluid within syringe 22 is pushed forward by a drive means, such as motorized piston 32 , extendable and retractable through opening 30 , which engages the rear surface 29 of plunger 26 to push plunger 26 forward in the syringe.
FIGS. 2–3 show views of a first embodiment of the present invention in an open position and FIGS. 4–5 show views of the first embodiment in a closed position. Specifically, as shown in detail in FIG. 2 , a fluid injector 40 ′ includes a pressure jacket 42 which is of an axially split or “clam shell” type. The pressure jacket 42 is mounted to the front face 23 of the injector head 20 . When syringe 46 is installed into pressure jacket 42 , as more fully described below, motorized piston 32 when driven forward, engages a syringe plunger (not shown) and pushes the plunger forward in the body of a syringe 46 to force fluid out of the syringe tip 48 . Syringe 46 , preferably manufactured of a clear plastic, includes a body 50 , a neck 52 connected to the body 50 and a luer connector 54 connected to the neck 52 . A connector tube (not shown) may be connected to luer connector 54 , which delivers fluid to the patient.
As shown in FIGS. 2–3 , pressure jacket 42 which includes a first jacket half 56 and a second jacket half 58 , is preferably manufactured from a clear plastic so that the position of the plunger within installed syringe 46 may be observed. The first jacket half 56 and the second jacket half 58 have interior surfaces, 64 and 66 , respectively, which conform to the exterior surface of the body 50 of the syringe 46 . The first and second jacket halves 56 and 58 are joined by a pivot hinge 60 which allows the first jacket half 56 and the second jacket half 58 to be swung to an open position, as shown in FIGS. 2 and 3 . Pivot hinge 60 has one end thereof affixed to the forward wall of injector head 20 at a point below injector head opening 30 , although in other embodiments the pivot hinge 60 may otherwise be radially displaced from opening 30 . For example, if it were desired that jacket halves 56 and 58 open to the side instead of from the top, the pivot hinge 60 would be positioned to one side of opening 30 . As shown in FIG. 2 , the pivot hinge 60 is preferably parallel to axis A of the injector piston movement. With the pressure jacket 42 in the open position, syringe 46 may be inserted between the first jacket half 56 and the second jacket half 58 . The two jacket halves 56 and 58 are then closed and locked by means of a latch 62 , as shown in FIGS. 4 and 5 , which in the illustrated embodiment is attached to first jacket half 56 . Alternatively, one of the first or second jacket halves 56 or 58 may be fixed to the forward wall 23 of injector head 20 and the other jacket half may be pivotally mounted to the forward wall 23 of injector head 20 .
As shown in FIGS. 2–5 , the first embodiment of the present invention allows front loading and removal of syringe 46 and any tubes attached thereto while minimizing fluid spills. Further, as syringe 46 is retained within pressure jacket 42 , the amount of material required to manufacture syringe 42 is reduced because the pressure jacket 42 , instead of the syringe walls, bears the majority of the pressure force exerted during a fluid injection procedure.
A second embodiment of the present invention is shown in FIGS. 6 and 7 . FIG. 6 shows a fluid injector 70 having a pressure jacket system 72 in an open position, which permits the loading and removal of a syringe 76 . Pressure jacket 72 , a generally “alligator jaw” type, is hingedly affixed to an injector head 20 to which syringe 76 may be releasably installed. Specifically, as shown in FIG. 7 , syringe 76 is held by a combination of a first or top jacket half 78 and a second or bottom jacket half 80 , together forming pressure jacket 72 , and a locking ring 82 . Both top jacket half 78 and bottom jacket half 80 are preferably made of clear plastic and have a semi-cylindrical shape. Interior semi-cylindrical surfaces 84 and 86 of top and bottom jacket halves 78 and 80 , respectively, conform to the exterior surface of the body of the syringe 76 . Jacket halves 78 and 80 have respective rear ends 88 and 90 located near the injector front face 23 and front ends 92 and 94 which coact to form an opening for the syringe neck 97 . The front ends 92 and 94 have interior surfaces that mate with the exterior conical transition region 96 of syringe 76 .
When the top jacket half 78 and bottom jacket half 80 are in the closed position, as shown in FIG. 7 , the locking ring 82 is placed about jacket halves 78 and 80 , preferably near the front ends 92 and 94 of jacket halves 78 and 80 . The top jacket half 78 is rotatable around a first hinge pin 98 while the bottom jacket half 80 is rotatable around a bottom hinge pin 100 . In order to open the pressure jacket 72 , the locking ring 82 is moved along the length of the top jacket half 78 and bottom jacket half 80 to the injector front face 23 , as shown in FIG. 6 . This allows the pressure jacket 72 to be opened by moving the top jacket half 78 about the first hinge pin 98 and moving the bottom jacket half 80 about the second hinge 100 . A link (not shown) between the two jacket halves 78 and 80 may be used to regulate the movement of the two halves so they move away and toward each other at the same rate. Alternatively, either the top or bottom jacket halves 78 or 80 may be fixed to the injector front face 23 while the other jacket half is pivotally mounted to the injector front face 23 . While in the open position, the syringe 76 may be inserted or removed from the pressure jacket 72 . The advantages relating to the first embodiment of the present invention, discussed above, are also realized with this second embodiment.
FIGS. 8–11 show a third embodiment of the present invention. A fluid injector indicated generally at 110 includes a pressure jacket 112 with a plurality of locking fingers 114 for engaging a syringe 116 , shown in an open position in FIG. 10 and a closed position in FIG. 11 . Pressure jacket 112 is connected at its rear end 132 to injector head 20 by any suitable means, such as a threaded connection (not shown). Syringe 116 has a cylindrical body 118 having a front end 120 and an open rear end 122 . The front end 120 of syringe 116 is tapered and connected to a neck 124 . A disk shaped drip flange 126 is formed around the neck 124 .
The pressure jacket 112 includes a hollow cylinder 128 that is preferably made of clear plastic. A distal end 130 of the cylinder 128 is open to allow loading and removal of the syringe 116 . The distal end 130 of pressure jacket 112 has an outside surface 134 that is slightly smaller in diameter than that of cylinder 128 . The outside surface 134 of the distal end 130 is threaded (not shown). A plurality of locking fingers 114 (in the illustrative embodiment, six are shown) pivot about respective pivot points 136 , as shown in FIG. 10 . Each locking finger 114 has a front end 131 , preferably beveled, and a rear end 133 . Pivot points 136 are located proximate to the rear ends 133 of the locking fingers 114 and are mounted within channels 138 located on the rim of distal end 130 . Locking fingers 114 may be kept in position by means of friction and are radially angularly spaced from each other on the rim of distal end 130 . It is understood that any number of locking fingers may be used.
As shown in FIGS. 8 , 10 and 11 , a locking ring 140 , generally cylindrical in shape, is threaded on its interior surface and threaded onto the outside surface 134 of the distal end 130 (threads not shown). The front end 142 of the locking ring 140 is a distal annulus extending radially inwardly to form an open orifice 144 which permits the syringe body 118 to be inserted into pressure jacket 112 , but does not permit the drip flange 126 to be inserted into pressure jacket 112 . FIG. 10 shows that the front interior surface of the front end 142 is sloped to engage locking fingers 114 when in a closed position, as shown in FIG. 11 and more fully described below.
FIGS. 10 and 11 show that the syringe 116 is inserted into locking ring 140 and cylinder 128 so that drip flange 126 rests on the front end 142 . Locking ring 140 is screwed further onto cylinder 128 , and thus, moved toward the rear end 132 of cylinder 128 , as shown in FIG. 11 . Locking fingers 114 are pivoted about there respective pivot points 136 from the open position of FIG. 10 to the closed position of FIG. 11 by the sloped interior surface of the locking ring 142 which engages the distal ends 133 of the locking fingers 114 . Front ends 131 of fingers 114 retain syringe 116 in place. When locking ring 140 is unscrewed away from the distal end 130 of the cylinder 128 , locking fingers 114 pivot into an open position. A spring member (not shown) may be used to bias the locking fingers 114 into the open position. Syringe 116 may then be removed from or inserted into the pressure jacket 112 . The advantages relating to the first embodiment, as discussed above, are also realized by this embodiment.
FIGS. 9A and 9B provide details of an alternative configuration of a locking finger. Specifically, the locking finger 314 of FIGS. 9A and 9B is an angled locking finger formed by an elongated base member 316 and retaining arm 318 , preferably integrally formed therewith. Base member 316 is pivotally mounted to cylinder 128 at pivot point 136 . The angle between base member 316 and arm 318 is similar to the angle of the taper of front end 120 of the syringe 116 to permit maximum retention of syringe 116 within pressure jacket 112 . As shown in FIG. 9A , syringe 116 may be removed from pressure jacket 112 by moving a screw-threaded locking ring 340 toward pressure jacket rear end 132 on threaded surface 134 of cylinder 128 . Alternatively, as shown in FIG. 9B , syringe 116 may be held in place by moving the locking ring 340 away from pressure jacket rear end 132 on threaded surface 134 of cylinder 128 . As locking fingers 314 are angled, retaining arms 318 serve as stops to prevent the axially outward motion of syringe 116 . Thus, locking ring 340 need not include a sloped inner surface, as described above.
A fourth embodiment of the present invention is shown in FIGS. 12 and 13 . FIG. 12 shows a fluid injection system indicated generally at 150 having a pressure jacket 152 of a split front plate type, in an open position, while FIG. 13 shows the pressure jacket 152 in a closed position. Similar to the third embodiment of the invention, the pressure jacket 152 includes a cylinder portion 164 which may be mounted at its proximal end 168 to the injector front face 23 by any suitable means, such as screw threads (not shown). A cylindrically shaped syringe 154 including a neck 156 may be inserted into the distal end 166 of pressure jacket cylinder 164 . Syringe 154 further includes an alignment flange 158 comprising two diametrically opposed radially projecting wings 160 and 162 , which aid in the alignment of the syringe 154 with respect to pressure jacket 152 . In a preferred embodiment, flange 158 is disposed in a plane including the axis of the syringe 154 .
Syringe 154 is held in place by means of a combination of first and second front plates 170 and 172 . In a preferred embodiment, first and second front plates 170 and 172 are semi-circular in shape, such that each plate 170 and 172 has one straight margin and one arcuate margin. Plates 170 and 172 each contain semi-circular indentations 174 and 176 in their respective straight margins, and these indentations 174 and 176 form a neck access 178 for the neck 156 of the syringe 154 . The straight margins of front plates 170 and 172 act as flange slots 180 and 182 , which conform to the wings 160 and 162 of syringe 154 . First front plate 170 has an end that is connected to a first tie rod 186 , which allows the first front plate 170 to be pivoted between an open position of FIG. 12 and a closed position of FIG. 13 . Similarly, the second front plate 172 has an end which is attached to a second tie rod 184 , which allows the second front plate 172 to be pivoted between the open and closed positions.
Tie rods 184 and 186 have proximal or rear ends which may simply be rotatably mounted to the injector front face 23 , or alternatively attached to gears (not shown) located in injector head 20 for automatic opening and closure. The tie rods 184 and 186 are preferably rigidly attached to the front plates 170 and 172 .
When the pressure jacket 152 is in an open position as shown in FIG. 12 , front plates 170 and 172 are pivoted away from the pressure jacket 152 by rotating the tie rods 184 and 186 . For example, sun and planetary gears (not shown) in the head 20 may provide symmetric rotation of the tie rods 184 and 186 . The open position allows the insertion or removal of syringe 154 . Once the syringe 154 is inserted within the jacket cylinder 164 , the front plates 170 and 172 are pivoted into the closed position as shown in FIG. 13 . In this closed position front plates 170 and 172 extend across the front end 166 of jacket cylinder 164 . When front plates 170 and 172 are pivoted into the closed position, flange slots 180 and 182 act with the syringe flange wings 160 and 162 of the flange 158 to force the syringe 154 into proper angular alignment within pressure jacket 152 . In the illustrated embodiment, in proper alignment the syringe flange 158 is parallel to the plane formed by the tie rods 184 and 186 . The flange slots 180 and 182 in conjunction with the syringe flange 158 also act to prevent the syringe 154 from rotating during injector head operation.
FIG. 12 also shows that front plates 170 and 172 include latches 192 and 194 , respectively, located at respective ends which are remote from or diametrically opposite from front plate pivot points 188 and 190 . Latches 192 and 194 clamp onto the distal ends of tie rods 184 and 186 respectively, and are operable to fix the front plates 170 and 172 in the closed position. Slots 196 and 198 are located near latches 192 and 194 , respectively, and are conformable to pivot points 188 and 190 , respectively, to permit a snug fit when front plates 170 and 172 are in a closed position. Front plates 170 and 172 may also include conical interior surfaces (not shown) that conform to the front of the syringe 154 when front plates are in a closed position.
The advantages of the first embodiment discussed above are realized with this embodiment. Additionally, the use of flange slots 180 and 182 in conjunction with alignment flange 158 allows automatic alignment of the syringe 154 to an asymmetrical injector head drive means, such as a piston (not shown).
An alternative to the above embodiment may be realized by making the tie rods 184 and 186 integral to the jacket cylinder 164 . A second alternative to the above embodiment may be realized by utilizing a syringe similar to that in FIG. 1 and eliminating the flange slots 180 and 182 , particularly if there is no need to automatically angularly align the syringe 154 .
FIGS. 14 and 15 show a fifth embodiment of the present invention. FIG. 14 shows a fluid injector indicated generally at 210 having a pressure jacket 212 of a swing front retainer type in an open position. FIG. 15 shows the pressure jacket 212 in a closed position. Like the other embodiments previously discussed, the pressure jacket 212 is mounted at its rear end 220 on the injector front face 23 by any suitable means. A syringe 214 inserted into the front end 218 of pressure jacket 212 , as shown in FIG. 15 , includes a neck 226 . The syringe 214 is held in place against force exerted by the injector drive means on the syringe plunger (neither shown) by a front retaining plate 222 , Which has a slot 224 that allows the neck 226 of the syringe 214 to extend from the cylinder 216 through the front retaining plate 222 . The slot 224 is significantly smaller in a direction transverse to the longitudinal axis than the diameter of the syringe 214 , so that the remainder of the retaining plate may resist forward-directed force placed on it by the syringe 214 during an injection operation. The slot 224 extends from the center of retaining plate 222 in a direction of the pivot of front plate 222 (discussed below) to the margin of plate 222 .
In a preferred embodiment, the inside surface of slot 224 is contoured to engage the outside surface of syringe neck 226 . For example, if neck 226 is cylindrical in shape, the inside surface of slot 224 is cylindrical. If neck 226 is conical in shape, the inside surface of slot 224 is angled.
An adapter 228 , which is an annular collar for tie rod connections, is mounted or integrally formed on the injector front face 23 and adjoins the pressure jacket cylinder 216 . The collar 228 has a pair of tie rod pins 230 and 232 . Bushings 234 and 236 rotate about tie rod pins 230 and 232 , forming pivots. Bushings 234 and 236 are connected to and may be integrally formed with the rear ends of tie rods 238 and 240 . The front ends of tie rods 238 and 240 are connected to the front retaining plate 222 . It is understood that pins 230 and 232 may be located either on the injector front face 23 or on the exterior of jacket cylinder 216 .
To open the pressure jacket 212 , the tie rods 238 and 240 , and front retaining plate 222 are pivoted about the pins 230 and 232 by bushings 234 and 236 , which allow the syringe 214 to be inserted into the front end 218 of the jacket cylinder 216 . The front plate 222 and the rods 238 and 240 are then pivoted back into place to retain syringe 214 . It is understood that an alternative to this embodiment may include a front plate 222 formed by two halves each connected to a rod 238 and 240 such that each halve of the front plate 222 is pivoted into place to retain syringe 214 . The advantages relating to the first embodiment, as discussed above, are also realized by this embodiment.
FIG. 16 shows a fluid injector indicated generally at 250 having a pressure jacket 252 of a “caulking gun” type. Like the embodiments already described, the pressure jacket 252 , when assembled, permits a piston (not shown) housed within an injector head 20 to apply forward force to a plunger (not shown) within a hollow body of a syringe 254 , thereby forcing fluid from a front connector end 256 thereof. The pressure jacket 252 has a jacket cylinder 258 which may be made of clear plastic. The jacket cylinder 258 may be rotated about pins 260 and 262 (the last shown in phantom), which are rotatably attached to the front face 264 of the injector head 20 . Front face 264 is curved or slanted which allows cylinder 258 to pivot about pins 260 and 262 . Cylinder 258 has an open front end 265 by which the syringe 254 may be loaded or removed.
Attached to the injector head 20 is the rear end of an elongated arm 266 which is disposed in parallel to the longitudinal axis of syringe 254 when the latter is loaded into pressure jacket 252 and is ready for an injection operation. A retaining wall 268 is orthogonally attached to the front end of arm 266 . The retaining wall 268 has an internal surface 270 which is generally spherical or conical in shape so as to mate with an external spherical or conical surface of a syringe transition region 272 located between a syringe cylindrical body 274 and syringe tip 256 . Retaining wall 268 has an upwardly open slot 276 for the insertion of the neck 256 of the syringe 254 when the pressure jacket cylinder 258 is moved to a closed position, as shown in FIG. 17A . The slot 276 is cut in the same direction as the direction of articulation of the pivoting pressure jacket 252 .
As shown in FIG. 16 , cylinder 258 of pressure jacket 252 is pivoted to an open position to allow the loading or removal of the syringe 254 into the open end 265 of the cylinder 258 . The cylinder 258 is then pivoted back to rest against the arm 266 and the syringe neck 256 is lowered into the slot 276 of the retaining wall 268 . The advantages discussed above are also realized by this embodiment.
FIG. 17B shows an alternative embodiment to that shown in FIG. 17A . A prong 277 attached to cylinder 258 is provided for engaging slot 276 of retaining wall 268 when the pressure jacket 252 is in the closed position so as to further secure syringe 254 within pressure jacket 252 .
FIGS. 18 and 19 show the final embodiment of the present invention which is a fluid injector 280 having a pressure jacket 282 of a “slideable canopy” type for receiving and retaining a syringe 284 . The pressure jacket 282 has a canopy 286 that has an open front end 288 and an open rear end 290 . Canopy 286 is slidably mounted on the injector head 20 . An opening 292 in the front plate 293 of injector head 20 allows the canopy 286 to be retracted within the injector head 20 . Canopy 286 is preferably made of clear plastic. Alternatively, canopy 286 may telescope into or over a fixed tube that extends from injector head 20 (not shown).
An arm 294 has a proximal or rear end mounted on the injector head 20 . The opposite, distal or front end of the arm 294 is orthogonally attached to a retaining wall 296 which has a slot 298 to allow placement of the neck 302 of the syringe 284 . In operation, the syringe 284 is placed on the arm 294 such that the neck 302 of syringe 284 is placed within the slot 298 of the retaining wall 296 . The retaining wall 296 has a conical shape to conform to the front of the syringe 284 . In order to hold the syringe 284 in place, the canopy 286 is moved along the arm 294 as by means of a channel 304 , as shown in FIG. 19 , formed in the interior surface 306 of the canopy 286 . This arrangement allows the canopy 286 to slide on the arm 294 from an open to a closed position or vice versa, allowing the removal or insertion of syringe 284 . The advantages discussed above are also realized by this embodiment.
The above-described embodiments are merely illustrative of the principles of this invention. Other arrangements and advantages may be devised by those skilled in the art without departing from the invention. The scope of the invention is indicated by the following claims, rather than by the foregoing description. All changes or modifications that fall within the meaning and range of equivalency of the claims are to be embraced within their scope. | An injector system includes a syringe and an injector. The syringe includes a body portion and a plunger movably disposed within the body portion. The injector includes a housing defining a front opening therein, a drive member extendible through the front opening of the housing for imparting motive force to the plunger disposed within the syringe, and a pressure jacket assembly associated with the housing for substantially enclosing the syringe during an injection procedure. The pressure jacket assembly includes a jacket cylinder having an open front end for receiving the syringe and a front member associated with the housing. The front member is pivotable between a closed position for retaining the syringe within the jacket cylinder and an open position for allowing the syringe to be inserted into and removed from the front end of the jacket cylinder. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to high sensitivity sensor devices and its related signal processing circuits to detect the gas, biomolecules, or biochemical agents. More specifically, this invention is related to sensor device comprising with at least one nano-chip for application in biomedical and industrial applications.
BACKGROUND OF THE INVENTION
[0002] A large benefit of this sensor according to this invention, is that there can be several on a single wafer. It is a device able to measure chemical agent concentrations at the part-per-billion (ppb) level and accurately determine the biomolecule agent and volume of biological cells present in human body. There is no device in the state-of-art, which allows concurrent detection of a chemical agent, biomolecule agent, and biological cell, all in a single system.
[0003] There are various kinds of sensor system. FIG. 1 shows a schematic representing the prior art of a sensor system 1 to detect biological cells, biomolecule agents or chemical agents (hereafter mentioned as specimen). The system I usually comprising with the sensor cell 2 , power supply 4 , detector 6 ) and analyzer 8 . The system 1 usually detects or senses by detecting the electrical signal 10 induced due to absorption of the specimen. Detector 6 will detect the output signal 10 and send to the analyzer 8 to analyze the concentration of the specimen.
[0004] Several techniques can be found as the prior art for detecting concentration of specimen (common term used hereafter separately for chemical, biomolecule agents, or biological cells). However, most of them are based on the standard electrical technique wherein only single specimen is considered to detect. In addition, most technique requires long time in detection and/or not highly sensitive. The following, as a point of reference, are some methods, which are already patented and described as biosensors, used for detection of biological cells.
[0005] Peeters, in U.S. Pat. No. 6,325,904, (issued on Dec. 4, 2001), discloses a nanosensor, using an array of electrodes at the atomic or nano scale (nanoelectrodes) level, formed by using specific receptors. Utilizing the level of current flow while specific biological cells attached determine the concentration. The drawbacks of such technique are: (i) requiring STM to position the receptor which time consuming fabricating such sensor, (ii) requiring specific nano-scale level gap in between electrodes containing receptor to conduct current, (iii) difficulties in measuring low current level (corresponding to low concentration) due to use of computer controlled technique, and (iv) requiring high power due to using of computer controlled signal processing.
[0006] Bornhop, et al., in U.S. Pat. No. 6,809,828, (issued Oct. 26, 2004), discloses an sensor system for detecting proteins or DNA. Concentration is estimated based on the fringe pattern, detected by the CCD camera in addition with laser beam analyzer. Fringe pattern is usually depending on the laser intensity and position of the CCD camera. The drawback of this technique are, (i) in accuracy in concentration measurement as fringe pattern is dependent on the laser intensity and position, (ii) difficulties in low level concentration measurement due to difficulties in finding small changes in fringe pattern, and (iii) complete system becoming bulky as CCD camera, position sensor, and laser beam analyzer are to be used.
[0007] Britton, Jr., et al., in U.S. Pat. No. 6,167,748, (issued Jan. 2, 2001). discloses a technique for detecting the glucose concentration in blood. Measurement of concentration is performed based on standard technique of measuring the changes in capacitance. Technique uses cantilever coated with the receptor for absorbing the glucose. Main drawbacks are. (i) inability to detect low level concentration as very low changes in the capacitive is difficult to measure, and (ii) difficulties of detection of different kind of biological cell at the same time as each cantilever require different coating. Similar detection techniques can also be found in other patents such as U.S. Pat. No. 6,856,125, of Kermani (issued Feb. 15, 2005), U.S. Pat. No. 5,798,031 Chariton et al., (issued Aug. 25, 1998), U.S. Pat. No. 5,264,103 of Yoshioka et. al., (issued Nov. 23, 1993), and U.S. Pat. No. 5,120,420 of Nankai et. al., (issued June 9 , 1992), in all of which capacitive techniques are used to detect the concentration, Chemical and biological sensors can be miniaturized using nanowires or carbon nanotubes. Continued advances in nanoscience and nanotechnology require tiny sensors and devices to analyze small sample sizes. The following is a discussion of the prior art in sensor fabrication.
[0008] After discussing the above issues pertaining to the state-of-art biosensors, chemical sensors, and biomolecule sensors, and methods of making them, we would now like to introduce a novel technique where multiple chemical agents can concurrently be detected in real time and the information can quickly be transmitted to a main station and displayed. It is small in size, so the end user may carry it anywhere to measure the biological cell volume, protein, and biomolecule cells in a medical science application and is also able to do concurrent real time detection of different kinds of chemical agents.
SUMMARY OF THE INVENTION
[0009] According to this current invention, it is an object to provide a sensor system comprising with a sensor more specifically relates to a novel nano-sensor. It is also object to provide the embodiments including novel methods, systems, devices, and apparatus for sensing one or more characteristics. One aspect of the present invention is a sensor, which is capable of distinguishing between different molecular structures in chemical agents at the same time. It is also capable of distinguishing between different types of biomolecule agents or biological cell concentrations. It is capable of detecting the concentration of different types of chemical agents, biomolecule agents, and biological cells.
[0010] This present sensor system is based on any type waveguide, including but not limited to: the slab waveguide, the ridge waveguide, or a dielectric materials structure based waveguide. Its bottom clad (hereafter mentioned as substrate) can be formed using an array of various dielectric materials, structured periodically, which can form the photonic-band-gap (PBG). In waveguide, the guided light usually suffers radiation loss due to weak optical confinement; this happens when the structure is not well optimized or the structural parameters are interrupted. The sensor structure is optimized for a fixed wavelength and is designed in such a way that the propagation loss is minimal. Alternatively, according to this invention, the sensor can also be designed to operate in broadband light operation. In that case, the waveguide for nano-chip can be designed to operate multi-mode of operation.
[0011] This sensor detects the concentration of gases (that exist in air) based on the change in the effective refractive index of the substrate caused when biomolecule gas/chemical agents fill the air (or receptor) spaces. The changes in the effective refractive index reduce the output optical power (measurable parameter). By comparing the output optical power with the reference input optical power, the proposed nanosensor can detect the biomolecule gas,/chemical agent concentration in ppb levels.
[0012] It is noted here that the type of chemical agent/gas can be specified by using a fixed receptor specifically made for absorbing said agent/gas. Also, the type of biomolecule agent or biological cell can be specified by using a fixed receptor to absorb the said biomolecule agent or biological cell. The concentration of the agent,/gas and the biomolecule agent, and the volume of biological cells can be ascertained by measuring the output optical power, which is a function of the change in effective refractive index and density. In this case, the detector will detect the presence of a chemical agent gas or a biomolecule agent or a biological cell. Then it will generate an electrical signal, which will be processed through a processing circuit. After the processing circuit, a digital monitoring system will display the actual concentration present via LED.
[0013] The materials used for the nanosensor and surrounding surfaces are selected based on their electrical and chemical properties. The PBG arrays may be included in a chamber, which can retain fluid for biological applications; another set of arrays can be used for chemical agents/gas detection. Several arrays may be used in a single chamber and several different chambers may be used in a single chip. Thus, one system may detect chemical agents/gas, biomolecule agents, and biological cells.
[0014] This proposed PBG based nanosensor array and chamber as attached should be separated from each other on a chip, so that each system works properly for each individual application. A Digital Signal Processing (DSP) function, Analog to Digital Converter (ADC), and microprocessor are provided to analyze signals from the nanosensors and/or do real time calculations of the accurate values obtained from the nanosensor.
[0015] In some other embodiments a communication setup is used in order to relay the output values long distances. This communication setup is included to analyze the real time sensing values remotely.
[0016] Further embodiments, forms, features, objects and advantages of the present invention will be apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The features and advantages of the present invention will become apparent from the following detailed description of the system, taken in conjunction with the accompanying drawings, wherein
[0018] FIG. 1 is a schematic of sensor system in prior art. FIG. 2 are the block diagrams representing the schematic of the sensor system for detecting the gas, bio-molecule, or biological cell concentration. FIG. 3A is a enlarged view of a nano-chip comprising with a waveguide based on photonic bandgap (or photonic crystal) structures having rectangular lattice, according to this invention, and FIG. 31 is a cross-section view across AA′ as shown in FIG. 3A .
[0019] FIG. 4 is a schematic diagram of a nano-chip comprising with a waveguide based on photonic bandgap (or photonic crystal) structures having triangular lattice according to this invention, and FIG. 4B is a cross-section view across BB′ as shown in FIG. 4A .
[0020] FIG. 5 is a schematic diagram of a nano-chip comprising with a waveguide based on photonic bandgap (or photonic crystal) structures having rectangular lattice, according to this invention, and FIG. 5B is a cross-section view across CC′ as shown in FIG. 5A where the PBG is rectangular in shape with holes and a slab waveguide is used.
[0021] FIG. 6 is a schematic diagram of a nano-chip comprising with a waveguide based on photonic bandgap (or photonic crystal) structures having defects and rectangular lattice, according to this invention, and FIG. 6B is a cross-section view across DD′ as shown in FIG. 6A .
[0022] FIG. 7 is a schematic diagram of a nano-chip comprising with a waveguide based on photonic bandgap (or photonic crystal) structures having defects, according to this invention,
[0023] FIG. 8 is schematic of interconnection between the nano-chip and its detector.
[0024] FIG. 9 is the block diagram representing an example of an electrical signal processing circuit to detect the specimen, according to this invention.
[0025] FIG. 10A is a schematic representing a integration circuit unit for signal pre-processing, a part of processing circuit, as shown in FIG. 9 , according to this invention, and FIGS. 10B and 10C are output signals at points A and B, shown in FIG. 10A .
[0026] FIG. 11A is a schematic representing a filter circuit unit, a part of signal post processing, according to this invention, and FIGS. 11B and 11C are output signals showing with capture points, with and without specimen absorption.
[0027] FIG. 12 is a schematic representing a read-out circuit used to store the reference signal,
[0028] FIG. 13 is a block diagrams representing monitoring unit according to this invention.
[0029] FIG. 14 is a schematic representing an alternative read-out circuit to store the reference signal.
[0030] FIG. 15 is a schematic showing an example of a complete sensor device for multiple specimens' detections according to this invention.
[0031] FIG. 16 is a schematic showing an example of a complete sensor device, packaged in small form-factor, according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof and in which is shown by way of illustration specific preferred embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention and it is to be understood that other embodiments may be utilized. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.
[0033] According to this current invention, it is our objective to provide a sensing device comprising with nanosensor and its signal processing circuit which can have the significantly high sensitivity. The sensor device detects the specimen concentration based on the principle of optics Using of the nano-sensor and signal processing circuit, according to this invention, high sensitivity can be achieved. Detection is mainly based on detecting the difference in intensity of optical signal obtained after specimen absorb in the receptor and converting to electrical signal and their arithmetic processing to achieve significant high sensitivity.
[0034] FIG. 2 shows a block diagram of the system according to this invention. In block diagram 22 , input optical signal 14 is generated from a laser 12 having a wavelength ranging from ultra-violet to infrared. The signal 14 will pass through the nano-chip 16 ( a, b, c, d, e ). For a unique and optimized design (with no presence of specimen or sample) intensity of output optical power 18 from the nano-chip 16 ( a, b, c, d, e ) can be same as that of input optical power 14 . This means that the coupling loss though the nano-chip is be zero. The presence of the specimen or sample inside of the nano-chip 16 ( a, b, c, d, e ) will cause a reduction in the output optical power 18 , detected by the detector 20 . The reduction in output optical power 18 , if any, is due to the change in the refractive index of the receptors with and without absorption of the specimen. The receptor is usually contained in the nanochip 16 ( a, b, c, d, e ), explained later in FIG. 3 . The detector 20 is used to convert the optical signal 1 8 into an electrical signal 26 and the said electrical signal 26 is processed through the processing circuit 28 , explained later in detail in FIGS. 9-1 3 . The resultant signals 29 ( a ) and 29 ( b ) from said processing circuit 28 is passed through digital signal processing circuit (DSP) 30 where related arithmetic function can be performed to monitor actual concentration of the specimen in real time. Details of the DSP circuits are provided in FIG. 13 .
[0035] According to this invention, the processing circuit can be made in hybrid using different functional chips or using single chip having all functions, and those can be fabricated from 350 nm or less geometry. The detector can be chosen based on the wavelength of the light to be used in the system 22 . For example, if the wavelength is selected in visible region, the silicon-detector can be used in system 22 . On the other hands, if the wavelength of near infrared is chosen, then the detector made from III-V compound semiconductor is required for having higher sensitivity.
[0036] According to this invention, the system 22 can be miniaturized into a very small package (e.g. less than 1 to 0.5 inches in dimension). The main advantage of the system 22 , according to this invention, is that only the power of output optical signal 18 needs to be known in order to ascertain the concentration. In system 22 ) very little power will be absorbed by the nano-chip and this is based on the percentage of the refractive index change. The system 22 has two parts: the first is a ‘detection part’ comprising of laser 12 , nano-chip 16 ( a, b, c, d, e ), and the detector 20 ; the second is an ‘analyzing part’, comprising of signal processing circuits 28 and 30 .
[0037] According to this invention, different nano-chips 16 ( a, b, c, d, e ) are explained in FIGS. 3 to 7 . FIG. 3A shows a schematic, representing the enlarge view of a nano-chip 16 a and FIG. 31 is the cross-sectional view of section AA″, as shown in FIG. 3A . According to this invention, the nano-chip 16 a can be made from photonic crystal comprising of dielectric rods 32 arranged periodically in hollow clad 33 (hereafter we define clad as a substrate with a refractive index ‘n sub ’) to form a photonic-band-gap (PBG) structure, having rectangular lattice 34 . The nano-chip 16 a has waveguide structure having core 35 having refractive index of ‘n core ,’ Each rod 32 has a radius of ‘r’ (from 0.1 μm to 0.3 μm or may be in different size depending on the design) and they are separated by a distance ‘a’ (known as pitch or lattice constant) 36 , which is equal to or greater than ‘2r’. Receptors 40 can be placed in-between the spaces of the rods 32 in hollow clad 33 .
[0038] Receptors 40 , shown in FIG. 3 (For example: ACh—Acetylcholine covers for nerve agents, AH—Aromatic Hydrocarbon, etc.) can be used inside the nano-chip 16 ( a, b, c, d, e ). Here, receptor 40 is used to detect the type of specimen and they absorb/interact with the respective specimen (e.g. biomolecule or chemical agents or biological cell) present in between the spaces of the dielectric rods.
[0039] Each rod 32 has a refractive index ‘n’ which can be either equal to ‘n core ’, or refractive index ‘n’ can be greater or less than the core refractive index n core ’, Optical signal input 14 to nano-chip 16 a is transmitted through the core 35 . Based on the absorption of the specimen (not shown here) by the receptor 40 located in the space between the rods 32 , the refractive index of the substrate ‘n sub ’ in combination with hollow clad 33 and receptor 40 is changed to ‘n eff ’, the effective refractive index, and as a result, the power output optical signal 18 is reduced. The concentration of the specimen can be determined by calculating the change of the refractive index of the receptors 40 after and before of absorption of the specimen and the changes in power of the optical signal 18 with respect to input optical signal 14 . Changes in power of optical signals between 14 and 18 can be determined by the power-factor, which is defined as the ratio of the output optical power over the input optical power. According to this invention, the main advantage is that by knowing the power factor, the changes in refractive index and also the concentration of the specimen can be determined. By calculating the power-factor, this proposed sensor would give the real-time concentration of the specimen.
[0040] Nano-chip 16 a used for system 22 is based on photonic-crystal and they are having different structures Two-dimensional (2-D) or three-dimensional (3-D) photonic crystal can be used to fabricate the nano-chip 16 a . In FIG. 3A , the photonic crystal is formed based on the dielectric rods 32 . Alternatively, the photonic crystal can be also made from holes, periodically arranged inside the dielectric materials
[0041] FIG. 4A shows a schematic, representing the enlarge view of an alternative nano-chip 16 b and FIG. 4B Is the cross-sectional view of section BB′, as shown in FIG. 4A , according to this invention wherein the same numerals in FIGS. 4A and 4B represent the same parts in FIGS BA and 3 B, so that repeated explanation is omitted here. Only difference in FIGS, 4 A and 4 B as compared with FIGS. 3A and 3B is that the photonic crystal is made from the dielectric rods 32 placed in hollow clad 33 , wherein the rods 32 is having the triangular lattice 44 .
[0042] FIG. 5A shows a schematic, representing the enlarge view of an alternative nano-chip 16 c and FIG. 5B is the cross-sectional view of section CC′, as shown in FIG. 5A , according to this invention, wherein the same numerals in FIGS. 5A and 5E represent the same parts in FIGS. 3A , 3 B 4 A, and 46 , so that repeated explanation is omitted here. The main difference in FIGS. 5A and 5B as compared with FIGS. 3A , 3 B, 4 A, and 4 B is that the photonic crystal is based on the holes 51 periodically arranged inside the slab acting as the clad 53 , wherein the holes 51 are filled up with the receptors 40 and also the holes 51 is having the rectangular shaped lattice 50 . According to this invention, optical signal 14 Is guided through the slab-type waveguide 48 located inside slab (or clad) 53 . Each hole 51 in nano-chip 16 c has a radius of ‘r’ and they are separated by a distance ‘a’ (also known as lattice constant) 52 . Inside each hole, receptors 40 are present to absorb/interact with the specimen/sample. 54 shows the cross sectional view of this nano-chip 16 c . The nano-chip can also be designed by making holes in a triangular shape. Specification of the radii of the holes ‘t’ and lattice constant ‘a’ 52 will be optimized depending on the size of the nano-chip 16 c.
[0043] FIG. 6A shows a schematic, representing the enlarge view of an alternative nano-chip 16 d and FIG. 6B is the cross-sectional view of section DD′, as shown in FIG. 6A , according to this invention, wherein the same numerals in FIGS. 6A and 6B represent the same parts in FIGS. 3A , 3 B 4 A, 4 B, 5 A, and 5 B, so that repeated explanation is omitted here. The main difference in FIGS. 6A and 6B as compared with FIGS. 5A and 5B is that the nano-chip 16 d is also based on photonic crystal, but comprising with defects 56 in the holes periodically structure in the core 57 . “Defects in the holes,” means that the diameter of some holes is bigger than the diameter of the ‘regular’ holes, all structured periodically. According to this invention, the defects 56 can also be filled with the receptor 40 and they can be created either using of holes 56 , as shown in FIGS. 6A and 6B , or using of the solid rods having specific radius (not shown here).
[0044] FIG. 7 shows a schematic, representing the enlarge view of an alternative nano-chip 16 e , according to this invention, wherein the same numerals in FIG. 7 represent the same parts in FIGS. GA and 6 B, so that repeated explanation is omitted here. The main difference in FIG. 7 as compared with FIGS. 6A and 6B is that the nano-chip 16 e is based on the solid slab 58 acting as the clad and the core 59 to guide the optical signal 14 , comprises with holes as defects 60 arranged periodically inside core 59 forming photonic band gap structure. As mentioned earlier, any type of specimen can be detected and their concentration can be known after processing the output optical signal 18 from nanochip. Type and concentration of any specimen such as gases, biomolecules, or any biological cells can be detected by making them to absorb on corresponding receptor 40 to be used in the holes 60 .
[0045] The nano-chip 16 ( a, b, c, d , and e ), can be fabricated using dielectrics, semiconductor, or polymer materials. The dielectric material can cover all kind of materials having dielectric or optical properties (e.g. refractive index), such as glass, quartz, polymer etc. According to this invention, alternatively, the nano-chip can also be fabricated from semiconductor materials, such as Si, GaCs, InP, GaN, SiC, diamond, graphite etc. which can be fabricated using standard's IC fabrication technology. This nano-chip itself can be from rigid or flexible substrate.
[0046] The nano-chip can be fabricated by standard dry or wet etching to form the holes or rods embedded inside the solid or hollow substrate. Alternatively, this can also be fabricated using spin-coated polymer or preformed polymer The low shrinkage in polymerization and the transparency of the synthesized polyurethane can also be used in fabrication of infiltrated inverse opal elastomeric photonic-crystal structures for the nano-chip according to this invention. The nano-chip 16 ( a, b, c, d , and e ) can have high-symmetry cross-sections and can allow integrated optical networks to be formed by only placing either the rods in air or air cylinders in the dielectric. The nano-chip 16 can also be fabricated in multiple layers by stacking the slabs on top of one another, separating them with a separator. According to this invention, the nano-chip 16 ( a, b, c, d , and e ) and surrounding circuitry can be made into the single chips using today's IC process technology.
[0047] The specific specimen can be detected using the nanochip with specific receptor. For example, Avidin Biotin which is the most common uses as a receptor for glycoconjugate analysis and DNA detection systems, can be used also as the receptor 40 in the nanochip 16 ( a,b,c,d , and e ). Single receptor agent or solution linked with other molecule acting as the receptor (for the specific specimen) can also be used as receptor 40 . For example, Dimethylsulfoxide (DMSO) solution containing 4 mg/ml of the heterobifunctional linker molecule succinimidyl-6-hexanoate (biotinamido) for a 1 hour at room temperature and the resultant receptor can be used as receptor 40 for DNA detection. According to this invention, the receptor 40 can be gel-type, solid, or solution based.
[0048] A derivation is given here for the generalized analytical equation for the nanochip described earlier in FIGS. 3 to 7 . This derivation helps to understand the insight of this current invention for high sensitivity sensor device, For simplicity in derivation, nano-chip, as shown in FIG. 7 , consisting of a ridge waveguide in the core formed by periodically structured PBG, is considered as the example and this nanochip can be considered as a linear system. The waveguide structure is considered to be optimized for providing almost same output optical power 18 for the specific wavelength of the optical input 14 . By knowing the output optical power the concentration of the specimen (e.g. biological cells, industrial gas, or biological cell agents) can be detected. According to this current invention, nano-chip is considered to be formed based on the 2-D photonic crystals. Related generalized equations, required for determining specimen concentration is described herewith. Noted here that type of specimen can be known from the specific receptor 40 , as explained earlier. The specific receptor is used for specific specific link or bond.
[0049] According to this invention, the waveguide structure is to be designed in such a way that maximum optical power for optical signal 18 is achieved (or very to optical power of input optical signal 14 ), and that condition (or optical power) can be considered as the reference (i.e. with specimen present) in the holes. The symbol used in derivation is summarized in Table I.
[0000]
TABLE I
Description of the symbols used in derivation
Parameter
Description
n cref
Reference refractive index of the core
n ceff
Effective (new) refractive index of the core
N
Gladstone-Dale constant
P in
Input optical Power
P out
Output Optical Power
Power Factor = P out /P in
Ratio of output optical power and input optical
power
ρ ref
Reference density (air or filled with receptor)
ρ new
New density after specimen absorbed
Δρ
Change in density
[0050] For linear system with ridge waveguide, Power Factor, ratio of output optical power (P out) , to input optical power can be derived as follows:
[0000]
Power
Factor
=
P
core
P
in
=
1
-
n
cref
2
-
n
ceff
2
n
cref
2
-
n
clad
2
(
1
a
)
[0000] Where, n cref is the reference refractive index of the core with optimized waveguide. n ceff is the effective refractive index of the core and n clad is the refractive index of the clad. From Eq. (1a), coupling loss can be written as
[0000] Coupling Loss =1−Power Factor (1b)
Where, Coupling Loss is,
[0051]
Coupling
Loss
=
n
cref
2
-
n
ceff
2
n
cref
2
-
n
clad
2
(
1
c
)
[0052] From Eq. (1a), relationship between Power Factor and density of the gas can be derived. The relationship between n cref ; reference core refractive index (with no gas condition) and ρ ref , reference density of receptor can be expressed by using of Gladstone-Dale relationship,
[0000] n cref −=ρ ref X N (2)
[0000] where, N is the Gladstone-Dale constant
[0053] As mentioned earlier, after sensing the gas, the density of the receptor ρ new , after absorbing the gas which changes the effective refractive index of the substrate, nceff (mentioned as new core effective refractive index). Similarly, nceff relates with ρ new as,
[0000] n ceff −1ρ new X N (3)
[0054] From Eqs. (2) and (3), this following expression can be derived.
[0000]
n
cref
-
1
n
ceff
-
1
=
ρ
ref
X
N
ρ
eff
X
N
(
4
)
[0055] From Eq. (4) n ceff expression can be derived as.
[0000]
n
ceff
=
1
+
(
n
cref
-
1
)
ρ
ref
ρ
new
(
4
a
)
[0056] After substituting Eq. (4a) into Eq. (1a), we get the new density as follows;
[0000]
ρ
new
=
[
n
cref
2
-
(
1
-
Power
Factor
)
(
n
cref
2
-
n
clad
2
)
-
1
]
ρ
ref
(
n
cref
-
1
)
(
5
)
[0057] Changes in density ρ can be expressed as,
[0000] Δρ=ρ new −ρ ref (6)
[0058] Concentration of the specific gas (considered here only for the biomolecule or industrial gas) in ppm, which is a function of the molecular weight and Δρ, and ppm can be written as
[0000]
ppm
=
Δ
ρ
×
24.45
Molecular
Weight
(
7
)
[0059] After substituting Eq. (6) into Eq. (7), the concentration of gas in Ace can be expressed as:
[0000]
ppm
=
(
ρ
new
-
ρ
ref
)
×
24.45
Molecular
Weight
(
8
)
[0060] Now substitute value of ρ new in Eq. (8) and we can derive ppm, which is
[0000]
ppm
=
(
[
n
cref
2
-
(
1
-
Power
Factor
)
(
n
cref
2
-
n
clad
2
)
-
1
]
ρ
ref
(
n
cref
-
1
)
Molecular
Weight
-
ρ
ref
)
×
24.45
(
9
)
[0061] According to this invention, by knowing the power factor (which is ratio of power of optical out 18 to power of optical in 12 to and from the nanochip 16 , respectively to the optical input), and appropriate arithmetic signal processing, the concentration of the specimen can be known. According to this invention, the gas is considered, it can be also be used for biomolecule gas, or biomolecule cells, if corresponding receptor is used. From FIGS. 8 to 14 , the signal processing for detecting small change in power factor are given. FIGS. 15 and 16 explain the sensor device according to this invention.
[0062] FIG. 8 shows a schematic representing the nano-chip and its detection block diagram according to this invention wherein same numerals represents the similar parts shown in FIGS. 2 , 3 , 4 , 5 , 6 , and 7 , so that similar explanation is omitted here. In FIG. 8 , the optical signal 18 from nano-chip 16 ( a, b, c, d , or e ) is detected by the (optical) detector 61 to convert into corresponding electrical signal 26 . The detector 61 should be selected based on the wavelength of the light used in the nano-chip. For example, for visible wavelength, Si-based photodetector can be used which can provide quantum efficiency close to 100% over visible wavelength. For Near infrared wavelength, III-V compound semiconductor based detector can be used.
[0063] Photodiodes can be used in either zero bias or reverse bias, In zero bias, light failing on the diode causes a voltage to develop across the device, which leads to current flowing in the forward bias direction. Diodes usually have extremely high resistance when reverse biased. This resistance is reduced when light of an appropriate wavelength incident onto the junction. Hence, a reverse biased diode can be used to generate the photo current. Circuit with reverse-biased detector is more sensitive to light than one with zero-biased detector.
[0064] The detector can be p-n junction based detector or avalanche photodiode (APD) detector, According to this invention; both type photodetector (p-n or APD) can be used. Only difference is there operational voltage. For example, APD requires high voltage and on the other hands, p-n junction requires low voltage. By using of APD, according to this invention, single photon level difference in optical power between input to nano-chip and output from nano-chip can be detected.
[0065] FIG. 9 shows the signal processing block diagrams according to this invention wherein same numerals represents the similar parts shown in FIG. 8 , so that similar explanation is omitted here. According to this invention, Electrical-processing circuit 28 , shown in FIG. 9 , comprises with electrical signal integration circuit 66 , filtering and sample-counter circuit 68 to remove electrical noise, and a read-out circuit 70 to store the data Each of these blocks 66 , 68 , and 70 are explained in details in FIGS. 10 , 11 and 12 . The electrical signal outputs from this signal-processing unit 28 are reference signal 29 ( a ) and signal 29 ( b ) after specimen absorbed by the nano-chip. In absence of specimen absorption, the electrical signals 29 ( a ) and 29 ( b ) are the same.
[0066] FIG. 10A shows the integrated circuit block in details, of the block diagrams, as shown in FIG. 9 , and FIGS. 10 and 10C are the waveforms of point A and B, as shown in FIG. 10A , according to this invention wherein same numerals represent the similar parts shown in FIGS. 8 and 9 , so that similar explanation is omitted here. The electrical integration circuit 66 means as shown in FIG. 10 is a part of the electrical processing circuits 28 . According to this invention, electrical integration circuit 66 means comprises with transimpedance amplifier (TIA) 72 , two sets of switches 77 and 78 , a an analog memory 74 to store the reference value as reference voltage 76 , and two sets of integrator circuits 73 ( a ) and 79 ( a ), two sets of comparators 73 ( b ) and 79 ( b ), and one differentiator 82 .
[0067] According to this invention, the signal 26 input to TIA 72 of the integrated circuit 66 to have the proportional voltage output V in . Initially, the switch S 1 77 is on and switch S 2 78 is off. While the Switch S 1 77 is on, the proportional voltage output V in is directly feed through the analog memory 74 to store the initial voltage as the reference voltage 76 (output of analog memory 74 ). Noted here that the reference voltage V ref can be either same or greater than that the proportional voltage output V in . The reference voltage V ref is integrated by the integrator 73 ( a ) and its output is directly feed to the comparator 73 ( b ) whose other input is set to V ref . While the integrator 73 ( a ) output is reached to V ref , the comparator 73 ( b ) output will reset the integrator 73 ( a ). The resultant waveform 63 from comparator 73 ( b ) is saw-tooth type waveforms as shown in FIG. 10B for the point A of FIG. 10A The resultant waveform 63 is acted as the output of V ref and mentioned here as V out1 , while there is no absorption of the specimen in the nano-chip explained earlier. As soon as integration for the pre-desired cycle (explained later in FIG. 10B ) is completed, the switch S 1 77 is turned to OFF and at the same time S 2 78 is turned on and the output from the TIA 72 is directly feed to the differentiator 82 whose other input is output 76 from Analog memory 74 . The differences 80 , output from the differentiator 82 is similarly feed to the integrator 79 ( a ), whose output is again feed to the comparator 79 ( b ). Noted here that other input to the comparator 79 ( b ) is V ref . The resultant waveform 65 is also saw-tooth like waveform (mentioned as V out2 ), as shown in FIG. 10C (at point B) and it can be generated by the reset 81 , as mentioned earlier. The differences between two sets of circuits as shown in FIG. 10A after and before switch S 1 77 ON and OFF is that they process the signals without and specimen absorption, respectively, According to this invention, the output waveforms 63 and 65 comprises with stream of saw-tooth like waveforms 83 ( a ) and 83 ( b ) which can be processed for captured explained later in FIG. 12 .
[0068] FIG. 11A is an example of the schematic showing the Filter-circuit of processing circuits 28 blocks shown in FIG. 9 , according to this invention wherein the similar numerals represent the same parts as shown in FIGS. 10A , 10 B, and 10 C. The filter & sample-counter means block 68 is a part of the electrical processing circuit 28 and comprises with an common clock signal 84 , two sets of filters 85 ( a ) and 85 ( b ), and two sets of sample counters 86 ( a ) and 86 ( b ). Two sets are used to process the outputs 63 and 65 separately. The filter & sample-counter block 68 is used to convert the waveforms achieved from the reference value 63 (with no specimen present) and new value 6 S (with specimen present). In FIG. 11A , “Filter” blocks 85 ( a ) and 85 ( b ) are used to avoid glitches of the signals generated from the integrated circuit, explained in FIG. 10A . The “Sampler & Counter” blocks 86 ( a ) and 86 ( b ) can be used to compare the values of “Filter” blocks 85 ( a ) and 85 ( b ) to the values from the integrated circuit 66 , in FIG. 10A .
[0069] FIGS 11 B and 11 C show the output signals 63 and 65 with capture time at different points for example at 87 ( a ) and 87 ( b ). These two signals 63 and 65 will provide us with two saw-tooth based waveforms with different slopes; represent the output signal amplitude (not shown here). They can have the different time intervals for example. t 1 , t 2 , t 3 - - - t n , total of ‘tn’ for output signal 63 (no specimen absorption) and t 1 , t 2 , - - - t n , total of the same time ‘tn’ for output signal 65 (with specimen absorption) for analysis. Several techniques can be used to analyze the waveforms to detect the concentration of the specimen absorbed. According to this invention, certain capture point 87 ( a ) and 87 ( b ) in waveforms 63 and 65 , respectively, can be used at different intervals and different amplitude to avoid the noise, if any, presence in the signals. The output signals from sampler and counter circuits 86 ( a ) and 86 ( b ) after capturing can be the stream of the digital signals 88 as shown FIG. 11B , and 88 and 29 ( b ) as shown in FIG. 11A . The corresponding analog signals output from filter circuits 85 ( a ) and 85 ( b ) is an integrated signals 90 ( a ) and 90 ( b ), respectively.
[0070] FIG. 12 is the schematic showing an example of read-out circuit, a part of processing circuits 28 blocks shown in FIG. 9 , according to this invention wherein the similar numerals represent the same parts as shown in FIGS. 10A and 11A . The read-out circuit means 70 shown in FIG. 12 averages the waveforms and then stores in the memory. Signals 88 received for reference value, will be stored into a read-out circuit 70 , shown in FIG. 12 , which is a part of the electrical processing circuit 28 , as shown in FIG. 9 . Read-out circuit 70 could be one for each of the reference value or specimen value to store (not shown here). Alternatively, one read-out circuit for reference value store can also be used which is used in FIG. 9 as for example. Any number of bits can be used for read-out circuit. As for example, a 12-bit circuit is considered in FIG. 12 . This read-out circuit 70 can be fabricated utilizing standard CMOS process technology. For example, this read-out circuit can be fabricating with standard 350 nm, 3.3 volt, and thin-oxide digital CMOS process geometry or less. The data will come to each bit ( 1 - 12 ) 91 of pass-gate transistor for storage. After the data is stored in the transistor, read-out port 92 will give us the stored values as outputs 29 ( a ) for the reference value 88 . This circuit will have a ‘reset’ line 93 , so that we can flush out the older data, if necessary. This circuit can be single transistor CMOS, p and n-channel transistor CMOS, or capacitive based circuit, which can be fabricated using conventional CMOS technology.
[0071] FIG. 13 is the schematics showing the block diagrams of the monitoring system, according to the invention, wherein the same numerals represent the same parts, explained in FIGS. 9 , 10 A, 11 A, and 12 , so that repeated explanation is omitted here. This monitoring system 30 comprise of several blocks such as. “Divider for (1−Power Factor)” block 94 , Digital Signal Processing (DSP) unit 96 , Digital to Analog Conversion (DAC) block 100 , Radio Frequency (RF) Transceiver block 102 , Concentration Display block 104 and remote Station block 106 to monitor the analyzed value. The RF unit 102 is for remotely monitor the specimen.
[0072] The signals 29 ( a ) and 29 ( b ) from the processing circuit unit 28 feed to the divider circuit 94 to calculate (1−power factor), as shown in EQ. 9, and its resultant output signal 95 feeds to the n-bit digital signal-processing unit 96 , where n is the number of the bit. Other inputs to DSP unit are known parameters such as reference concentration (mentioned as background concentration of the specimen, if any), other required refractive indices related to the nano-chips, explained earlier. The DSP unit 96 is commercially available from various vendors or the unit can be fabricated with standard CMOS technology, depending on the specification criterion. This DSP unit 96 includes a system controller for coordination. The system controller of the DSP unit 96 may be chosen to be an n-bit RISC/CISC-type processor, which is commercially available by various vendors such as Texas Instrument, INtel. The processor and system controller may share a memory for program and data storage
[0073] Output signals of the DSP block 96 , which are digital signals, can be converted into analog by using the “DAC” block 100 . Output signals from the “DAC” block 100 can be transmitted through the “RF Transceiver” block 102 . Signals from block 102 may be wirelessly monitored from the remote “Station” block 106 by using standard wireless protocol such as BLUETOOTH, 802.11a/b/g protocol or other proprietary protocols. The system can be embed with the standard (display) based monitoring unit 104 by feeding a part of DSP signal to the monitoring unit 104 to monitor in real time the concentration of the specimen. According to this invention, whole processing unit can be made into a single chip and can be fabricated using standard IC technology. Alternatively, whole processing unit can be also build hybridly.
[0074] According to this invention, FIGS. 9 to 13 explain the signal-processing unit to monitor the specimen concentration. This is given for example only, Various signal processing ways (utilizing similar idea as shown in FIGS. 9-13 ) can be used to monitor the specimen concentration, For example, alternatively, single switch (single pole double through) can be used instead of using two switches (S 1 and S 2 ), explained in FIG. 10A . In addition, alternatively analog divider (not shown here) can also be used instead of using digital divider 94 , (shown in FIG. 13 ). Additional analog to digital converter may require converting the resultant analog signal after dividing by divider (not shown here).
[0075] According to this current invention, any microprocessor, FPGA, or ASIC circuit can be used instead of DSP to perform the DSP functionality. These are available from the commercial vendors, For example, microprocessor can be obtained from Intel, FPGA from Actel and Xilinx, and ASIC circuit could be custom designed for required functionality, and it can be off-shore design and manufacturing.
[0076] According to this invention, alternatively the read-out memory circuit can be made based on capacitive load. FIG. 14 shows a schematic diagram of an alternative read-out circuit, wherein same numerals represent the same parts as shown in FIG. 12 , so that repeated explanation is omitted here. The difference of read-out circuit as shown in FIG. 12 is that read-out circuit 118 in FIG. 14 is based on capacitive load 110 and a 1 to 1 switch 112 . The advantages of using this circuit are: low area and low power. At least one 1 to 1 switch 112 and at least one capacitive load 110 can be used for single bit of memory Input signal 88 can be stored by each capacitor 110 and the stored values can be as output signal 29 ( a ) as a reference (initial) value.
[0077] According to this invention, the signal processing unit and the monitoring units both as shown in FIGS. 9 to 14 can be fabricated monolithically into a single chip. Standard Si-CMOS technology can be used for fabricating the signal processing and monitoring chip either in single chip form or multiple chips. The geometry of the silicon-CMOS technology can be ranged from 0.35 μm 20 nm or less. The divider 94 can be designed in different ways for example carry-save, Boolean, binary type or synthesis library specific type, depending on the desired performance and area.
[0078] FIG. 15 shows a schematic of the nano-sensing detection system unit according to this invention wherein the same numerals represent the same parts as explained in FIGS. 2 to 14 , so that repeated explanation is omitted here. The sensing means 120 comprises with at least one laser 12 connecting with electrical driver 122 through electrical connection 124 , splitter 126 , nano-chip 16 ( a, b, c, d, e ), at least one detector 20 , signal processing unit 130 , connecting with the external power supplies through connection 132 , and a common carrier substrate 134 . According to this invention, light 14 having fixed wavelength is made to couple to the 1 xk splitter 126 (where k is the number of splitters which is at least one) to split the intesity of light 14 into k numbers and made to pass through the nano-sensor 16 ( a,b, c, d and e ) Alternatively, according to this invention, the splitter and nano-chip can also be designed to operate in broadband light. In that case, the waveguide is to be multi-mode to operate in broad spectrum of light.
[0079] The splitter can be designed based on the photonics crystals having rod or holes, arranged periodically to made photonic band gap structure. Both splitter and nano-chips can have the same photonic band gap structure or different, and they can be fabricated on the common substrate 136 . Alternatively, the splitter can be designed based on the homogeneous (solid) substrate (without photonics crystal) and the nano-chip can be based on photonic crystal base. Again, they can be fabricated onto the common substrate 136 , or both splitter 126 and nanochip 16 ( a, b, c, d and e ) can be fabricated in separate substrates, and afterwards hybridly packaged onto the common substrate (not shown here). To detect different types of specimens. For example different bio-molecules, different types of receptors can be used in the nanochips. The outputs from each nanochip are made to incident to the detector 20 to convert optical signal into corresponding electrical signals (not shown here). The electrical signal is processed by the IC 130 to determine the concentration of each specimen. The electrical IC 130 can be single chip or multiple chip based on the circuit means, as explained previously from FIGS. 9 to 14 . All electrical components can be made into the single chip. Optical chip comprising with the splitter and the waveguide, and single chip can be packaged on the common substrate 134 to make the small package of dimension below 1″×1″×0.5″(W×L×H) A key feature of this system 120 is that multiple sensors can be fabricated on a single wafer 136 . Utilizing the multiple sensor help to detect multiple specimens at the same time. For example, one sensor can detect chemical agent sensor, the second can be a biomolecule sensor, and the third can be a biological cell detector, and so on. Other example could be a single sensor unit can detect different gases or different types of bio-molecules simultaneously in real time, and any combination thereof.
[0080] FIG. 16 is a schematic representing the small form-factor sensor system, according to this invention, wherein the same numerals represent the same parts, as explained in FIGS. 2 to 7 and 15 , so that repeated explanation is omitted here. The small form factor sensor system 138 comprises with two parts wherein first part is a passive section of the system and comprises with sample handler 140 , two waveguides 142 ( a ) and 142 ( b ) for incoming and outgoing optical signals 14 and 18 , respectively, and a common substrate 144 , and the second part is an active section of the system and it comprises with carrier substrate 146 , laser 12 , laser driver 122 , detector 20 , preamplifier 148 , signal processing integrator circuit 150 , and electrical connection 152 .
[0081] According to this invention, specimen 154 ( a ) is made to pass through the inlet 156 ( a ) of the specimen handler 140 and pass out the specimen 154 ( b ) from the outlet 156 ( b ) The passive section of the sensor system 138 is designed in a way that a portion of its internal section is made to expose to the nanochip 16 to make enough contact of the specimen while passing through this specimen handler 140 . The optical signal 14 is made to propagate through the nanochip 16 via waveguides 142 ( a ) and 142 ( b ) used for guiding the signals on the passive section of nano-chip 16 . For simplicity in handling and also for the purpose of reusage of the sensor system for long time, the passive section can be a separate section apart from the active sections and can be replaceable and easily stackable to the active section. Alternatively, both passive and active sections could be single section attached permanently. In FIG. 16 , an example of a small form-factor sensor system containing a single nano-chip 16 is shown for simplicity in drawing. This can cover also for m-number of sensors containing in passive section of the sensor system (not shown here) for m-number of specimens detection. In that case, at least one specimen handler can be used and each nanochip can have with same or different receptors.
[0082] According to this invention, the active section of the sensor system 138 has signal transmitting section, OE (optical to electrical conversion), and signal processing units (not shown separately). Transmitting section comprises with the laser 12 and driver 122 , OE unit comprises with detector 20 and preamplifier 148 , and signal processing unit comprising with a chip 150 for further signal processing and monitoring. The signal processing chip 150 contains preprocessing unit, post processing, and monitoring units, explained earlier in FIGS. 9 to 14 . Transmitting, OE, and signal processing units are placed on the carrier substrate 146 and they can be hybridly integrated on carrier substrate 146 or fabricated monolithically as single chip, The carrier substrate 146 has the groove 158 , housed appropriate to the passive section holding. Under operation, both waveguides 142 ( a ) and 142 ( b ) are coupled to the laser 12 and detector 20 , respectively to transmit and receive the signals 14 and 18 to and away from the nano-chip Source (e.g. laser diode or light emitting diode) 12 with specific wavelength or ranges of wavelength, appropriate to the refractive index of the nanochip 16 can be used and it can be electrically drived by the driver circuit 122 . The OE section has the detector 20 , having high sensitivity to the source light, can be used to convert the optical signal to electrical. The detector signal is amplified by the preamplifier 148 and processed by the chip 150 for post processing and monitoring the concentration of the specimen. The electrical connection 152 connects all electrical components to the external power supplies (not shown here). According to this invention, transmitter section, OE section, and signal processing section can be fabricated into a single chip utilizing the standard IC technology. Alternatively, each component in active section could be a separate component, hybridly integrated on the substrate (e.g. 146 ).
[0083] According to this invention, the nano-chip described from FIGS. 3 to 7 and FIGS. 14 and 15 , can be fabricated using any kind of substrates which cover, semiconductor, polymer, ceramic, exhibiting optical properties. Semiconductor cover Si, III-V or II-VI based compound semiconductors The rods or holes, periodically arranged inside substrate and/or in waveguide to form the photonic crystal structure, can be made by utilizing standard wet or dry-etching process frequently using in IC manufacturing. Alternatively, electrochemical or photo-electro-chemical etching process can also be used to create the holes inside the substrate, According to this, alternatively air-spheres inside can also be used forming photonic crystal based nano-chip, and they can be made by conventional electrochemical process. For example, large scale of air-spheres in silicon, strong variation of the diameter with a length of the lattice constant can be made using photo-electro-chemical process for crating photonic crystal structure for the nanochip. Alternatively, porous material (semiconductor, insulator, polymer, or metal) having pores can also be used for fabricating nanochip. The waveguide and the substrate carrying the waveguide could be same kind of material or different material. Alternatively, nanochip can also be made from the combination of the nanoparticles deposited or synthesized on the substrate arranged in periodically.
[0084] Alternatively, according to this invention, the nanometer sized rods, wire or tubes can also be made from the carbon type materials (semiconductor, insulators, or metal like performances) such as carbon nano-tubes, which could be single, or multiple layered. They can be made using standard growth process for example, MOCVD, MBE, or standard epitaxial growth. According to this invention, the self-assembled process can also be used to make wires, rods, or tubes and their related pn-junction to increase the junction area. These tubes can be grown on the semiconductors (under same group or others), polymers, or insulator. Alternatively, according to this invention, these rods, wire, or tubes, can be transferred to the foreign substrate or to the layer of foreign substrate acting as a common substrate for waveguide for nano-chip The foreign substrate or the layer of material can be any semiconductor such as Si, Ge, InP, GaAs, CaN) ZnS, CdTe, CdS, ZnCdcTe, HgCdTe, etc. The substrate can cover also all kinds of polymers or ceramics such as AIN, Silicon-oxide etc. The material can be conductive or non-conductive.
[0085] According to this invention, different substrates can be used for making sensing device as shown in FIGS. 14 and 15 . For example, carrier substrate 134 and common substrate 136 for the splitter and nanochip can be same or both can be different substrate, in hybrid integrated together. Alternatively, the splitter used for the multiple nanochip can be fabricated from the separate substrate and integrated on the carrier substrate 134 . As a carrier substrate, substrate made of any kind of material such as semiconductor, ceramic, metal, or polymer can be used.
[0086] According to this invention, concentration measurement by determining the power factor is explained here. This nanochip based on photonics crystal can also detect the concentration by other methods, such as measuring the fringe-pattern by using of CCD camera and laser beam analyzer, or absorption spectrum of the optical output by spectroscopy. The concentration and type of the specimen can be known by comparing with the reference pattern for the case fringe pattern technique, and by comparing intensity and chemical absorption for the case of absorption spectrum technique.
[0087] Whereas many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that the particular embodiments shown and described by way of illustration are in no way intended to be considered limiting. Therefore, reference to the details of the preferred embodiments is not intended to limit their scope. Although the invention has been described with respect to specific embodiment for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modification and alternative constructions that may be occurred to one skilled in the art which fairly fall within the basic teaching here is set forth.
[0088] Although the invention has been described with respect to specific embodiment for complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modification and alternative constructions that may be occurred to one skilled in the art which fairly fall within the basic teaching here is set forth.
[0089] The present invention is expected to be found practically use in the industrial, commercial, and bio-medical application. Using of such sensor device will help to detect very low level concentration (in ppb level) of gases, requiring in industrial application. Example of various gases detection using proposed invention can be found in (Sengupta, Rabi and Dutta, A., ‘Novel nanosensor for biomedical and industrial applications’, SPIE Proceed. 6008, Paper No. 60080T, November 2005). This sensor devices is not limited to use in chemical gas, bio-molecule gas only, this can also be used in biological cell detection and their low level concentration measurement. The main advantages of this invention are that detection and concentration of multiple specimens at a real time can be possible. Multiple specimens can be multiple gases, multiple bio-molecules, or multiple biological cells, or their combinations. | A sensing device able to do concurrent real time detection of different kinds of chemical, biomolecule agents, or biological cells and their respective concentrations using optical principles. The sensing system can be produced at a low cost (below $1.00) and in a small size (˜1 cm 3 ). The novel sensing system may be of great value to many industries, for example, medical, forensics, and military. The fundamental principles of this novel invention may be implemented in many variations and combinations of techniques. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a variable-length coding device for compressing video data and, more particularly, to a variable-length coding device capable of coding video data at high speed.
It has been customary, in a variable-length coding device for video data compression to read out a predefined variable-length code which matches input video data, to sequentially shift the variable-length code, one bit at a time, depending on the number of bits of remaining valid data stored in the currently used address of a compressed data memory (i.e., where the final bit of the immediately preceding variable-length code was written), and to OR the resulting shifted variable-length code with the "remaining" data to produce combined compressed data suitable for storage, beginning with the currently used address. The problem with this procedure is that it consumes a substantial period of time when the variable-length code must be shifted a number of times. Particularly, when the variable-length code has two or three bytes, the processing time is doubled or tripled. Further, since data transfer to the compressed data memory occurs on a bit-by-bit basis, it is necessary to manage the address of the last data in the memory, again increasing the processing time.
In light of the above, Japanese Patent Laid-Open Publication No. 59-57576 discloses a procedure for promoting rapid variable-length coding. The procedure taught in this Laid-Open Publication uses a counter for counting the bits of the variable-length code to be stored and controls the shift on the basis of this count. Specifically, the variable-length code is shifted, two bits at a time, from the upper bits, and then is transferred to a memory. As for the last bit, whether the count of the counter is even or odd is determined. The last bit is shifted by two bits if the count is even or by one bit if it is odd and then transferred to the memory. Such a procedure successfully reduces the number of shifts. However, when the variable-length code has, for example, a great bit length, even this procedure needs a great number of shifts. This, coupled with the fact that whether or not the number of bits is even or odd must be determined, prevents the processing time from being sufficiently reduced.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a variable-length coding device capable of processing video data at high speed.
A variable-length coding device for compressing video data or the present invention has a first memory for storing compressed data, and a second memory for storing the pre-defined variable-length codes. Along with pre-shifted versions thereof. The second memory stores, in addition to data entries having the variable-length codes and their pre-shifted corresponding, first counts for determining, based on the respective variable length code of an entry, a code bit length of "remainder" data stored in the last used address of the first memory, and corresponding second counts for determining the particular number of bytes in which the compressed data will be written to the first memory.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken with the accompanying drawings in which:
FIG. 1 shows a specific example of compressed data already stored in a compressed data memory;
FIG. 2 is a flowchart demonstrating a specific variable-length coding procedure;
FIG. 3 is a block diagram schematically showing a variable-length coding device embodying the present invention;
FIG. 4 shows data stored in a variable-length code memory included in the embodiment; and
FIG. 5 is a flowchart representing a specific operation of the embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, specific compressed data already stored in a compressed data memory are shown. In a conventional variable-length coding device for video data compression, a variable-length code which corresponds to input video data, is read. This code is sequentially shifted, one bit at a time, depending on the number of bits of valid "remaining" data already stored at the currently used (i.e., next write) address of the compressed data memory, (i.e., where the aforementioned shifted variable-length code is to be written). The shifted variable-length code and the remaining data are ORed to produce combined compressed data suitable for storage, beginning at the currently used address of the compressed data memory.
FIG. 2 shows a conventional variable-length coding procedure implementing the above concept. Assume, for example, that a variable-length code has ten bits of valid data. First, video data are read out of a file unit (step S11). The address of the memory storing pre-defined variable-length code corresponding to the video data is calculated (step S12). As a result, a ten valid bit variable-length code [XXXXXXXX XX000000]is read out of the memory as the current data (step S13). In the code, each "X" and each "0" represent valid and invalid data, respectively. Subsequently, a pre-determined value indicating the number of bits of the variable-length code (i.e., 10), and assigned thereto beforehand is calculated (step S14). Then, the remaining data in the used (i.e., next write) address of the compressed data memory [AAA00000]as shown in FIG. 1 are read out of the compressed data memory (step S15). The number of remaining bits of the remaining data [AAA00000]is detected ("3" in this example). This number ("3") indicates the number of shifts to be performed (step S16). In FIG. 1, each "A" represents valid, already stored, compressed binary data, i.e., ZERO or ONE. Subsequently, the first and second bytes of the current data are shifted to the right three times (step S17) to produce shifted current data [000XXXXX XXXXX000]. The first byte (000XXXXX) of the shifted current data and the remaining data of the currently used address of the compressed data memory (AAA00000) are ORed (step S18) to produce combined data [AAAXXXXX XXXXX000], which is suitable for storage beginning at the currently used address of the compressed data memory. These combined data are written to the compressed data memory byte by byte (step S19). To calculate the new next write address "3" (number of remaining data bits) and "10" (number of bits of the variable-length code) are summed and then modulo divided by "8" (byte length) giving "1". Hence, "1" is added to a variable indicting the currently used address of the compressed data memory, thereby showing that the address is changed by one address (step S1A). Such a procedure is repeated up to the last data file (step S1B).
Japanese Patent Laid-Open Publication No. 59-57576 teaches a variable-length coding procedure which achieves higher speed than the above conventional procedure with some additional circuitry. The procedure taught in this Laid-Open Publication uses a counter for counting the bits of a variable-length code and controls the shift on the basis of a count. Specifically, a variable-length code is shifted, two bits at a time, from the upper bits and then transferred to a memory. As for the last bit, whether the count of the counter is even or odd is determined. The last bit is shifted by two bits if the count is even or by one bit if it is odd and then transferred to the memory. The procedure disclosed in the above Laid-Open Publication successfully reduces the number of shifts. However, when the variable-length code has, for example, a great bit length, even such a procedure needs a great number of shifts. This, coupled with the fact that whether or not the number of bits is even or odd must be determined, prevents the processing time from being sufficiently reduced.
In accordance with the present invention, a variable-length code memory stores predefined entries comprising bit patterns prepared by shifting a single variable-length code. In addition, the entries of the variable-length code memory store output counts (each of which represents a particular number of bytes to be written to a compressed data memory), and remainder counts each of which indicates a particular number of remaining valid data bits left in the next write address of compressed data memory). The respective bit patterns, output counts and remainder counts are stored in the variable-length code memory in combination as data having a fixed length. This successfully eliminates the need for shifts and thereby promotes rapid variable-length coding.
Referring to FIG. 3, a variable-length coding device embodying the present invention will be described. As shown, the device has a CPU (Central Processing Unit) 10, a ROM (Read Only Memory) 12, storing a program, and a RAM (Random Access Memory) 14. The CPU 10 executes the program stored in the ROM 12 by using the RAM 14 as a work area. A file unit 16 stores video data to be compressed. The CPU 10 accesses the file unit 16 to read a portion of video data therefrom, transforms it into a corresponding variable-length code with a coder 18, and then writes the coded data to a compressed data memory 20, beginning at the next write address. The reference numeral 22 designates a variable-length code memory.
FIG. 4 shows an example of some of the specific data stored in the variable-length code memory 22 in accordance with the invention. As shown, a remainder counter R, an output counter C, and a variable-length code field are assumed to have four bits, four bits, and ten valid bits, respectively. [XXXXXXXXXX]represents the ten valid bits of a variable-length code having the bit pattern which corresponds to the portion of video data. The predefined entries of the variable-length code memory 22 are made by sequentially shifting the bit pattern by zero to seven bits in order from the top to the bottom. In the figure, each "X" represents one of the ten valid binary data bits, i.e., ZERO or ONE. The remainder counter R indicates, when the bit pattern is divided into bytes, the number of valid data bits [X] existing in the last byte of the pre-shifted variable length code. The output counter C shows how many bytes of saturate combined data (i.e., bytes of combined data not having any invalid data) are obtainable when the remaining data and the pre-shifted variable-length code field are ORed. More specifically, the output counter C shows which is the last byte of the combined data that will have valid data in the least significant bit (LSB) thereof.
The operation of the CPU 10 will be described with reference to FIG. 5 and by taking the data shown in FIGS. 1 and 4 as an example. First, the CPU 10 reads video data out of the file unit 16 (step S31). The count of the remainder counter R is "3", as derived from the data at the next write address of content of the compressed data memory 20 (step S32). The CPU 10 calculates the correct address of the corresponding pre-shifted variable-length code in memory 22 from the video data and the count of the remainder counter R (step S33) and then reads out of the memory 22 the entire data entry [000XXXXX XXXXX000 00000000 00010101]as shown in FIG. 4 (step S34). Subsequently, the CPU 10 saves the value "1" of the corresponding output counter C and the value "5" of the corresponding remainder counter R in registers thereof, and then produces a variable-length code (000XXXXX XXXXX000 00000000) corresponding to the current data (step S35). Then, the CPU 10 reads the remaining data (AAA00000), FIG. 1, out of the next write address of the compressed data memory 20 (step S36). Here, "A" represents valid, already stored, compressed binary data, i.e., ZERO or ONE. The CPU 10 ORs the remaining data and the first byte (000XXXXX) of the current combined data (step S37). As a result, data [AAAXXXXX XXXXX000 00000000] is produced. The CPU 10 writes this combined data in the compressed data memory 20 (step S38) beginning at the next write address.
Subsequently, the CPU 10 adds the count "1" of the output counter C to a variable representing the next write address of the compressed data memory 20 (step S39), thereby showing that one byte of data has been updated. At the beginning of the next operation or loop, the CPU 10 recognizes the data [XXXXX000]of the second byte of the current data as remaining data and sees, based on the value "5" of the remainder counter R, that data of the zero-th bit to the fourth bits are valid.
In summary, it will be seen that the present invention provides a variable-length coding device capable of producing compressed data by effecting ORing only once without regard to the length of a variable-length code, thereby reducing the processing time to a noticeable degree. Further, since the present invention performs coding on a byte basis in place of the conventional bit basis, it can deal with the address of a compressed data memory with ease and, therefore, can code video data at high speed.
Various modifications will become possible for those skilled in the art, after receiving the teachings of the present disclosure, without departing from the scope thereof. | A variable-length coding device for compressing video data includes a variable-length code memory, which stores predefined and pre-shifted variations of variable-length codes in entries thereof. Each entry also has two counter fields, one for indicating the number of combined data bytes to be written to a compressed data memory, and another for indicating the number of valid bits remaining in the final byte written to the compressed data memory. The variable-length coding device does not require shifting of variable-length codes at storage time, and realizes an increase in efficiency. | 7 |
FIELD OF THE INVENTION
The invention relates to the field of optically recordable information carriers with multiple information layers accessible from the same side of the media.
BACKGROUND OF THE INVENTION
The invention relates to a method of recording information onto an optically recordable information carrier having at least two different superposed optically recordable layers. The method includes a first step in which information is recorded on a first one of the optically recordable layers by laser light to which the information carrier is exposed from a first side. The first step is followed by a second step in which information is recorded on a second one of the optically recordable layers, light to which the information carrier is also exposed from the first side.
The invention further relates to a recording apparatus for the recording of information on an optically recordable information carrier having at least two different superposed optically recordable layers. The apparatus includes comprising a device adapted to record information on a first one of the optically recordable layers by laser light to which the information carrier is exposed from a first side. The device is also adapted and to record information on a second one of the optically recordable layers, which second layer differs from the first layer, by laser light to which the information carrier is also exposed from the first side.
Optically recordable information carriers are generally known and are used in recording apparatuses which record data on the information carrier by a laser beam. The laser beam is focused into a focal spot on a recording layer in the information carrier. In the case of an adequate laser beam intensity the optical properties of the recording layer at the location of the focal spot will change, as a result of which a mark is produced in the recording layer. By varying the laser beam intensity a pattern of marks can be formed in the recording layer. The recorded pattern contains the data to be recorded in coded form. An example of such an optically recordable information carrier is the CD-R (Compact Disc Recordable).
In order to extend the storage capacity of optically recordable information carriers information carriers have been introduced which include a plurality of superposed recording layers. Examples of such multi-layer optically recordable information carriers are described in U.S. Pat. Nos. 5,761,188 and 5,202,875. Each recording layer in a multi-layer optically recordable information carrier can be inscribed separately by focusing the laser beam onto the relevant recording layer. The recording apparatuses use a high numerical aperture (NA). Owing to this high numerical aperture, the diameter of the laser beam, at the location of the recording layers situated between the source of the laser beam (laser light source) and the recording layer to be inscribed (hereinafter referred to as the intermediate layers), is comparatively large. As a result of this, the intensity of the laser beam at the location of the intermediate layers will be inadequate intensity to produce marks on these layers, whereas producing marks on the layer to be inscribed is possible. Also at the location of each of the intermediate recording layers, having a distance between the respective layer and the laser light source which is larger than the distance between the recording layer to be inscribed and the laser light source, the intensity of the laser beam is inadequate to produce marks in these layers owing to the comparatively large diameter of the beam.
Although the intermediate layers cannot be inscribed, they have on influence on the laser beam. A part of the laser beam will be reflected, diffused and absorbed by the intermediate layers. The remainder of the laser beam, quantified by the transmission coefficient, will be transmitted by the intermediate layers. The magnitude of the transmitted part depends on the optical properties of the intermediate layers. However, the optical properties of the intermediate layers change when these layers are inscribed. The intensity of the laser beam should be so high that in all cases each recording layer in the multi-layer optically recordable information carrier can be inscribed.
The above citations are hereby incorporated in whole by reference.
It is an object of the invention to provide a method of writing information onto an optically recordable information carrier, which allows the sequence in which the recording layers are inscribed to be selected in an optimum manner.
The method includes a first preparatory step in which the changes of the effective transmission properties of the optically recordable layers before the recording of information on the layers with respect to the effective transmission properties of the optically recordable layers after the recording of information on the layers is determined. The first step is followed by a second preparatory step in which the sequence of recording of the first and the second optically recordable layer is determined. If the changes of the effective transmission properties of the optically recordable layers are known a priori, they can be communicated to the method, for example, by a user or a recording apparatus. The sequence in which the optically recordable layers are inscribed can be determined in an optimum manner, for example, so as to minimize the laser beam intensity required for inscribing these layers. This results inter alia in the heat generation during recording onto the optically recordable information carrier not being unduly large and in the possibility of using a comparatively simple and cheap laser light source.
In a variant of the method the first preparatory step includes the reading of information about the changes of the effective transmission properties of the optically recordable layers from an area on the optically recordable information carrier. Such area contains information about the physical properties of the optically recordable information carrier. If the optically recordable information carrier has an area which contains information about the physical properties of the optically recordable information carrier, such as for example a lead-in area, the method can automatically read this information and derive from this information the changes of the effective transmission properties of the optically recordable layers. The area containing information about the physical properties of the optically recordable information carrier may be provided during the manufacture of the optically recordable information carrier.
In a special variant of the method the first preparatory step includes a first measurement step in which the effective transmission properties of the optically recordable layers before the recording of information on the layers is measured. The first step is followed by a second measurement step in which the effective transmission properties of the optically recordable layers, after the recording of information on the layers is measured is, followed by a comparison step. In the comparison step the measured effective transmission properties of the optically recordable layers before the recording of information on the layers is compared with measured effective transmission properties of the optically recordable layers after the recording of information on the layers. If no information is available about the change of the effective transmission properties of the optically recordable layers during recording onto these layers, this change can be measured in a plurality of measurement steps. For the write operations necessary to carry out these measurement steps it is possible to reserve for example a portion of the optically recordable information carrier.
In a variant of the method the first and the second optically recordable layers are inscribed successively, starting with the optically recordable layer situated farther from the laser light source and ending with the optically recordable layer situated nearer the laser light source if the effective transmission properties of the optically recordable layers after the recording of information on the layers have decreased with respect to the effective transmission properties of the optically recordable layers before the recording of information on the layers. An advantage of writing onto the optically recordable layers in the sequence as defined for the present variant of the method is that the maximum laser beam intensity that is required corresponds to the intensity required for inscribing the optically recordable layer which is farthest from the laser light source while the intermediate layers have not been inscribed and are consequently comparatively transparent. During the recording onto the optically recordable layers the laser beam intensity necessary for inscribing these layers will decrease according as successive layers are written.
In another variant of the method the first and the second optically recordable layer are inscribed successively, starting with the optically recordable layer situated nearer the laser light source and ending with the optically recordable layer situated farther from the laser light source if the effective transmission properties of the optically recordable layers after the recording of information on the layers have increased with respect to the effective transmission properties of the optically recordable layers before the recording of information on the layers. An advantage of inscribing the optically recordable layers in the sequence as defined for the present variant of the method is that the laser beam intensity necessary for inscribing the successive layers will increase to a minimal extent as the successive layers are written.
The recording apparatus is adapted to determine the changes of the effective transmission properties of the optically recordable layers before the recording of information on the layers with respect to the effective transmission properties of the optically recordable layers after the recording of information on the layers, and the recording apparatus is adapted to determine the sequence of recording of the first and the second optically recordable layer.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will now be described in more detail with reference to the drawings. In the drawings
FIG. 1 is a diagrammatic cross-sectional view of a multi-layer optically recordable information carrier of which one layer is being inscribed by a focused laser beam received from a laser light source,
FIG. 2 is a partial plan view of an inscribed intermediate layer exposed to a laser beam,
FIGS. 3A and 3B show flow charts of the method in accordance with the invention, and
FIG. 4 shows a block diagram of the device in accordance with the invention in the recording apparatus for recording information onto a multi-layer optically recordable information carrier.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a cross-sectional view of a part of multi-layer optically recordable information carrier 1 . A plurality of optically recordable layers 41 through 43 are shown. A laser beam 2 from a laser light source 3 is focused onto the optically recordable layer 41 to be inscribed. An example of a laser light source 3 is a solid-state laser which emits light having a wavelength in the visible part of the spectrum or light having a wavelength in the non-visible part of the spectrum, such as for example, infrared (IR) light and ultraviolet (UV) light. At the location of the focal spot 5 the intensity of the laser beam is such that a mark can be formed in the optically recordable layer 41 to be inscribed. At the location where the laser beam 2 traverses the intermediate layers 42 , the diameter of the laser beam is comparatively large, as a result of which the intensity of the laser beam is inadequate to produce a mark in these intermediate layers.
FIG. 2 is a partial plan view of an intermediate layer 42 in a multi-layer optically recordable information carrier 1 taken on the line II—II in FIG. 1 . This intermediate layer 42 has already been inscribed, as a result of which marks 6 are situated on the layer. The intermediate layer 42 is illuminated by the laser beam 2 . The portion 21 of the intermediate layer 42 exposed to the laser beam 2 includes both an area with marks 6 and an area without these marks. The transmission coefficient of the intermediate layer 42 at the location of the marks 6 will generally differ from the transmission coefficient of the intermediate layer in an area without these marks. As a result of this, the intermediate layer 42 cannot be characterized by a fixed transmission coefficient. However, the intermediate layer 42 can be characterized by an effective transmission coefficient which is a combination of the transmission coefficient of the intermediate layer at the location of the marks 6 and the transmission coefficient of the intermediate layer in the area without these marks. The value of this effective transmission coefficient depends inter alia on the density of the spatial distribution of the marks 6 . If the intermediate layer 42 has not yet been inscribed and, consequently, there are not yet any marks 6 on the layer, the effective transmission coefficient will correspond to the transmission coefficient of the intermediate layer in an area without marks.
The marks 6 in the optically recordable layers 41 through 43 may reflect the laser beam 2 to a greater extent or to a smaller extent than an area without any marks. If the laser beam 2 is reflected to a greater extent by the marks 6 , this is referred to inter alia as white writing layers, in which, the effective transmission properties generally decrease after the layers have been inscribed. If the laser beam 2 is reflected to a smaller extent by the marks 6 this is referred to as black writing layers, in which, the effective transmission properties generally increase after the layers have been inscribed.
FIG. 3A is a flow chart of an example of a variant of the method in accordance with the invention. The variant comprises three steps 31 through 33 . Step 33 , in which information is written onto the optically recordable layers 41 through 43 , is preceded by a first preparatory step 31 , and a second preparatory step 32 . In the first preparatory step 31 the changes of the effective transmission properties of the optically recordable layers 41 through 43 before the recording of information on layers with respect to the effective transmission properties of the optically recordable layers after the recording of information on the layers (ΔEƒƒ.Trans.) are determined. The determining can be effected inter alia in that information about the changes of the effective transmission properties is entered by a user or by the recording apparatus, or is read from the multi-layer optically recordable information carrier 1 itself, or is determined by a measurement. Subsequently, in a second preparatory step, the information about the changes of the effective transmission properties is used for determining the sequence in which the optically recordable layers 41 through 43 are to be inscribed in the step 33 .
By way of example, the second preparatory step 32 is represented diagrammatically in greater detail in FIG. 3 B. In a sub-step 320 , a subsequent sub-step 321 or a sub-step 322 is chosen depending on the change of the effective transmission properties. If the effective transmission properties of the optically recordable layers 41 through 42 after information has been written onto the layers have decreased (▾) with respect to the effective transmission properties of the optically recordable layers before information is written onto the layers, the sequence in which the optically recordable layers 41 through 43 are to be inscribed will be determined in the sub-step 321 in such a manner that the layers will be inscribed consecutively starting with the optically recordable layer farthest from the laser light source 3 and ending with the optically recordable layer nearest the laser light source. Conversely, if the effective transmission properties of the optically recordable layers 41 through 42 after information has been written onto the layers have increased (▴) with respect to the effective transmission properties of the optically recordable layers before information is written onto the layers, the sequence in which the optically recordable layers 41 through 43 are to be inscribed will be determined in the sub-step 322 in such a manner that the layers will be inscribed consecutively starting with the optically recordable layer nearest the laser light source 3 and ending with the optically recordable layer farthest from the laser light source. It will be obvious to the expert that there are other alternatives for the step 32 . The alternative for the step 32 then depends on the desired result.
FIG. 4 shows a block diagram of a device 50 for recording information on a multi-layer optically recordable information carrier 1 . A laser beam 2 from a laser light source 3 is focused onto one of the optically recordable layers 41 through 43 . For positioning the focal spot of the laser beam 2 on the optically recordable layer 41 to be inscribed, a unit which comprises a positioning logic 52 applies a control signal 60 to the laser light source 3 . When information is recorded onto the optically recordable information carrier 1 , an information stream 612 is applied from an information processing unit 51 to the laser light source 3 . When information is read from the optically recordable information carrier 1 , an information stream 611 is applied from an optical system 31 to the information processing unit 51 . The device includes an analysis logic 55 for detecting the changes of the effective transmission properties of the optically recordable layers 41 through 43 , before the recording of information on the layers, with respect to the effective transmission properties of the optically recordable layers after the recording of information on the layers. Information about these changes 711 is applied to a decision unit 56 . In this decision unit 56 , the sequence of recording of optically recordable layers 41 through 43 is determined. Information about the sequence 712 , thus determined, is applied to the unit comprising the decision logic 52 . The analysis logic 55 can receive external information 70 received from a user or from another device in the recording apparatus, or information 621 which is received from the optically recordable information carrier 1 via the information processing unit 51 . While measurements are being carried out, the analysis logic 55 can apply measurement signals 622 to the optically recordable information carrier 1 via the information processing unit 51 .
The invention has been disclosed with reference to specific preferred embodiments, to enable those skilled in the art to make and use the invention, and to describe the best mode contemplated for carrying out the invention. Those skilled in the art may modify or add to these embodiments or provide other embodiments without departing from the spirit of the invention. Thus, the scope of the invention is only limited by the following claims. | A circuit derives information about the changes of the transmission coefficients of the layers due to writing information onto these layers. On the basis of the derived information a circuit determines the sequence in which the layers are to be recorded so as to minimize the required intensity of the laser beam, thereby precluding unnecessary heating of the carrier and allowing comparatively simple and cheap laser beam sources to be used. | 6 |
DESCRIPTION
1. Technical Field
Casings for the installation of air-conditioning, cooling, or ventilation apparatus.
2. State of the Art
The construction of thermally and/or acoustically insulated casings for receiving air-conditioning apparatus, cooling apparatus, and the like is known, which are usually disposed in the basement or in the attic, or outside of the building.
These casings are made of plate elements with standardized dimensions and exhibit an inner insulating layer, which are covered with sheet metal on the outside. The mounting together of the elements themselves or, respectively, the attachment of these elements to a supporting structure, is performed by means of connection elements or attachment elements, which are attached to the plate elements or which are formed as a single piece at the plate elements. Such plate elements are known from the description of the U.S. Pat. No. 3,372,520, of the French Pat. No. 927,270, of the U.S. Pat. No. 3,670,466, and of the German Patent Laid Out DE-A 3,042,109.
All these conventional plate elements, including those which are subject-matter of the above patent literature, are concerned with elements which surround the insulating core on all sides and which exhibit on the outside grooves, ribs, protrusions, clamps or other mutual connection and attachment elements. The production of such plate elements thus requires the use of profiles with a branched cross-section, a sheet metal cut to size, as well as various attachment elements, where the latter are formed or attached as a single piece at the plate elements. The production of the plate element occurs in various work processes by means of specific equipment. The mounting together of the plate elements to casings in contrast requires work phases, such as screwing together, insertion of studs or locking screws, alignment of protrusions or the like. Furthermore, at the positions of the application of the attachment elements, the corrosion-resistant layer can be damaged easily, and corrosion-susceptible outer and/or inner faces are generated, at which dust and condensation water can be deposited and, finally, an unfavorable electro-chemical effect occurs based on the mutual contacting of various metals. In addition, such faces are not smooth and thus are difficult to keep clean and therefore look unesthetical.
DESCRIPTION OF THE INVENTION
It is an object of the invention to provide for a plate element as described above. The attachment and mounting elements of said plate element are not visible from the outside. The plate element is provided with smooth outer surfaces and exhibits an inner attachment system in a protected region. The attachment system of the plate element is easily accessible after mounting of the plate element. Furthermore, the plate element is resistant to corrosion at the metallic contact points of various pieces, such as attachment elements. Said plate element can be economically manufactured.
This object is achieved according to the invention by employing a box-shaped flat element which can be closed by a snap-on cover and which box-shaped element is filled with insulating material. The box-shaped element as well as the cover can be made of sheet metal or of a plastic laminate.
The elastically deformable members, forming the snap connection between the box-shaped element and the cover, are preferably made as a single piece with the respective element and they enhance in particular the required stiffening of the element. However, it is not excluded that elastic parts out of various materials are applied at one or both elements. The snap connection between the box-shaped element and the cover is preferably of the kind which allows a later demounting of the cover. The insulating layer placed in the box-shaped element is preferably of a soft and/or bendable kind, such as glass fiber or the like, however, the application of stiff or composed insulating plates, such as stiff-bendable, is not excluded.
The connection of the plate elements according to the invention between themselves or with a supporting structure with or without insertion of seals, inserts, or the like, comprises the use of conventional elements used in the sheet metal and laminate processing. These elements are applied on the inside of box-shaped elements before the insertion of the insulating layer and before the snapping on of the cover. Bores can already be provided for the placing of these attachment elements which are, for example, tapping screws, sheet metal screws, blind rivets, or the like, or they can be produced during mounting in a simple fashion at the desired locations. The area for the application of the attachment elements is usually the narrow continuous edge determing the depth of the box-shaped elements. However, for the forming of edges or subdividing walls, it is not excluded to place them at the floor of the box-shaped element. Furthermore, it is possible to connect the box-shaped elements and the floor to each other. According to the invention, the represented connection system allows in addition the simple attachment of the plate elements to profiles and to walls in general, which represent for example the supporting structure of the casing, respectively of the aggregate to be insulated. Furthermore, this attachment system is also applicable for the mounting of tie rods, of tension rods, of bearings, of supports, and the like, in particular at the inner side of the casings. Seals, inserts, or shim stock can be inserted between the adjoining faces of the connected plate elements, which seals, inserts, or shim stock can be maintained in a desired position by way of the described attachment elements.
According to the invention, ribs or the like can be provided at the cover as well as at the floor of the box-shaped element in order to enhance the form stability. For the same purpose, elastic arms can also be provided at the edges of the cover or, respectively, there can be used the inwardly protruding wings of the box-shaped elements, which form the snap connection.
In addition, a sealing or an insert or a shim stock can be inserted between the continuous edge of the cover and the corresponding stop at the box-shaped element. The effect of the elastic tongue at the wing, which forms the seat of the snap connection, is such that a pull of the cover is performed toward the box-shaped element, whereby the possibly inserted seal is subjected to pressure. The invention does not exclude the application of conventional elastic elements for forming of the snap connection between the cover and the box-shaped element.
The potentially corrosion-resistant surface treatment of the box-shaped element and of the cover can, according to the connection system of the invention, always only be damaged at an internally disposed and thus covered region.
SHORT DESCRIPTION OF THE DRAWING
The invention is explained in more detail by way of an embodiment of invention plate elements illustrated in the accompanying drawings. This schematic representation has a purely explanatory and not a limiting purpose.
FIG. 1 illustrates the cross-section through the connection location of two invention plate elements, disposed in the same plane,
FIG. 2 shows the cross-section through the connection location of two invention plate elements, which are attached at a profile at a right angle to each other.
METHOD FOR THE IMPLEMENTATION OF THE INVENTION
The box-shaped element exhibits a continuous wall 1a, which determines the depth of the box. This wall continues in a stop 1b, which extends in a plane disposed parallel to the floor and which ends in a wing 1c, which is inclined toward the continuous wall 1a. In particular, the stop 1b and the wing 1c contribute much in that a substantial form stability is imparted to the box-shaped element 1. The cover 2 exhibits a folded-together strip 2a in the region of the continuous edge, which folded-together strip 2a ends in an elastic arm 2b with the insertion bevel 2c. The elastic arm 2b with the insertion bevel 2c can extend over the full length of the sides or it can be limited to certain regions. The folded-together strip 2a as well as the elastic arm 2b with the insertion bevel 2c can contribute to the form stability of the cover and this is the case in particular where the latter extend continuously over all sides. The elastic arm 2b, with reference to the cover 2, is inclined toward the outside and effects, by way of the elastic tension, by resting at the inclined wing 1c of the box-shaped element 1, the connection between the two parts (1-2) without excluding a later demounting.
The mounting together of the plate elements themselves is performed according to the invention, before the insertion of the insulating layer 7 and the snapping on of the cover 2, by way of attachment elements 5, which penetrate the adjoining walls of the box-shaped elements (FIG. 1) or, respectively, which penetrate the walls of the box-shaped elements and those of an adjoining profile or the like (FIG. 2). There can be inserted seals 3, 4, 4a or inserts or shim stocks between the stop 1b of the box-shaped element 1 and the corresponding region of the cover 2, as well as in the attachment region between the box-shaped element 1, as well as between the latter and the supporting structure 6.
According to the invention, the insulating layer 7, which can be attached at the cover 2, can be inserted separately or upon snapping on of the cover 2 onto the box-shaped element 1.
COMMERCIAL APPLICATION
The particularly economic mode of production of the parts forming the plate elements, as well as their form stability and the substantial functional capability, together with the time-saving simple mounting, are inducements to employ the plate elements, in addition to the construction of insulating chambers, also for wall coverings and for the insulation of movable aggregates. | The prefabricated panel elements for the construction of insulating chambers consist of an interlocking element (1) surrounding an insulating core, and of a cover (2). The interlocking element and the cover can be either attached to each other or to a support structure. The panel elements are assembled to form walls and insulating chambers, in particular for the installation of air conditioning equipment, cooling plant and similar. | 4 |
BACKGROUND
A variety of situations can arise where it can be desirable to control the humidity levels and water content of materials within a building or other enclosed area need to be controlled. For example, when a building has been flooded or otherwise water damaged, removing water from the materials and air within the building is critical to prevent further damage to the material and reduce the unwanted growth of microorganisms and mold inside the building. If the water is promptly removed from the building by drying out carpets, floors, walls, and other wet items, many of the effects of the unwanted water can be minimized. However, if no efforts are taken to accelerate the drying process, wood framing and drywall may take from several months to several years to dry out, depending on saturation levels. When the conditions are right, mold growth may start in a couple of days, making it important that accelerated drying be started as promptly as possible and remove the water as quickly as possible.
Walls are particularly difficult to dry because they contain enclosed areas that trap moisture, as well as materials that absorb and retain water. For example, the spaces in between studs in a wall create void where water can be trapped. Often the spaces in between the studs are filled with insulation or sound proofing, which absorb and retain water. Many popular wall coverings, such as drywall, absorb and are easily damaged by water.
One method of gaining access to the interior of a wall involves removing the saturated drywall to allow air to circulate through cavities in walls. This destroys the drywall, paint and other decor. Replacing these interior building elements is expensive and time consuming. If the portions of the building interior that contain significant moisture can be rapidly dried, further water damage and mold growth can be avoided. Ideally, this drying would occur without removing the drywall from the building walls.
In many situations, the unwanted water does not fill the entire building, but is only a few inches deep. By protecting and facilitating the access to the bottom portion of the wall, the most frequent damage can be minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate various embodiments of the principles described herein and are a part of the specification. The illustrated embodiments are merely examples and do not limit the scope of the claims.
FIGS. 1A , 1 B, and 1 C are front, side, and perspective view, respectively, of an illustrative wall shoe, according to one embodiment of principles described herein.
FIG. 2 is a cross-sectional drawing of an illustrative wall shoe installed in a wall, according to one embodiment of principles described herein.
FIG. 3 shows the sill member being dried through channels in an illustrative wall shoe, according to one embodiment of principles described herein.
FIG. 4 is an illustrative diagram showing the interior of a wall being dried after the removal of base board and wall shoe, according to one embodiment of principles described herein.
FIG. 5 is a flowchart showing an illustrative method for utilizing a wall shoe to mitigate water damage to walls, according to one embodiment of principles described herein.
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION
The wall shoe can be placed under the bottom edge of a sheet of drywall such that the drywall is elevated above the floor level. The wall shoe may be installed during construction, restoration, or remodeling. By lifting the drywall a few inches off the floor the wall shoe prevents the drywall and wall coverings from absorbing water in most minor water disasters. Channels through the wall shoe allow the lowest portions of the wall to be quickly dried without removing either the drywall or the wall shoe. In situations where the water damage extends upward and the drywall and wall interior have absorbed significant amounts of water, the wall shoe can be removed to allow access to the interior of the wall. By quickly accessing and drying the interior of the wall, damage to the drywall and interior of the wall can be minimized. In many cases the drywall and interior can be successfully dried before replacement of the wall or drywall is necessary. After the wall has been dried the shoe and baseboard can be replaced or reinstalled, resulting in a significant savings of time and money.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present systems and methods. It will be apparent, however, to one skilled in the art that the present apparatus, systems and methods may be practiced without these specific details. Reference in the specification to “an embodiment,” “an example” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least that one embodiment, but not necessarily in other embodiments. The various instances of the phrase “in one embodiment” or similar phrases in various places in the specification are not necessarily all referring to the same embodiment.
FIGS. 1A , 1 B, and 1 C illustrate one exemplary embodiment of a wall shoe ( 100 ). FIG. 1A shows a front view of a wall shoe ( 100 ). The wall shoe is comprised of a generally rectangular body ( 110 ). In one exemplary embodiment, the wall shoe ( 100 ) has a plurality of channels or grooves ( 120 ) through the thickness of the rectangular body ( 110 ). In general, the wall shoe ( 100 ) can be of any length. In one illustrative embodiment, the wall shoe comes in lengths or rolls that can be cut to the desired size by the installer. In another illustrative embodiment, the wall shoe is substantially the same length as one side of a sheet of drywall. Standard drywall has a short side that is typically four feet wide and a longer side that is typically eight feet high. With the rising popularity of 9 foot ceilings in new home construction, 4.5 feet wide panels have become available. In some commercial applications, drywall sheet which sizes up to 16 feet are used. Additionally, drywall is manufactured in metric sizes, such as a 1.2 meter by 0.9 meter sheet. By manufacturing the wall shoe in sections that correspond to standard drywall dimensions, the wall shoe can be conveniently purchased, transported and installed with the drywall.
The wall shoe ( 100 ) may be made of a variety of materials. Suitable materials may be selected for a variety of attributes including water resistance, durability, cost, ease of installation, fire resistance, and other factors. By way of example and not limitation, the wall shoe may be constructed from plastic or other polymer base material, ceramic, stone, wood, composite material, laminate, or other suitable material. According to one exemplary embodiment, the wall shoe ( 100 ) is formed from fire proof plastic, such as fireproofed polystyrene.
FIG. 1C shows a perspective view of the wall shoe ( 100 ). The channels ( 120 ) pass across the thickness of the wall shoe. In one exemplary embodiment, the wall shoe ( 100 ) has a thickness that matches the thickness of wall covering that rests above it. By way of example and not limitation, standard drywall can be purchased in thicknesses ranging from ⅜ inch to 1 inch, which ½ and ⅝ths inch thicknesses being most common. According to this embodiment, the wall shoe can be covered by a base board. In another illustrative embodiment, the wall shoe extends beyond the wall covering, creating an integral base board.
The height of the wall shoe ( 100 ) may also vary. In one exemplary embodiment, the wall shoe is about 1⅞ inches tall, which will allow the wall shoe to be covered by most common baseboards.
FIG. 2 is a cross-sectional drawing of wall shoe ( 100 ) installed in a wall structure ( 200 ), according to one exemplary embodiment. As illustrated in FIG. 2 , a wall structure ( 200 ) is constructed perpendicular to and resting on a floor ( 210 ). The sill member ( 240 ) is the base structure of the wall ( 200 ), and is the most common element to be saturated by floods because of its proximity to the floor ( 210 ). The wall shoe ( 100 ) is installed along the bottom of the wall ( 200 ) so that the channels ( 120 ) in the bottom side of the wall shoe are toward the floor and provide access to the through the wall shoe to the sill member ( 240 ). The drywall ( 220 ) is then place above the wall shoe and secured in position. A base board ( 230 ) is then attached to the wall, covering the bottom edge of the drywall ( 220 ) and the wall shoe ( 100 ). On the opposite side of the wall, a second sheet of drywall ( 250 ) is attached to the structural elements of the wall ( 200 ), creating an interior cavity ( 255 ).
In the event of a minor flood that does not extend above the wall shoe ( 100 ), the wall shoe ( 100 ) prevents the drywall ( 220 ) from being saturated by water. FIG. 3 shows disaster restoration in progress wherein only a portion of the sill ( 240 ) is saturated by water ( 310 ). As mentioned above, if this water is not expeditiously extracted, the water can migrate to other areas and contribute to mold growth or other undesirable damage. The baseboard ( 230 , FIG. 2 ) has been removed and equipment ( 300 ) is directing air into the channels ( 120 , FIG. 1 ) of the wall shoe ( 100 ). By way of example and not limitation, the equipment may dehumidify and/or heat the air ( 305 ) prior to applying it to water saturated portions of the building. The channels ( 120 , FIG. 1 ) allow for direct access to the sill. The dehumidified and/or heated air extracts the water ( 310 ) from the sill ( 240 ) and carries it away. Typically, the moisture laden air is exhausted outside the building to prevent high humidity within the building.
In more severe floods, the wall shoe ( 100 ) can facilitate access to the interior areas ( 255 ) of the wall. FIG. 4 shows a disaster restoration method where the base board ( 230 , FIG. 2 ) and wall shoe ( 100 , FIG. 2 ) have been removed to access the wall interior ( 255 ). By removing the baseboard ( 230 ) and wall shoe ( 100 , FIG. 2 ) after a flood or other water damage, the interior of wall ( 255 ) can be accessed without the necessity of further damaging the drywall ( 220 ). The equipment ( 300 ) directs air ( 400 ) through the opening created by removing wall shoe ( 100 , FIG. 2 ). FIG. 4 shows the air ( 400 ) entering and exiting through the same opening. In other embodiments, the air may be injected in one location and exit in another location. For example, exiting electrical outlets could be used an additional for entry or exit of air ( 400 ). In other embodiments, air may not be actively directed into the cavity. Instead, the air surrounding the saturated materials is heated and/or humidified. The opening in the wall allows for sufficient natural convection and diffusion to dry the interior of the wall. After the wall ( 200 ) has been dried, the shoe ( 100 , FIG. 2 ) and baseboard ( 230 , FIG. 2 ) can be replaced or reinstalled, resulting in a significant savings of time and money.
FIG. 5 is a flowchart showing an illustrative method for utilizing a wall shoe to mitigate water damage to walls. In a first step, the wall shoe and drywall are installed, with the wall shoe elevating the drywall above the floor (step 500 ). The baseboard is then attached to cover the wall shoe and bottom edge of the drywall (step 505 ). Following a disaster event, the water damage is assessed to determine if water absorption is confined to the sill (determination 510 ). Typically, this would correspond to a water depth of one to one-and-half inches of water. If the water absorption is confided to the sill, the baseboard is removed and the sill is dried through the channels in the wall shoe (step 515 ). Following the completion of the drying process, the baseboard is replaced (step 520 ).
If the damage is not confined to the sill, but extends into the interior of the wall, both the baseboard and the wall shoe are removed (step 530 ) to provide access to the interior of the wall. The interior of the wall is dried through the opening between the drywall and sill (step 535 ). Following the extraction of the excess moisture from the interior of the wall and wall elements, the wall shoe and base board may be replaced (step 540 ).
The preceding description has been presented only to illustrate and describe embodiments and examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. | A wall shoe includes a generally rectangular body that is placed beneath a wall covering to protect the wall covering from water damage; the wall shoe providing access to the interior of a wall. A method of extracting moisture from the interior components of a wall includes interposing a wall shoe between a lower edge of a wall covering and a floor, the wall shoe being a rectangular body with a number of channels passing through the thickness of the rectangular body; following exposure of the wall to water, utilizing the wall shoe to provide access to the interior components of the wall; and providing an air flow; the air flow drying the interior of the components of the wall through access provided by the wall shoe. | 4 |
REFERENCE TO RELATED CASES
[0001] This application is a continuation of PCT/US04/14207, filed May 7, 2004, which has a priority date of May 9, 2003 based on U.S. patent application Ser. No. 10/435,620 filed on May 9, 2003, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The field of the present invention is devices for the delivery or placement of therapeutic or diagnostic agents into a living body.
[0003] Some medical procedures employ the infusion of therapeutic agents into living bodies over periods of time, making a syringe inconvenient and/or inappropriate. Such procedures have been used for the infusion of insulin, for example. In other cases, monitoring of internal body conditions with small sensors or other devices also makes syringes and like devices inappropriate for continuing access to subcutaneous tissue. To provide access in either circumstance, ports have been devised which provide support for a flexible cannula implanted in the body. Ports typically provide a housing which has a mounting side that is held by tape, dressings or direct adhesive against the body. A flexible cannula extends from the housing into the body.
[0004] Ports used for infusion may be employed in combination with a delivery tube extending to the housing of the port and in communication with the cannula as a complete infusion set. The delivery tube of such an infusion set is in communication with the flexible cannula through an infusion fluid chamber in the port to deliver therapeutic agents. Diagnostic agents such as biosensors may be delivered in like manner.
[0005] To place such ports or infusion sets including such ports, insertion sets have been used. An insertion set typically includes the port and necessarily includes a rigid sharp such as a needle which is placed through the flexible cannula for insertion into the body. The needle typically extends through a resilient barrier such as a resealable resilient mass, through a chamber and then axially through the cannula. Once the cannula has been positioned in the body, the port is positioned and the needle can be withdrawn. The resealing of the mass as the needle is withdrawn prevents fluid from leaking from the port while remaining in position at the site. Once the port has been placed with the flexible cannula extending into the body, the agent or agents can be delivered.
[0006] A first type of insertion set includes an infusion set having the port and a delivery tube in communication with the cannula. The insertion set needle accesses the housing through a different path than the delivery tube. The seal is typically bypassed by the delivery tube in this instance. Alternatively, the insertion set is used with a port rather than a complete infusion set. The delivery tube is placed after insertion of the port to complete an infusion set. The same path is used for the insertion needle as part of the insertion set as is used for communicating the tube of the infusion set with the cannula. In this latter case, the delivery tube is associated with a hub which includes a member able to pierce a resealable resilient mass for communication between the delivery tube and the cannula once the insertion set has been disassembled through retraction of the needle.
[0007] Mechanisms referred to as inserters have been devised to rapidly insert the needle and cannula into the body at the site. For the infusion of insulin in particular, diabetics self medicate. Consequently, they, a family member or other care provider places the port for infusion. This can be emotionally and physically difficult when repeated infusions are required over long periods of time. Inserters alleviate this burden somewhat by making the placement of the needle automatic and quick. Further, pressure by the inserter about the targeted site reduces the sensation of pain.
[0008] Inserters typically include a housing with a driver slidable in the housing. The driver includes a socket to receive the insertion set. A spring is operatively placed between the housing and the driver to advance rapidly an insertion set positioned in the socket. A latch then controls the advancement of the driver. One complete system including an infusion port, an insertion set having the infusion port and an insertion needle, and an inserter is illustrated in U.S. Pat. No. 6,293,925.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a system for the delivery of therapeutic and/or diagnostic agents and components thereof. An inserter for a port assembly includes a housing assembly and a port driver with a spring operatively between the two. The housing assembly includes a housing having a bore and a latch. The port driver includes a seat for receiving a port assembly. The port driver also includes a socket. A cannula insertion member is positioned in the socket and is inseparable from the socket. With the insertion member inseparable from the socket, the inserter becomes disposable. Potentially, the port assembly and an access hub could be included with the inserter as a disposable system. The inserter can come fully prepared and sterile with seals at either end of the bore. The housing assembly can also serve as a package serving to appropriately discard the inserter with the needle covered.
[0010] Therefore, it is a principal object of the present invention to provide a new inserter for a port assembly. Other and further objects and advantages well appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a plan view of a port assembly.
[0012] FIG. 2 is a side view of the port assembly of FIG. 1 .
[0013] FIG. 3 is a cross-sectional view of the port assembly of FIG. 1 taken through the axis thereof along line 3 - 3 of FIG. 2 .
[0014] FIG. 4 is a cross-sectional view of the port assembly taken at 90° to the cross-sectional view of FIG. 3 .
[0015] FIG. 5 is a detail view as seen in FIG. 3 .
[0016] FIG. 6 is a perspective view of a resilient barrier.
[0017] FIG. 7 is a cross-sectional view of the resilient barrier.
[0018] FIG. 8 is a perspective view of a second port assembly.
[0019] FIG. 9 is a cross-sectional view of the port assembly of FIG. 8 taken through the axis.
[0020] FIG. 10 is a cross-sectional view of a third port assembly also taken through the axis of the assembly.
[0021] FIG. 11 is a perspective view of a port inserter.
[0022] FIG. 12 is a cross-sectional view of the port inserter of FIG. 11 taken through the axis of the port inserter.
[0023] FIG. 13 is a cross-sectional view of the port inserter of FIG. 12 with the inserter discharged and closed, the view being at 90° to FIG. 12 .
[0024] FIG. 14 is a cross-sectional view of a second port inserter taken through the axis of the inserter.
[0025] FIG. 15 is a plan view of a third port inserter.
[0026] FIG. 16 is a cross-sectional view taken along an axis of the port inserter of FIG. 15 .
[0027] FIG. 17 is a cross-sectional view taken along an axis of the port inserter of FIG. 15 at 90° to the view of FIG. 16 .
[0028] FIG. 18 is a cross-sectional view taken along an axis of a fourth port inserter.
[0029] FIG. 19 is a cross-sectional view taken along an axis of the port inserter of FIG. 18 at 90° to the view of FIG. 18 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Turning in detail to the drawings, FIGS. 1 through 7 illustrate a first port assembly, generally designated 20 . The port assembly 20 includes a base 22 which is shown to be frustoconical. The base may alternatively be cylindrical. Other shapes, of course, can also be employed. The base includes a mounting side 24 . The mounting side may include adhesive for retention at a site on a living body. The adhesive is preferably nondrying and may or may not include a coated paper cover to be removed prior to use. A port 26 is arranged in the base 22 to be open to the other side of the base from the mounting side 24 . In this embodiment, the port opens into a cavity 28 defined by a cannula mounting element 30 and a retainer element 32 which are sonically welded, press fit or cemented into the main part of the base 22 .
[0031] A cannula 34 extends from the base 22 . In this embodiment, the cannula extends perpendicular to the mounting side 24 . Other angles might be appropriately employed. The cannula mounting element 30 provides a passage 36 into which the cannula 34 is positioned. The cannula 34 has a mounting flange 38 to retain the cannula 34 from being drawn through the passage 36 . The cannula 34 may be retained in the cannula mounting element 30 and a seal formed with the passage 36 through the use of adhesive, sonic welding where the materials are compatible, a press fit, or sealing elements. In the preferred embodiment, the cannula mounting element 30 insures retention of the cannula 34 by ultrasonically swaging the body of the element 30 to draw material from that element 30 over the flange 38 , as best seen in FIG. 5 .
[0032] The port assembly 20 further includes a resilient barrier 42 . The resilient barrier 42 is preferably an elastomer. It is positioned in the cavity 28 and overlies the cannula 34 . The resilient barrier 42 controls fluid communication from the port 26 to the cannula 34 .
[0033] The resilient barrier 42 is illustrated in this embodiment to be a valve. The valve 42 is defined by a circular elastomeric septum 44 . The septum 44 includes a slit 46 therethrough. The slit 46 is cut so that the valve remains closed when in the unstressed state. A frustoconical concavity 48 provides relief for flexure of the septum 44 downwardly to open the slit 46 . As can best be seen in FIG. 6 , the septum 44 includes shaped protrusions 50 to influence the distortion of the septum 44 with pressure from above. The septum 44 further includes circular beads 52 and 54 . These beads provide seals for sealing contact with components on either side of the septum 44 . Thus, the circular bead 54 provides sealing contact with the cannula mounting element 30 about the cannula 34 and also about the concavity 48 . Thus, the resilient barrier 42 controls communication from the port 26 to the cannula 34 through pressure on the upper side thereof.
[0034] An access hub, generally designated 56 , includes a hub 58 . A connector 60 extends from the main body of the hub 58 . A tube 62 extends laterally from the main body of the hub 58 . A fitting 64 is located at the end of the tube 62 for receipt of an infusion tube (not shown). Other fittings may be employed to rigidly engage such tubing or other components. A passage 66 extends through the fitting 64 , the tube 62 and the connector 60 to provide flow communication through the access hub 56 . The tube 62 has a length of reduced outside diameter to receive a tab 68 . The tab 68 is pivotally mounted about the area of reduced cross section of the tube 62 . The tab 68 includes a split hub 70 for forced mounting on the tube 62 . Ribs 72 on the tab 68 provide increased purchase. The tab 68 has a first position as illustrated in FIGS. 1 and 2 . In a second position, the tab may be pivoted to extend more aligned with the longitudinal direction of the connector 60 for easy gripping between thumb and forefinger.
[0035] The access hub 56 is constructed such that the connector 60 can be positioned through the port 26 into the cavity 28 and fully against the resilient barrier 42 , as seen in each of the relevant Figures. The bottom of the connector 60 includes a surface able to press against the shaped protrusions 50 on the opposed surface of the circular elastomeric septum 44 . The protrusions 50 might alternatively or additionally be found on the end of the connector 60 but it is preferred that they be located on the septum 44 such that rotation of the access hub 56 relative to the port assembly 20 will not impact on the communication through the slit 46 . The connector includes an annular surface 74 which, in cross section as illustrated in FIG. 5 , is shown to provide a segment of a circle. The curved portion of the surface 74 facing toward the distal end of the connector 60 aids in the location of the access hub 56 into the port assembly 20 . The more proximal portion of the annular surface 74 cooperates with a radially resilient bearing ring 76 located within the cavity 28 . Together the annular surface 74 and the radially resilient bearing ring 76 define a coupling between the port assembly 20 and the access hub 56 . The ring 76 is preferably split to create adequate radial resilience. The ring 76 includes an inner concave track 78 meeting with the annular surface 74 . The resilience in the ring 76 and the shape of the concave track 78 cause the ring 76 to draw the connector 60 further into the cavity 28 as the ring 76 attempts to contract. This bias forces the flat end of the connector 60 against the circular bead 54 to result in sealing contact therebetween. The placement of the connector 60 is such that the circular bead 54 is located about the end of the passage 66 . The annular surface 74 is small enough to fit through the port 26 and to force open the ring 76 .
[0036] The port assembly 20 and access hub 56 of this first embodiment provide for the placement of the port assembly 20 in the body prior to an assembly of the port assembly 20 and the access hub 56 . Once assembled, the connector 60 of the access hub 56 is biased against the septum 44 , resulting in the circular beads 52 and 54 sealing against the connector 60 and the cannula mount element 30 , respectively. The distal surface of the connector 60 forces the shaped protrusions 50 toward the cannula 34 to open the slit 46 . Once open, the slit 46 provides communication from the passage 66 to the cannula 34 . Further, the access hub 56 can be pivoted about the centerline of the connector 60 . When the access hub 56 is removed by extraction force transmitted by the tab 68 , the slit 46 returns to the closed position as the force acting upon the shaped protrusion 50 is removed.
[0037] Another port assembly, generally designated 80 , is illustrated in FIGS. 8 and 9 . This port assembly 80 exhibits a flat rather than frustoconical profile. A base 82 again provides a mounting side 84 which may include adhesive 86 . A cannula mounting element 88 is fixed in the base 82 and has a retainer element 90 thereabout which is also fixed in the base 82 . The cannula mounting element 88 retains a cannula 92 much as in the first embodiment. Further, a resilient barrier 94 defined by the circular elastomeric septum 44 as illustrated in FIG. 6 of the first embodiment is held between the cannula mounting element 88 and the retainer element 90 . The retainer element 90 defines a port 96 . The retainer element 90 also defines a post about the port 96 including an annular surface 98 . The surface 98 defines a concave track about the post thus defined.
[0038] An access hub generally designated 100 , can be assembled with the port assembly 80 . The access hub 100 includes a hub 102 having a hub circular periphery 104 . This periphery 104 includes cut-outs 106 diametrically opposed with undercut sides 108 . The cut-outs 106 expose the base 82 so that a pinching of the assembly with the thumb and forefinger will separate the access hub 100 from the port assembly 80 .
[0039] The hub 102 provides a cylindrical cavity 110 which has one portion about the periphery thereof modified for the provision of a fitting 112 . The fitting 112 again provides for infusion tubing (not shown). An inclined asymmetry 114 at the fitting 112 insures that the infusion tubing is not pushed so far into the fitting 112 that a further passageway into the access hub 100 is closed off.
[0040] An inner hub element 116 fits within the cylindrical cavity 110 and defines a connector 118 and a passage 120 . The passage 120 extends from the fitting 112 to through the connector 118 . The passage 120 is formed as a channel in the inner hub element 116 and closed by the hub 102 . Further, the passage 120 extends through the connector 118 . As with the prior embodiment, the connector 118 is insertable to the resilient barrier 94 , operating in the same way as the first embodiment in the influence on opening the valve mechanism associated therewith.
[0041] A retainer 122 is fixed to the inner web element 116 . The retainer 122 is contemplated to extend fully about the inner cavity 124 defined within the inner hub element 116 . The inner hub element 116 and the retainer 122 capture a radially resilient bearing ring 126 within the inner cavity 124 . This bearing ring 126 is preferably split and includes a convex annular bead 128 which cooperates with the annular surface 98 to define a coupling between the port assembly 80 and the access hub 100 . Albeit the location of the elements are inverted, the ring 126 acts in a similar way to that of the first embodiment in that it is sized and arranged to force the connector 118 into sealing contact with the resilient barrier 94 . Again, one of the end surfaces of the connector 118 and the resilient barrier 94 includes shaped protrusions to cause opening of the valve upon placement of the connector 118 in the port 96 .
[0042] A further port is illustrated in FIG. 10 . The access hub 130 is identical to that of the embodiment of FIGS. 8 and 9 . Further, FIG. 8 applies equally to the embodiments of FIG. 9 and FIG. 10 . The port assembly 132 includes a base 134 which is defined by a cannula mounting element 136 and a disk 138 having a cylindrical flange about the outer periphery thereof. Together the mounting element 136 and disk 138 provide a flow area therebetween which is able to reach a plurality of cannulas 142 extending from the mounting surface 144 . These cannulas 142 are rigid but are contemplated to be very short so as to provide dispersed infusion into living tissue or multi-sensor diagnostic access. The cannulas are rigidly fixed within the cannula mounting element 136 . Further, the cannula mounting element 136 provides a broader opening which communicates with the flow area between the plate 136 and the disk 138 for adequate distribution of infusion fluids thereabout.
[0043] FIGS. 11 through 19 provide inserter embodiments. These embodiments are shown to mate with the port assembly 20 . Through slight modification of the seat within which the port assembly is positioned, the embodiments of FIGS. 8 through 10 might also be accommodated. The first two embodiments, FIGS. 11 through 13 and 14 are advantageously configured for disposable use. The embodiment of FIGS. 15 through 17 is most advantageously reusable. Finally, the embodiment of FIGS. 18 and 19 is configured for reusable or disposable use.
[0044] In the embodiment of FIGS. 11 through 13 , the inserter, generally designated 148 , is shown to include a housing assembly including a housing 150 . The housing 150 is conveniently cylindrical with a bore 152 and outwardly extending flanges 154 to define circular attachment surfaces at either end of the bore 152 . First and second closures 156 and 158 can be retained on the flanges 154 . These closures 156 and 158 include a tab 160 such that they are conveniently removably mounted across the bore 152 with adhesive. The closures 156 and 158 are preferably peal-off sheets commonly employed for sterile closures.
[0045] The housing 150 further includes a mount 162 extending across the bore 152 and integrally formed with the housing 150 . The mount 162 is in the form of a plate perpendicular to the axis of the bore 152 . A central hole 164 is provided through the mount 162 to receive a latch discussed below. Two holes 166 elongate in cross section extend to either side of the central hole 164 . These holes are parallel and are located symmetrically about the center axis of the housing. Certain additional holes 168 are provided through the mount 162 for molding purposes.
[0046] The housing 150 further includes stops 170 extending inwardly in the bore 152 and conveniently being diametrically opposed to one another. The holes 168 for molding purposes are aligned with the stops 170 such that molding of the stops 170 is facilitated. Indexing tabs 172 are also diametrically placed to one side of the mount 162 and are also formed as part of the inner wall of the housing 150 . On the other side of the mount 162 , a key 174 extends into the bore 152 and from the mount 162 .
[0047] A latch 176 is positioned to one side of the mount 162 . The latch includes a plate 178 extending substantially across the bore 152 of the housing 150 . Additionally, the latch 176 includes upwardly extending walls 180 forming segments of a cylinder. One of these segments of the walls 180 includes a keyway 182 which receives the key 174 . The keyway 182 has a substantial portion having a first height to receive the key 174 with the latch 176 axially positioned as shown in FIG. 12 . At one point, the keyway 182 is of increased depth parallel to the centerline of the housing 150 which allows the latch 176 to move toward the mount 162 . The walls 180 have three gaps 184 therebetween. One of the walls 180 also includes an undercut section 186 .
[0048] Hooks 188 extend in the opposite direction of the walls 180 from the plate 178 . These hooks 188 include outwardly extending barbs 190 which extend through the central hole 164 in the mount 162 . The barbs 190 have inclined surfaces 192 such that they can be forced into the central hole 164 with the hooks 188 exhibiting some resilience. The barbs 190 on the hooks 188 are spaced such that once inserted through the central hole 164 , they will engage the rim of the hole 164 regardless of the angular orientation such that the latch 176 is permanently captured by the mount 162 .
[0049] Setoffs 194 extend in the same direction from the plate 178 as the hooks 188 . These setoffs 194 are straight and parallel to one another and equally displaced from the axis of the housing. The setoffs 194 match the parallel holes 166 so that the latch 176 may be forced closer to the mount 162 . However, the hooks 188 also each have an inclined surface facing outwardly which inhibits substantial movement of the latch 176 toward the mount 162 from the position a shown in FIG. 12 . In position for use, the latch 176 is oriented such that the standoffs 194 are not aligned with the parallel holes 166 such that the latch 176 is held axially within the bore 152 of the housing 150 . During assembly of the inserter might the latch be angularly rotated to match the setoffs 194 with the parallel holes 166 to insure that assembly can be accomplished.
[0050] A cover 198 is arranged with the latch 176 . The cover also includes a plate 200 which generally lies against the plate 178 of the latch 176 . A cylindrical wall 202 extends upwardly from the plate 200 . This wall 202 includes three blocks 204 which extend radially outwardly from the wall 202 . These blocks 204 engage the gaps 184 in the upwardly extending walls 180 of the latch 176 . Consequently, rotation of the cover 198 will result in rotation of the latch 176 with the two components in mating relationship.
[0051] The cover also includes two fingers 206 diametrically opposed and spaced in cutout portions of the cylindrical wall 202 . One of these fingers 206 includes a rounded circumferentially extending bar 208 which engages the undercut section 186 in one of the upwardly extending wall segments 180 . The bar 208 provides some retention of the cover 198 but allows it to be removable with a small amount of force. The two opposed fingers 206 are slightly shorter than the full extent of the upstanding wall 202 and have inclined surfaces 207 . The fingers 206 are somewhat resilient and can move radially inwardly because of the cuts to either side of the fingers 206 in the cylindrical wall 202 .
[0052] Centrally located in the plate 200 , an integral channel 210 extends across the cover 198 . This integral channel 210 forms a chamber 212 open toward the latch 176 .
[0053] The structure of the cover 198 is such that it can be extracted from association with the latch 176 and pulled from the housing 150 . The cover 198 may then be turned over and forced into the other end of the housing 150 within the bore 152 as seen in FIG. 13 . The fingers 206 resiliently ride over the diametrically opposed stops 170 across the inclined surfaces 207 and lock on the upper surface of the fingers 206 .
[0054] The cylindrical wall 202 has an additional rim 214 about its circumference to fit closely within the bore 152 of the housing 150 in this position. As such, the lower end of the bore 152 is closed by the cover 198 after use. The upper end of the bore 152 remains substantially closed by the plate 178 of the latch 176 .
[0055] A port driver, generally designated 216 , is slidably mounted within the bore 152 of the housing 150 . The port driver 216 includes a cylindrical outer wall 218 which slides within the bore 152 . The cylindrical outer wall 218 includes two gaps (not shown) diametrically opposed. These gaps mate with the indexing tabs 172 which extend from the mount 162 . These gaps also provide clearance to allow the port driver 216 to be mounted in the housing 150 across the stops 170 . The gaps extend fully through the port driver 216 and allow for air flow as the driver 216 moves through the housing 150 . A cylindrical inner wall 220 defines an annular spring cavity 221 for receiving a coil spring 222 . The cylindrical inner wall 220 includes an inwardly extending flange 224 which includes notches 226 diametrically opposed where there is no inwardly extending flange 224 . As such, the hooks 188 which extend through the central hole 164 further extend into the cylindrical inner wall 220 and engage the inwardly extending flange 224 unless aligned with the notches 226 .
[0056] A plate 228 extends across the port driver 216 from which the cylindrical walls 218 and 220 extend to form the annular spring cavity 221 . This plate 228 provides a seat 230 which is shown in FIGS. 12 and 13 to be conically formed to accommodate the first embodiment port assembly 20 . The seat 230 may easily be formed to accommodate the port assemblies 80 and 132 . In this disposable embodiment, the seat 230 does not in any way restrain the port assembly 20 from moving away from the seat 230 . The plate 228 does extend outwardly to the wall of the bore 152 such that the stops 170 will engage the plate 228 as it moves to the end of the housing 150 .
[0057] The plate 228 includes a central portion 232 having holes 234 facilitating the molding process of the flanges 224 . The holes are directly aligned with the inwardly extending flange 224 to that end. A socket 236 is centrally located within the central portion 232 . This socket 236 is sized to receive a needle which may be forcefully fit within the socket 236 or permanently retained there by a bonding agent. In either circumstance, the socket is designed to rigidly and permanently fix a needle employed as a cannula insertion member.
[0058] A cannula insertion member 238 in the form of a sharp needle is permanently affixed within the socket 236 . This needle 238 extends downwardly through the port assembly 20 and through the cannula 34 associated therewith. The cannula 34 is fit snugly about the needle 238 such that friction does exist between the cannula 34 and the needle 238 . The retention force thus provided maintains the port assembly 20 in place prior to application. The adhesive on the mounting side 24 is formulated to have a greater separation force than the retention force between the cannula 34 and the needle 238 . Further, the base 22 is sized to miss these stops 170 .
[0059] In operation, the inserter 148 is assembled by pressing the latch 176 into position with the hooks 188 extending through the central hole 164 . The cover 198 is also positioned on the latch 176 and forced into place. The latch may be oriented such that the parallel setoffs 194 engage the parallel holes 166 so that the latch 176 may be forced further into the bore 152 to insure engagement with the port driver 216 . The coil spring 222 is placed between the mount 162 and the port driver 216 in the annular spring cavity 221 . The port driver is aligned with the housing 150 so that the gaps match up with the stops 170 . With the spring operatively positioned between the mount 162 and the port driver 216 , the port driver is forced upwardly and angularly displaced until the hooks 188 engage the inwardly extending flange 224 .
[0060] The cannula insertion member 238 may originally be part of the inserter 148 by location in the socket 236 with a bonding agent or through forced interference fit. Alternatively, the cannula insertion member 238 may first be temporarily assembled with the port assembly 20 through the cannula 34 and then associated with the port driver 216 as the port assembly 20 is positioned. Ultimately, the cannula insertion member 238 becomes a fixed part of the port driver 216 .
[0061] The closures 156 and 158 are then positioned and fixed on the ends of the housing 150 and the device sterilized. Depending on the method of sterilization, the device is sterilized after placement of the closures 156 and 158 .
[0062] In use, the closures 156 and 158 are removed by pulling on the tabs 160 . The inserter 148 is then placed on the body site. The cover 198 is then rotated until the hooks 188 meet the notches 226 in the inwardly extending flange 224 , releasing the port driver 216 . The spring 222 propels the port driver 216 forwardly to the end of the housing 150 where it engages the stops 170 . The port assembly 20 is advanced with the port driver 216 until the adhesive contacts the surface of the body. In doing so, the cannula insertion member 238 is rapidly advanced into the body along with the supported cannula 34 . Once placed, the housing 150 is retracted from the body retaining the port driver 216 including the cannula insertion member 238 . The resilient barrier 42 prevents flow from the body through the cannula 34 . With the inserter 148 removed, the cover 198 is pulled from the end of the housing 150 and placed on the other end thereof to engage the fingers 206 with the stops 170 . The container 212 defined by the channel 210 receives the cannula insertion member 238 to cover the sharp and close the container.
[0063] With the port assembly 20 in place and the inserter 148 removed, an access hub 56 can then be placed. As the connector 60 is inserted into the port 26 of the port assembly 20 , the end surface of the connector 60 extends against the shaped protrusions 50 of the resilient barrier 42 . The connector 60 does not extend through the slit 46 but opens the valve through its positioning in the cavity 28 . The coupling mechanism including the radially resilient bearing ring 76 and the annular surface 74 is engaged; and the connector 60 is pressed against the circular bead 52 . The access hub 56 is then movable in the port assembly 20 and can be pivoted to best advantage for the associated infusion tubing. Removal of the access hub 56 , in this embodiment by the tab 68 , will withdraw the connector 60 and allow the slit 46 to again close in the resilient barrier 42 .
[0064] Turning to the port driver 240 illustrated in FIG. 14 , the mechanism is substantially identical to that of the embodiment of FIGS. 11 through 13 . However, the cover 242 is differently configured principally with a channel 244 having a container 212 which is askew to bend the cannula insertion member 246 to the side as the cover 242 is placed on the driver end of the housing 248 . Stops 250 again engage the cover 242 to hold it in place.
[0065] Turning to the inserter embodiment of FIGS. 15 through 17 , a reusable inserter, generally designated 252 , is disclosed. The inserter includes a housing 254 which is substantially identical to prior housings. The bore 258 includes a mount 260 extending across the housing 254 as previously described. However, the central hole 262 is increased in size for placement considerations.
[0066] The port driver 264 includes a cylindrical outer wall 266 and a cylindrical inner wall 268 defining an annular spring cavity 270 . Inwardly extending flanges 272 are located at the end of the cylindrical inner wall 268 most adjacent the mount 260 . Again, notches 274 in the inwardly extending flanges 272 are arranged diametrically. A coil spring 276 is located within the annular spring cavity 270 . In this embodiment, the center area of the port driver 264 is open. An annular plate 278 closes the bottom of the annular spring cavity 270 and defines a seat for a port assembly 20 . In this embodiment, the base 282 of the port assembly 20 includes a circular channel 284 . The seat 280 of the annular plate 278 includes a retainer 286 in the form of a circular ring which engages a circular channel 284 with minimal release force generated by a minimal interference fit to retain the port assembly 20 in place prior to insertion.
[0067] The cannula insertion member 288 includes a sharpened needle 290 and a needle hub 292 . The needle 290 is permanently retained within the needle hub 292 . The needle hub 292 includes an engagement shoulder 294 at its distal end and a plug 296 that fits within the port 298 of the port assembly 20 .
[0068] A latch 300 is located to the other side of the mount 260 from the port driver 264 . The latch includes a plate 302 extending across the bore 258 of the housing 254 . A cylindrical wall 304 extends along the bore 258 . A keyway 306 is found in the cylindrical wall 304 to receive a key 307 associated with the housing 254 . Hooks 308 are provided as in prior embodiments but are spaced further apart to allow for the needle hub 292 .
[0069] A socket 310 is centrally located in the plate 302 of the latch 300 . This socket 310 releaseably retains the needle hub 292 which is otherwise slidable within the socket 310 . The socket 310 includes a passageway 312 which is open at the end toward the port assembly seat 280 . A shoulder 314 is presented at the end of the passageway 312 to encounter and retain the engagement shoulder 294 of the needle hub 292 . The socket 310 is also split diametrically along its length to form two socket elements 316 . The length of the socket 310 is such that, in combination with the needle hub 292 , the engagement shoulder 294 and the shoulder 314 do not stop insertion of the cannula insertion member until the needle 290 has penetrated the body to the point that the associated cannula 34 will not extend beyond the needle 290 . The arrangement is designed to stop the cannula insertion member 288 before the port driver 264 has traveled fully to the stop 318 located in the bore 258 of the housing 254 .
[0070] With the inserter 252 having been actuated by rotation of the latch 300 and the port assembly 20 placed, the inserter 252 can be withdrawn along with the cannula insertion member 288 as a component of the inserter 252 . Once withdrawn, the cannula insertion member 288 can be released from the reusable inserter 252 . The plate 302 defines a slightly flexible web across the bore 258 of the housing 254 . Two opposed levers 320 extend upwardly from that web 302 . These levers are aligned with the socket elements 316 defining the socket 310 . By pinching the levers 320 together, the socket elements 316 splay apart and release the needle hub 292 . A new cannula insertion member 288 can then be positioned in the inserter 252 by forcing it past the shoulder 314 . This may be accomplished with or without the port assembly 20 .
[0071] With the reusable inserter 252 , the device may be prepared by positioning the cannula insertion member 288 in the port assembly 20 . The cannula insertion member 288 is then engaged with the socket 310 by forcing the needle hub 292 through the shoulder 314 on the socket elements 316 . These levers 320 may be pinched together to facilitate this assembly. The port assembly 20 is then forced against the port driver 264 to place the port assembly 20 in the seat 280 with the circular channel 284 and the circular ring 286 engaged with slight interference. Where the port assembly has exposed adhesive on the mounting side 322 , it is advantageous that the port driver 264 is forced into engagement with the latch 300 before placement of the port assembly 20 . Once prepared, the inserter 252 may be placed at the site and the levers 320 turned to rotate the latch 300 such that the hooks 308 meet the notches 274 and release the port driver 264 . The inserter 252 is then withdrawn, retaining the cannula insertion member 288 as part of the inserter assembly. The port assembly 20 remains at the site with the cannula 34 extending into the living body. An access hub 56 is then positioned with the connector 60 in the port 26 . Force is applied to engage the coupling between the two such that the access hub 56 is then movably retained within the port assembly 20 . The system is then ready for delivery of therapeutic agents or diagnostic agents through the cannula into the living tissue. The access hub 56 may be withdrawn through force exerted on the tab 68 , or by pinching the access hub in the second or third embodiments. The valve of the resilient barrier 42 responds appropriately by sealing the pathway when the access hub 56 is not in place and opening the pathway when it is.
[0072] A further port inserter as illustrated in FIGS. 18 and 19 , generally designated 324 , combines a number of features of the prior port inserters. The device may come fully sealed and sterile. Further, the port inserter 324 contemplates the intended release of the needle after use or the enclosure of that needle with the inserter for discard. A cylindrical housing 326 , as generally described in preceding embodiments, includes an extended length to accommodate closure elements 328 and 330 . A latch 332 operates identically to that in the prior embodiment of FIGS. 15 through 17 and cooperates with a needle hub 334 and needle 336 in a like manner. The extended portion of the housing 326 encloses the levers of the latch 332 and receives a cover 338 . This cover is constructed so that it may be forced against the driver 340 from the bottom to enclose the needle 336 and lock the cover over the stops 342 . The driver 340 is the same as that of prior embodiments and is driven by a spring 344 in like manner. Likewise a port 20 also is as in prior embodiments.
[0073] Thus, improved ports and inserters therefor have been described. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore is not to be restricted except in the spirit of the appended claims. | A system for delivery of therapeutic and/or diagnostic agents into a living body includes a port assembly having a cannula extending from the mounting side, a port opening away from the mounting side and a resilient barrier between the port and the cannula. An access hub includes a connector positionable at the port for opening the resilient barrier. The access hub is movable in the port assembly, is engaged therewith through a resilient ring coupling and forms a seal with the resilient barrier, reducing the amount of volume to be primed. Inserters, both disposable and reusable, include the cannula insertion member as part of the assembly. A spring loaded port driver is operatively mounted within the housing with movement controlled by a latch. The driver includes a seat for receipt of a port assembly. The cannula insertion member is nonremovably fixed in a socket in the port driver in the disposable assembly. In the reusable inserter, the cannula insertion member is slidably mounted within a socket associated with the latch. Slidable movement is limited by locking shoulders. The socket is split and may be splayed to release the cannula insertion member following use. | 0 |
More than one reissue application has been filed for U.S. Pat. No. 6 , 251 , 478 . The reissue applications are U.S. Ser. No. 09 / 996 , 636 ( the present application ) and U.S. Ser. No. 10 / 776 , 035 , both of which are divisional reissues of U.S. Pat. No. 6 , 251 , 478 .
FIELD OF THE INVENTION
The present invention relates to the encapsulation and stabilization of volatile, and temperature and oxygen sensitive substances.
BACKGROUND OF THE INVENTION
Three are many materials that exist in nature, or are synthesized, that have low stability under ambient conditions. These materials may decompose, disassociate, lose viability, etc. through reaction with oxygen present in the atmosphere, or losing essential components by volatilization at ambient and elevated temperatures. Examples include flavors, flavor compounds, aromas, fragrances, vitamins, nutrients (such as omega 3 oils, carotenoids, vitamin A and E), alcohols, acetones, ketones, aldehydes, organic acids, antioxidants, biologically active substances etc., hereinafter referred to as sensitive materials.
Sensitive materials may have single or multiple components that can be categorized based on their level of volatility. Components that reach the boiling point at low temperatures are categorized as having high volatility, high notes or top notes. An example of a low boiling point component is diacetyl (2,3-Butanedione) with a boiling point of 88° F. (water has a boiling point of 212° F.) Diacetyl is used to bring the characteristic dairy flavor in butter, coffee, and vinegar.
Volatile materials may comprise a single low boiling point component or may comprise a mixture of low, medium and/or high boiling components. The medium and low notes are not volatile at ambient or elevated temperatures (250° F. and above), and are therefore generally unaffected by atmospheric conditions or elevated processing temperatures. Loss of the high notes in volatile materials very often results in a finished product that is out of balance.
The high notes of volatile materials are the most sensitive portions of the product. High notes can be lost through volatilization which is accelerated at temperature above 40° F. Loss of high notes can also occur during storage, incorporation in a food product, processing of a food product, and storage of that food product even under frozen conditions.
There have been attempts to overcome the problems associated with maintaining high notes in a formulation. For instance, over formulation is used to supply the high notes (high volatiles) in greater quantities to compensate for the losses. However, this solution does not address the relative concentrations of differing volatile compounds in the original product versus the resulting product. Furthermore, it is difficult to anticipate how much of the high notes will be lost. In addition, high notes are lost over a period time and the amount of loss can depend on temperature, so that the composition of the volatile material is constantly changing.
Another approach to delivering a balanced composition of high, medium, and low notes has been through encapsulation technology. Early attempts used spray drying and spray chilling technologies to stabilize the flavor and fragrance compositions. With spray drying, a volatile substance is first emulsified in an aqueous solution of a water-soluble protective colloid, such as gelatin, and carbohydrates (e.g. gum arabic, starch, dextrin. The emulsion is then sprayed into a column of heated air or gases to evaporate the water. The resulting dry particles have a water-soluble shell or capsule of the water-soluble colloid in which the volatile substance, such as a flavor, is embedded or encapsulated in the form of minute droplets. Spray chilling is differentiated from spray drying by having the emulsion being sprayed into a column of ambient or chilled air.
U.S. Pat. No. 3,857,964 teaches controlled release flavor compositions which comprise flavor particles having an outer coating of a physiologically inert, water-softenable and swellable material. Flavor particles may be formed by adding and stirring volatile agents, such as cyclic acetal compounds, into a polymeric material. The resulting flavor particles are then coated by stirring them into a sodium alginate solution, passing them through a size-limiting orifice into a room temperature bath of calcium lactate solution.
U.S. Pat. No. 5,607,708 relates to an encapsulated flavoring material formed of an edible, oil-insoluble, water-soluble outer shell surrounding an edible, water-insoluble inner core that is liquid at a temperature of about 45° C. and contains a volatile, oil-soluble flavoring material dissolved or dispersed in the inner core. Materials suitable for the outer shell include gelatin, water soluble gums, starches or dextrins. The cover material may be an unsaturated vegetable oil, fat and/or partially hydrogenated oil or fat. It is important during the manufacture of the core materials that the material have a relatively low melting point so that the volatile components may be mixed with this material at low temperatures, thereby minimizing the loss of the volatile component. Coannular centrifugal extrusion methods may be used to form particles of the core material and simultaneously to coat them with the shell material. Coannular extrusion means are used in U.S. Pat. No. 5,399,368 to produce coated materials in which volatile materials, such as coffee oil, are entrained.
U.S. Pat. No. 5,874,102 teaches encapsulated fatty acid salt products comprising a core material coated with continuous film that serves as a barrier to volatile compounds contained in the core matrix. The particles may then be coated by direct spraying means. Direct spraying of a volatile-containing core material by an aqueous solution of first and second coagulating agents is also shown in U.S. Pat. No. 5,558,889. U.S. Pat. No. 5,004,595 teaches the production of similar coated particles using a fluidized bed process.
U.S. Pat. No. 4,689,235 discloses an encapsulating matrix composition that is extrudable at a pressure in the range of 1 to 10 atm and having an improved loading capacity up to 40% comprising maltodextrin and hydrogen octenylbutanedioate amylodextrin. The matrix may contain from 5 to 40 wt. % of a normally liquid or volatile active ingredient which is added in a tank having heating and agitating means.
U.S. Pat. No. 4,576,826 relates to a method for producing flavorant capsules by forming a stable emulsion of an edible oil and an aqueous essence. The emulsion is directly sprayed or dropped in a dropwise manner onto an agitated powdered edible protein, carbohydrate or mixture thereof to form capsule shells thereon. Frozen essences may be utilized in the form of frozen particles which are added to the coating material prior to curing.
While spray drying and spray chilling were able to transform a liquid flavor into a solid particle, they also had inherent limitations such as the use of large volumes of air. Compounds sensitive to oxygen in air will begin to oxidize and decompose. For example, materials with multiple double bonds such as conjugated linoleic acid, omega 3 oils, fish oils, as well as anaerobes and facultative anaerobes such as, but not limited to, Bifidobacterium sp., and Lactobacillus sp., will lose potency or activity after exposure to oxygen. Additionally, heat is involved in both processes that will cause almost complete volatilization and/or oxidation of the low boilers or sensitive materials even with over formulation.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for the encapsulation of temperature/oxygen sensitive materials including flavors, fragrances, nutrients, colors, anaerobic bacteria, and products with similar characteristics without the loss of volatile portions due to reaction with oxygen or elevated temperatures.
A further object of the present invention is to provide protection and prevent undesirable oxidation of alcohols, acetones, ketones, aldehydes, organic acids, and antioxidants.
A further object of the present invention is to provide improved stability of biologically active compounds which include Lactobacilli, Bifidobacterium, Enterococci, phytase, amylases, lipases, invertases, transglutaminases, proteases, lipoxygenases and pentosanases.
The present invention is directed to an encapsulation technique whereby “topnotes” or sensitive substances, which do not typically survive current encapsulation process such as spray drying, spray chilling, and fluid bed technologies, are captured and stabilized.
The invention is directed to a method of encapsulating a sensitive substances some of which require: plating the volatile material onto a solid carrier, in an atmosphere inert to the volatile material, to form a plated material; and encapsulating the plated material.
DETAILED DESCRIPTION OF THE INVENTION
A sensitive substance such as a volatile liquid material is first plated onto a solid carrier in a sealed reactor. The reactor is then filled with nitrogen, carbon dioxide, or any other suitable gas inert to the sensitive substance to displace any unconditioned air. Then the plated material is encapsulated either in the same vessel in which the plating occurred or in another vessel.
The carrier is placed in a vessel capable of being sealed and supporting mechanical mixing. Preferably the mechanical mixing creates a fluidized bed. The vessel is then sealed and then oxygen is displaced through the introduction of an inert gas. Suitable gases include, but are not limited to, carbon dioxide, nitrogen, and helium. The inert gas also acts as a blanket. The inert gas is selected so that it will not react with the volatile material or the carrier. The carrier material is then agitated.
A liquid material (oxygen sensitive liquid material) is then agitated to ensure a fully homogenized mire. Without exposing the liquid material to air or oxygen, the liquid material is then supplied, e.g. pumped, into the sealed vessel and introduced into the vessel by a nozzle. The nozzle is used to form small droplets that are more easily absorbed onto the carrier material. The time involved in spraying is dependent upon the addition level of the liquid onto the solid and the time required to ensure complete absorption to form a free flowing powder. While the volatile liquid material is being added, the carrier is agitated or mixed to ensure even distribution of the liquid material onto the solid carrier.
A typical volatile liquid material has a boiling point between about 40° F. and about 250° F., preferably about 50° to about 100° F., and more preferably about 60° to about 80° F. Examples of volatile materials also include, but are not limited to, flavors, flavor compounds, aromas, fragrances, vitamins, nutrients (such as omega 3 oils, carotenoids, vitamin A and E), alcohols, acetones, ketones, aldehydes, organic acids, antioxidants, and essential oils. Examples of volatile materials are: lemon oil, spearmint oil, vanilla extract, garlic oil, cinnamon extract and other essential oils derived from botanical origins.
Other sensitive materials include biologically active compounds which include, but are not limited to, Lactobacilli, Bifidobacterium, Enterococci, phytase, amylases, lipases, invertases, transglutaminases, proteases, lipoxygenases and pentosanases.
The carrier may be any porous or semi porous material such as, but not limited to, maltodextrin, dextrins silicon dioxide, starches, gums or hydrocolloids. The carrier is selected based upon its ability to entrap the liquid material. Suitable carriers include, but are not limited to, the following. N-ZORBIT M which is a tapioca maltodextrin derived from tapioca and K-4484 which is a tapioca dextrin with high solubility, good clarity, and bland flavoring. N-ZORBIT M and K-4484 are products of National Starch and Chemical Company.
The particle size of the carrier is preferably between about 50 microns and about 2,000 microns, preferably between about 100 microns and about 1000 microns, and more preferably between about 200 and about 500 microns. Both the volatile liquid material and solid carrier may be edible.
Loading levels of the liquid onto the solid carrier are between about 1% and about 70% by weight, preferably 5% to 40%, more preferably between about 10% and about 30%, and most preferably between about 15% and about 25%. One skilled in the art would understand the amount of volatile material needed for a particular end product. For example, garlic is very strong and thus would require a lower loading concentration as would cinnamon. Apple juice would likely require a higher concentration.
Prior to adding the liquid material, the carrier may be chilled by, for example, the addition of liquid nitrogen which has a temperature between minus 198° and minus 208° C. The liquid material may also be chilled to below about 40° F., and kept chilled while it is added to the carrier. If desired, the vessel may also have a cooling jacket to cool the vessel during the plating process.
Any suitable mixer vessel, such as a paddle mixer, ribbon blender, or V-blender, may be used in the present invention to plate the solid onto the carrier.
After the volatile liquid material is plated onto a solid carrier to form a plated material, the plated material is encapsulated either in the same vessel in which the plating occurred or in another vessel. In a preferred embodiment, the plated material is removed from the sealed mixer and placed in a reactor designed to encapsulate solid particles. In either case, the encapsulation reactor must be capable of being sealed. The reactor is then filled with nitrogen, carbon dioxide, or any other suitable gas inert to the volatile material to displace any unconditioned air. Preferably, the vessel has means to agitate and heat the contents of the vessel.
Any suitable encapsulant material may be used. Preferably the encapsulating material is a lipid material such as, but not limited to, mono-, di-, and triacylglycerols, waxes, and organic esters derived from animals, vegetables, minerals, and modifications. Examples include glyceryl triesterates such as soybean oil, cotton seed oil, canola oil, tallow and palm kernal oil, and esters of long chain fatty acids, and alcohols, such as carnauba wax, beeswax, bran wax, tallow and palm kernal oil. The lipid material preferably has a melting point between about 60° and about 200° F.
Specific encapsulants include, but are not limited to, the following. NATIONAL 46 which is a low viscosity product designed for the encapsulation of citrus flavors, such as orange and lemon, and other delicate flavor oils. CAPSUL which is a modified food starch derived from waxy maize designed for encapsulation of flavors, clouds, vitamins, and spices. N-LOK which is a low viscosity product designed for the encapsulation of flavors, fats, oils, and vitamins. NATIONAL, CAPSUL, and N-LOK are all products of National Starch and Chemical Company.
In a preferred embodiment, the encapsulant material is melted and the liquefied material is then pumped into the encapsulation reactor. The flow rate is dependent upon the type of encapsulation reactor used in the procedure and is well within the skill of the art. The carrier containing volatile material is fluidized in the reactor by methods known to those who are skilled in the art such as by forcing an inert gas upward through a bed of particles so that the particles undergo a continuous circular, tumbling action. As the particles are fluidized, the liquefied material is sprayed onto the fluidized particles.
The final percentage of encapsulant (coating) in the resulting encapsulated particles is between about 10 to about 90%, preferably about 20 to about 80% and more preferably between about 30 and about 50% by weight.
EXAMPLES
Example 1
Encapsulation of lyophilized Lactobacillus acidophilus, a temperature and oxygen sensitive biologically active substance
A culture of Lactobacillus acidophilus was lyophilized and milled to make powdered product. The powdered product may be used in, for example, gel capsules. However, the powdered product of lyophilized Lactobacillus acidophilus culture can quickly lose its biological potency or activity at ambient conditions without proper storage conditions, such as refrigeration or freezing, since the microorganism is very sensitive to elevated temperatures and moisture. The microorganism is also sensitive to oxygen, although to a lesser degree compared to its sensitivity to moisture, since Lactobacillus acidophilus is facultative. The encapsulation technique described below demonstrates the improved stability of the microorganism under accelerated storage conditions (e.g. 40° C).
Powdered lyophilized Lactobacillus acidophilus culture is introduced into an encapsulation vessel, such as a fluid bed and alike, that has been properly sanitized. Airflow passing through the working space (e.g. a room) enclosing the encapsulation vessel is dehumidified to reduce potential humidity exposure of the microorganism. The microorganism in the vessel is also blanketed with an inert gas, such as nitrogen, to reduce potential oxygen exposure throughout the entire encapsulation process. When the encapsulation process bins, the internal temperature of the microorganism culture in the vessel gradually increases to the range between 60° to 120° F. before spraying a suitable melted coating into the encapsulation vessel. Spraying of the melted coating continues until a desirable level of coating has been applied depending upon the predetermined level of protection. The finished batch, i.e., encapsulated lyophilized Lactobacillus acidophilus, is in turn released from the encapsulation vessel, screened to obtain the appropriate particle size, and packaged.
The following table compares stability of unencapsulated lyophilized Lactobacillus acidophilus (the Control) with two encapsulated Lactobacillus acidophilus with different levels of coating Encap 1 and Encap 2 were encapsulated with 15% and 25% coating, respectively. The encapsulation process significantly affected the activity or biological potency of the original lyophilized Lactobacillus acidophilus as reflected in the 0-day CFU values since the same weights of samples were used for enumeration of the Control, Encap 1 and Encap 2. All lyophilized Lactobacillus acidophilus were stored at refrigeration (4° C., appropriate storage), ambient (20° C., normal distribution channel to retail level), or an elevated (40° C., abusive) temperature for 4 weeks before the evaluation of shelf life by enumeration. By the 4th week, the Control showed at least a 2-log reduction in the population of viable cells compared to Encap 1 and Encap 2, and therefore suggested improved shelf life in the encapsulated forms.
Temperature and period (days) of storage
4° C.
20° C.
40° C.
Sample
0 A
14
28
0
14
28
0
14
28
Control
4.44 B
1.12
3.0
4.44
2.36
3.88
4.44
1.22
5.6 ×
10 7
Encap 1
3.76
1.2
3.88
3.76
2.0
4.92
3.76
1.6
9.2 ×
10 9
Encap 2
3.48
1.92
2.84
3.48
1.2
2.24
3.48
1.12
9.6 ×
10 9
A days of incubation
B indicates number × 10 10 cfu/g (or 10,000,000,000 colony forming units/grams)
Example 2
Encapsulation of natural lemon oil using the temperature and/or oxygen sensitive materials process
Natural lemon oil is well-known to be susceptible to oxidation. In addition, the oil contains certain high volatile components that contribute to the full flavor profile of lemon oil expected by those who are familiar with the material, such as flavor chemists. The following encapsulation technique has shown to successfully capture the highly volatile components of lemon oil and to result in strong sensory impact when lemon oil is released.
In general, lemon oil is first plated onto a selected carrier, such as starch or maltodextrin, by spraying liquid lemon oil into an appropriate device like a Ribbon blender, a V-blender, or other blender that can thoroughly mix the lemon oil with the carrier. The blender is blanketed with nitrogen or other inert gas throughout the entire plating process to reduce oxidation. The blender may be insulated depending upon the flavor material to be plated. The mixing process in a blanket takes about 10 to 30 minutes according to predetermined loading level of lemon oil, other flavors, or other liquid materials that are sensitive to oxygen and/or elevated temperatures. The plated lemon oil, which is now a mix of solid particles, is in turn discharged into an encapsulation vessel that can be closed and blanketed with nitrogen or other inert gas.
When the encapsulation process begins, the plated lemon oil is gradually heated to the range between 60° to 150° F. in the encapsulation vessel. Melted coating is sprayed into the encapsulation vessel containing plated lemon oil when the batch temperature reaches the target point. Spraying of melting coating stops at the predetermined level of coating, depending upon degree of protection needed for lemon oil or other flavors. The finished product, e.g., encapsulated lemon oil, is then discharged from the encapsulation vessel, screened to appropriate particle size and packaged.
It will be apparent to those skilled in the art that various modifications and variations can be made in the compositions and methods of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A process for stabilizing a sensitive substance; (a) plating a sensitive substance onto a solid carrier under a controlled atmosphere to reduce loss of the sensitive substance; (b) encapsulating the plated material under controlled atmosphere and airflow to reduce volatilization during the process and stabilize the sensitive substance. | 0 |
FIELD OF THE INVENTION
This invention relates generally to internal combustion engines having electric-actuated fuel injectors that inject fuel into combustion chambers of the engine. More particularly it relates to a system and method that uses several variables, including injector control pressure and the duration of an injector-actuation signal applied to the fuel injectors, in a process that calculates, by a mathematical formula, the quantity of fuel injected by a fuel injector during an injection, and that calibrates each fuel injector by adjustment of the formula.
BACKGROUND OF THE INVENTION
A known electronic engine control system comprises a processor-based engine controller that processes various data to develop fueling data for the engine. The fueling data represents a quantity of fuel that is to be introduced into the engine for combustion. That control system also includes an injector control module, or injector driver module, for operating fuel injectors that inject fuel into the engine in quantities corresponding to the fueling data. The fueling data is supplied to the injector control module from the engine controller, and the injector control module has its own processor for processing the supplied data to develop proper data for causing the fuel injectors to inject fuel in quantities corresponding to the fueling data calculated by the engine controller. For any one or more of various reasons that need not be discussed here, the injector control module may also make certain adjustments to the supplied data when the engine control strategy and/or injector calibration make it appropriate to do so.
The injector control module also comprises injector drivers each of which delivers an electric current signal to an electric actuator of the respective fuel injector. A fuel injector may have one or more electric actuators depending on its particular construction. The signal that is applied to a fuel injector to cause an injection of fuel is commonly referred to generically as a pulse width modulated signal. In the case of a fuel injector that has a single actuator, the actuating signal is a true pulse whose width sets the amount of time of an injection, and hence essentially determines the quantity of fuel that the fuel injector injects into the corresponding engine cylinder in consequence of that applied pulse. In the known engine controller that is being referred to, it is the injector control module that calculates the pulse width by processing the fueling data supplied to it by the engine controller.
The particular nature of the electric actuation of any particular fuel injector depends on the particular construction of the fuel injector. There is the single actuator type mentioned above. Another type of fuel injector, one for a compression-ignition internal combustion engine, comprises an intensifier piston for creating a high-pressure injection of fuel directly into an associated engine cylinder. The intensifier piston comprises a head of given end area exposed to a control fluid, oil for example, in a control chamber, and a plunger, or rod, of smaller end area exposed to liquid fuel in an injection chamber. The electric actuator comprises a spool valve that uses two electric actuators, i.e. solenoid coils, to control the introduction of pressurized control fluid into the control chamber and the draining of control fluid from the control chamber.
When an electric signal for initiating a fuel injection is applied to one of the two electric actuators for the spool valve, control fluid is introduced under pressure through one portion of the spool valve into the control chamber to downstroke the intensifier piston and cause fuel in the injection chamber to be injected under pressure from a nozzle of the fuel injector into an associated engine cylinder. The intensifier piston amplifies the pressure of the control fluid by a factor equal to the ratio of the head end area to the plunger end area to cause the amplified pressure to be applied to liquid fuel in the injection chamber. As a result, fuel is injected into a combustion chamber at a pressure substantially greater than the pressure of the control fluid.
When an electric signal for terminating the fuel injection is applied to the other electric actuator, the spool valve operates to terminate the downstroke of the intensifier piston and instead allow control fluid to drain from the control chamber through another portion of the spool valve so that the intensifier piston can then upstroke to re-charge the injection chamber with liquid fuel in preparation for the next injection.
Examples of fuel injectors having valves like those just described appear in U.S. Pat. Nos. 3,837,324; 5,460,329; 5,479,901; and 5,597,118.
Where a single electric actuator controls a fuel injector valve, the beginning of an electric pulse applied to the actuator initiates an injection, and the injection terminates when the pulse ends. The injection time is therefore set by the width, i.e. time duration, of the actual electric pulse applied to the injector actuator.
Commonly assigned U.S. Pat. No. 6,029,628 is an example of a fuel injector comprising two electric actuators that operate respective valve mechanisms. A supply valve mechanism is controlled by an electric supply valve actuator for selectively controlling flow of control fluid through a supply passage for downstroking an intensifier piston. A drain valve mechanism is controlled by an electric drain valve actuator for selectively controlling flow of control fluid through a drain passage. Each valve actuator is selectively operable independent of the other to selectively operate the respective valve mechanism independent of the other. Actuation of the supply valve mechanism while the drain valve mechanism is not being actuated initiates an injection, and the injection terminates when the drain valve mechanism is actuated.
The use of two electric signals, each applied to a respective one of the two actuators, to set the duration of a fuel injection is like that described previously for the fuel injector that has two actuators for operating a spool valve because the difference between the times at which the two actuators are actuated, rather than the time duration of an actual electric pulse, controls the duration of an injection. But the two signals in effect define a pulse width for operating the fuel injector that is equivalent to the pulse width of a single pulse signal that determines the injection time of a fuel injector that has only a single electric actuator. Hence, reference to pulse width in a generic context should be understood to include an actual pulse width of a single signal or an equivalent pulse width resulting from the use of one signal to initiate an injection and another signal to terminate the injection.
The known engine controller also contains one or more look-up tables that its processor uses to calculate the desired fueling data, which is then processed to calculate the widths of electric pulses that operate the fuel injectors. The look-up tables are derived from actual testing of fuel injectors. Fuel injectors are mapped for various combinations of values for injector control pressure and actuating signal pulse width. Each combination of values defines a corresponding value for desired fueling data. A sufficient number of combinations are needed to cover the relevant ranges of the variables, but the available size of the look-up tables ultimately determines how many combinations can actually be stored in memory of the controller.
While increasing look-up table size, and hence the number of combinations that can be stored, will endow the tables with a higher degree of resolution that may be desirable for increased fueling accuracy, the increased size of the electronic storage medium that is required to contain the stored data increases the cost of the controller. A greater amount of mapping is also required in order to obtain the greater amount of data.
A lesser number of stored combinations may decrease the resolution, and hence decrease fueling accuracy. The processor may then on occasion have to interpolate the mapped data in order to yield desired fueling data, and where non-linearity is present in the fuel injector, linear interpolation may not yield the accuracy that would be obtained from a larger table of greater resolution.
Regardless of fuel injector type or of how fuel injector data is mapped into a controller, fuel injector calibration is also important for securing desired fueling. Mass production methods inherently result in some variation in calibration from fuel injector to fuel injector, and while such methods may strive to minimize the range of these variations, the ranges remain significant enough that some classification of fuel injectors according to a number of different calibration categories, or groups, is appropriate in a mass production environment. The mapping of fuel injector data that has been described above may therefore represent mean data obtained from mapping a number of individual fuel injectors statistically representative of a universe of fuel injectors, in which case the calculated fueling data may be further processed to account for individual fuel injector calibration.
Hence, before it is assembled to an engine, a mass-produced fuel injector is operated to ascertain its actual calibration. The actual calibration determines into which particular one of a number of different calibration categories the fuel injector falls. The fuel injector is then identified by that particular category. When an engine is being manufactured, the associated engine controller is programmed in such a way that the particular calibration category of the fuel injector for each particular engine cylinder is made available to the controller. The controller uses that data to calibrate electric control signals to the fuel injectors, typically to secure injection of fuel in substantially equal quantities to each combustion chamber for a given value of fueling data calculated by the engine controller.
U.S. Pat. No. 5,575,264 discloses a method for associating actual performance data with a fuel injector. The data is contained in a medium, such as an EEPROM, that is mounted on the fuel injector body and that is suitable for reading by an associated engine controller.
U.S. Pat. No. 5,839,420 relates to a method for compensating a fuel injection system for fuel injector variability. Each fuel injector includes a storage medium that contains a calibration code identifying the actual calibration of the fuel injector. An associated engine controller converts a raw energizing time to a calibrated energizing time for each fuel injector based the calibration code for the fuel injector.
U.S. Pat. No. 5,634,448 relates to another method for trimming fuel injectors to compensate for fuel injector variability.
U.S. Pat. No. 4,402,294 relates to a system for calibrating fuel injectors.
Other patents that relate to systems and methods for calculating engine fueling and/or correcting the calculation for factors such as individual fuel injector calibration are U.S. Pat. No. 4,379,332; U.S. Pat. No. 4,619,234; and U.S. Pat. No. 5,806,497.
Given the significant effort that is needed to map and calibrate fuel injectors, and the amount of media needed to store a sufficient amount of mapped data to cover relevant ranges of variable parameters affecting engine fueling, as discussed above, it would be desirable to provide a system and a method that reduce the extent of the mapping effort and of the amount of data storage that is needed. The inventor's commonly assigned patent application “SYSTEM AND METHOD FOR PREDICTING QUANTITY OF INJECTED FUEL AND ADAPTATION TO ENGINE CONTROL SYSTEM”, Ser. No. 10/003,980, filed Oct. 31, 2001, relates to such a system and method.
SUMMARY OF THE INVENTION
The present invention is a further invention resulting from the invention of Ser. No. 10/003,980, and concerns calibration of fuel injectors in an engine control system that calculates injection duration by mathematical formula.
Accordingly, a generic aspect of the present invention relates to a method of calibrating an electric-actuated fuel injector for an,engine that uses injector control pressure to inject the fuel from the injector into the engine. Before the fuel injector is installed in the engine, it is electrically actuated by a predetermined electric actuation at a first predetermined injector control pressure. The resulting quantity of fuel injected is measured. It is again electrically actuated by the predetermined electric actuation but now at a second predetermined injector control pressure. The resulting quantity of fuel injected is measured. The measured quantities, the predetermined injection control pressures, and the applied predetermined electric actuation are correlated with values of quantity of fuel injected, injector control pressure, and electric actuation that are related by a predetermined multiple term mathematical formula to ascertain, for the same quantities of injected fuel at each predetermined injector control pressure, difference between the applied predetermined electric actuation and that required by the formula.
Another generic aspect of the present invention relates to a system that comprises apparatus for performing the method just described.
Still another generic aspect of the present invention relates to an internal combustion engine comprising one or more electric-actuated fuel injectors each of which injects fuel into a respective combustion chamber of the engine as a function of injector control pressure and the duration of an electric actuating signal that sets the duration of a fuel injection to achieve an injection quantity determined at least in part by a desired fueling data representing desired fueling of the engine. An engine control system comprises one or more processors that calculate the desired fueling data, and from the desired fueling data, the duration of the electric actuating signal for each fuel injector by processing the desired fueling data and data representing injector control pressure, including processing, according to a mathematical formula, data correlated with the desired fueling data and data representing injector control pressure, to develop data that the control system further processes to calculate the duration of the electric actuating signal. Each fuel injector is marked with data that is entered into the engine control system incidental to installation of the fuel injector in the engine and that defines difference between the operating characteristic of the fuel injector and that of a general fuel injector on which the multiple term mathematical formula is based. The control system modifies the formula for each fuel injector according to the marked data on each fuel injector to thereby calibrate each fuel injector in the engine so that each fuel injector injects fuel substantially in accordance with desired fueling data that is calculated by the control system and then is used in the formula as the quantity of injected fuel.
The foregoing, along with further features and advantages of the invention, will be seen in the following disclosure of a presently preferred embodiment of the invention depicting the best mode contemplated at this time for carrying out the invention. This specification includes drawings, now briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general schematic diagram of an exemplary embodiment of certain apparatus used in measuring the actual calibration of a fuel injector.
FIG. 1A is a general schematic diagram of an exemplary engine and control system embodying principles of the present invention.
FIG. 2 is a graph showing an example that illustrates certain steps involved developing a general formula for calculating quantity of fuel injected by a fuel injector.
FIG. 3 is a graph showing additional steps.
FIG. 3A shows a portion of FIG. 3 on a larger scale.
FIG. 4 is a graph showing correlation of actual fueling measurements with calculated desired fueling derived through use of the inventive principles.
FIG. 5 is a graph showing the relationship between desired fueling and pulse width for several different injector control pressures.
FIG. 6 is a graph similar to FIGS. 2 and 4, but with axes reversed, showing correlation of actual fueling measurements with calculated desired fueling derived through further refinement of the general equation.
FIGS. 7-11 are graphs of operating characteristics of several fuel injectors useful in explaining principles of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1A shows a schematic diagram of an exemplary engine control system 10 that utilizes results from a method that will subsequently be described with reference to FIG. 1 . Control system 10 comprises a processor-based engine controller 12 and an injector control module, or injector driver module, 14 for controlling the operation of electric-actuated fuel injectors 16 that inject fuel into combustion chambers of an internal combustion engine 18 , such as in a multi-cylinder, compression-ignition internal combustion engine that powers an automotive vehicle. Although FIG. 1A shows an arrangement for only one cylinder 20 , a respective fuel injector 16 is associated with each cylinder. Each fuel injector comprises a body that is mounted on the engine and has a nozzle through which fuel is injected into the corresponding engine cylinder.
Controller 12 operates each fuel injector 16 via injector control module 14 , causing a respective driver circuit (not shown) in module 14 to actuate the respective fuel injector at the appropriate time in the engine operating cycle. The processor of controller 12 processes various items of data to develop data representing desired quantities of fuel to be injected by the individual fuel injectors. Such data will be referred to as desired fueling data represented by the symbol vfdes. The desired fueling data is supplied to injector control module 14 , which may have its own processor for perform further processing of the supplied data to develop data that is in turn converted to corresponding electric signals for the injector drivers that operate the fuel injectors. Data representing the present injector control pressure ICP is also available to injector control module 14 .
Each fuel injector 16 comprises an electric-actuated injection mechanism, such as one of the types described earlier. A fuel injection from an injector is initiated by an initiating electric signal applied to the fuel injector by the respective driver circuit. The fuel injection terminates when the electric signal changes to a terminating electric signal. The initiating electric signal may be the leading edge of a rectangular pulse, and the terminating signal, the trailing edge in the case of an injector that has a single electric actuator. The time between the edges is the pulse width, which may be modulated according to the amount of fuel to be injected. Therefore, when a true pulse width modulated signal is used to operate the fuel injector, using the leading edge of a pulse as an injection-initiating signal and the trailing edge as an injection-terminating signal, the timing of the initiating and terminating electric signals determines the quantity of fuel injected, and the actual pulse width may be adjusted to take into account other data that at certain times is appropriate to use in making some adjustment of vfdes.
Injector control module 14 may therefore at times make certain adjustments to the desired fueling data vfdes received from controller 12 for developing the pulse widths of the electric current signals supplied to the fuel injectors. One reason for injector control module 14 to make an adjustment of the desired fueling data that is supplied from controller 12 is to compensate for certain characteristics of the specific fuel injectors, such as the injector calibration mentioned above, and that is the subject of the present invention. Another reason for adjustment of the desired fueling data, a reason that need not be discussed here, is to compensate for prevailing conditions that otherwise would contribute to deviation of the actual amount of fuel injected from the desired amount, such as a cold start for example.
The desired fueling data vfdes supplied to injector control module 14 represents a certain pulse width for the signal to be applied to a fuel injector to deliver a corresponding amount of fuel to the engine cylinder based on some set of base conditions for the engine and ambient.
In the case of a fuel injector that has two electric actuators, one of which is energized to initiate a fuel injection and the other of which is energized to terminate the fuel injection, a respective signal is applied to each actuator. However, as explained above, the difference in time between the applications of the two signals is equivalent to a pulse width of a single electric actuating signal. Further description of the invention with reference to the drawing Figures is premised on the fuel injectors being of the two-actuator type.
The invention of Ser. No. 10/003,980 relates to a system and method of deriving a formula for calculating a quantity of fuel injected by each such fuel injector 16 . The method comprises mapping a representative fuel injector 16 by applying various combinations of different selected hydraulic fluid pressures and different selected durations of the electric actuating signal. For each combination, the quantity of fuel injected is measured to create a corresponding data set for the combination. Each data set comprises the corresponding selected hydraulic fluid pressure, the corresponding selected electric signal duration, and the quantity of fuel injected in consequence of the application of the corresponding selected hydraulic fluid pressure and the corresponding selected electric signal duration to the fuel injector. The mapping apparatus is shown generally in FIG. 1 and includes various pieces of measuring equipment and processing apparatus.
Because the fuel injector of the example has two electric actuators, a first signal P 1 is used to initiate a fuel injection by energizing one of the two actuators, and a second signal P 2 is used to terminate the fuel injection by energizing the other of the two actuators. Hence, the result of the mapping comprises a number of data sets each containing P 1 data, P 2 data, injector control pressure data, and injected fuel quantity data. The data sets are then sorted into groups such that the injector control pressure data for the data sets of a given group is the same. A multiple linear regression is conducted on the data in each group. The following is an example of an actual mapping undertaken on a particular fuel injector. (A multiple polynomial regression can be undertaken injector control pressures that occur within a pressure range, low injector control pressures for example, where linearity is questionable.)
The equations used for the multiple linear regression are given below as taken from Probability and Statistics for Engineers and Scientists , Walpole and Myers. (2 nd edition 1978, 3 rd edition 1985, MacMillan, N.Y., N.Y.). nb o + b 1 ∑ i = 1 n x 1 i + b 2 ∑ i = 1 n x 2 i + b 3 ∑ i = 1 n x 3 i = ∑ i = 1 n y i b o ∑ i = 1 n x 1 i + b 1 ∑ i = 1 n x 1 i 2 + b 2 ∑ i = 1 n x 1 i x 2 i + b 3 ∑ i = 1 n x 1 i x 3 i = ∑ i = 1 n x 1 i y i b o ∑ i = 1 n x 2 i + b 1 ∑ i = 1 n x 1 i x 2 i + b 2 ∑ i = 1 n x 2 i 2 + b 3 ∑ i = 1 n x 2 i x 3 i = ∑ i = 1 n x 2 i y i b o ∑ i = 1 n x 3 i + b 1 ∑ i = 1 n x 1 i x 3 i + b 2 ∑ i = 1 n x 2 i x 3 i + b 3 ∑ i = 1 n x 3 i 2 = ∑ i = 1 n x 3 i y i
where x 1 =P 1 , x 2 =P 2 , x 3 =injector control pressure, n=the number of measurements, and y=injected fuel quantity.
The equations are then solved for b 0 , b 1 , b 2 , and b 3 at three different injector control pressures, those pressure being 6 Mpa, 12 Mpa, and 24 Mpa in the example. This resulted in the following equations for injected fuel quantity (fuel volume per injection, or stroke): @ 6 Mpa : Fuel ( mm 3 Stroke ) = - 27.622 + 0.018 * P 1 + 0.036 * P 2 - 0.029394
@ 12 Mpa : Fuel ( mm 3 Stroke ) = - 32.51 + 0.021 * P 1 + 0.057 * P 2 - 1.8775
@ 24 Mpa : Fuel ( mm 3 Stroke ) = - 18.391 + 0.025 * P 1 + 0.082 * P 2 - 8.8671
Plotting the actual data for each of the three injector control pressures vs. their respective predicted values gives the correlation agreement shown in FIG. 2 . As can be seen from the substantial 45 degree line fit, the correlations on an individual basis are quite good, approximately 95%-96% confidence.
Because it is considered impractical to implement an infinite number of equations each of which would represent one of an infinite number of possible injected fuel quantities, the next step in the example involves determining the equations which best represent,the individual coefficients. This can be done by plotting the coefficients vs. injector control pressure for best fit as shown in FIGS. 3 and 3A.
From the equations for the line fits of the coefficients vs. injector control pressure, the following equations for the coefficients were obtained: Constant = 5.9847 * ICP - 40.211 * ICP + 34.967 P1Coeff . = 0.0029 * ICP + 0.011 P2Coeff . = 0.0187 * ICP - 0.009 ICPCoeff . = - 0.6625 * ICP + 3.3953 * ICP - 4.3539
And then by applying the coefficients to terms of an equation and including a shift factor, the following generalized equation for injected fuel quantity was developed: FuelDelivery ( mm 3 Stroke ) = 13 + ( 5.9847 * ICP - 40.211 * ICP + 34.967 + ( 0.0029 * ICP + 0.011 ) * P 1 + ( 0.0187 * ICP - 0.009 ) * P 2 + ( - 0.6625 * ICP + 3.3953 * ICP - 4.3539 ) * ICP
Hence the foregoing shows that data from the data sets was processed to create terms of a multiple term mathematical formula that can be used to calculate the quantity of fuel injected, wherein the terms of the formula include as variables, the electric signal duration and the hydraulic fluid pressure.
FIG. 4 verifies that the method of using the general equation, or formula, derived according to the inventive method, can calculate, with satisfactory accuracy, injected fuel quantity based on P 1 , P 2 , and injector control pressure for this type of injector within specified operating ranges.
It is to be understood that each particular type of fuel injector may require development of its own unique general equation, but fuel injectors of the same type can be calibrated to an engine control system in accordance with principles of the present invention.
The correlation shown by FIG. 5 is based on the linear segment for pressures between 6 and 24 Mpa in the particular example. Accuracy below 6 Mpa and at maximum fuel deliveries is problematic due to injector control pressure fluctuations as well as factors that create non-linear conditions, and for such reasons, a multivariable polynomial regression may be required, as noted earlier.
Using the statistical software known as SIGMA PLOT, it is possible to improve upon the general equation by using the non-linear regression model. Use of non-linear regression is premised upon having derived the general equation, as described above. The general equation is entered into the SIGMA PLOT software as well as data sets for the three independent variables (P 1 , P 2 , and injector control pressure) and the one dependent variable (injected fuel quantity), and the curve fit was tightened. The improved correlation agreement is shown in FIG. 6 . An R 2 value of 98% was found.
The refined equation is given as: FuelDelivery ( mm 3 Stroke ) = 13 + ( 7.217 * ICP - 47.78 * ICP + 34.967 ) + ( 0.008461 * ICP + 0.011 ) * P 1 + ( 0.01866 * ICP - 0.009 ) * P 2 + ( - 0.9927 * ICP + 4.628 * ICP - 4.3539 ) * ICP
The development of a single empirical equation that can predict fuel deliveries over a range of 6-24 Mpa with a correlation agreement of 98% is believed to afford opportunities to engine control strategy designers and engine calibrators to significantly simplify control strategy and calibration procedures.
Processors of engine control systems can process data sufficiently fast to calculate, in real time, the duration of injector actuation using the above general equation or its refined version. In such case, the control system is programmed with either equation, but with the equation rearranged to solve for P 2 . The engine controller processes certain data that is relevant to calculating desired engine fueling in terms of quantity of fuel injected per injection, or stroke of a fuel injector. The calculated data representing desired engine fueling is compared to a predefined limit that is contained in the control system. The control system selects a predetermined constant as data for P 1 when the desired fueling data exceeds the predefined limit, but equates P 1 to P 2 by substituting P 2 for P 1 in the formula when the desired fueling data is equal to or less than the predefined limit. The result of the processing is data that defines a value for P 2 , that in conjunction with the data for P 1 , defines the duration of a fuel injection that will cause the quantity of fuel injected during the injection at the prevailing injector control pressure ICP to be substantially equal to the desired fueling, ignoring for the moment possible adjustment due to factors that may call for some adjustment, as mentioned earlier, to compensate for certain influences. Even when adjustment is made, the actual quantity injected is determined at least in substantial part by the general formula, or its refined version, as rearranged to develop data for setting the duration of injector actuation to produce one injection of fuel.
The present invention tailors the general formula, or its refined version, to take into account the particular calibration of each fuel injector in an engine. FIG. 7 shows the injection At characteristic for each of several fuel injectors of the same type for an injector control pressure of 6 Mpa. As can be seen, the characteristic is subject to injector-to-injector variation, due essentially to slight variations in manufacture employing mass production techniques.
FIG. 8 shows how the variable P 2 must change for each fuel injector in order for all fuel injectors to deliver the same quantity of fuel per injection for a given desired fueling vfdes.
In accordance with the inventive method, each fuel injector is operated at the conclusion of its manufacture, and certain measurements are made. A specific example comprises operating a fuel injector at a certain higher injector control pressure and at a certain lower injector control pressure with the same electric actuating signal and measuring the quantity of fuel injected in each instance. The two measurements would described a straight line on a graph plot of quantity of injected fuel vs. injector control pressure. This straight line is then compared with a straight line calculated by using the general formula. Substantial coincidence of the two lines would not call for any adjustment of the general formula for this particular fuel injector when the fuel injector is operating in an engine. Lack of substantial coincidence would call for an appropriate adjustment.
An appropriate adjustment is made by making certain changes in certain coefficients of the general formula that will result in values of P 2 that when applied to this particular fuel injector, will secure its proper calibration in the engine. In order for the associated engine control system to provide those coefficient changes, the fuel injector is marked in a certain manner to identify how the coefficients should be modified. Marking is preferably done electronically in a way that allows the engine control system to electronically read the marked data and cause the modified coefficients to be used in the general formula whenever data for P 2 is calculated for this particular fuel injector.
The engine control system has the capability to do this for each fuel injector. FIGS. 9, 10 , and 11 show examples of how the modification of formula coefficients can secure calibration of three respective fuel injectors in an engine.
It is possible that a particular control strategy may still at times adjust the tailored formula to compensate for certain influences that call for compensation, such as cold starting for example.
Certain fuel injection strategies employ a pilot injection, followed by a main injection. Principles of the invention may be applied to either or both types of injection in such an injection strategy.
While a presently preferred embodiment of the invention has been illustrated and described, it should be appreciated that principles of the invention apply to all embodiments falling within the scope of the following claims. | A method of modifying a general formula that is used by an engine control system ( 10 ) to calculate duration of fuel injector actuation. Coefficients (P 1 coeff., P 2 coeff., ICP coeff.) of the formula are modified to calibrate individual fuel injectors ( 16 ) in an engine. The amount of calibration needed is determined by data that is marked on each fuel injector in electronically readable format after the fuel injector has been operated and its operating characteristic ascertained. The control system reads the marked data and then makes the proper coefficient adjustment. | 5 |
BACKGROUND
1. Field of the Invention
The present invention relates generally to telecommunications systems. More particularly, the present invention relates to an advanced intelligent network that provides a system and method for delivering calling name information to a voicemail system subscriber.
2. Background of the Invention
As is well known in the art, voicemail systems (“VMS”) are generally accessed by subscribers through a telephone call. That is, a subscriber dials a telephone access number for the VMS and once the call is connected, the subscriber interacts with the VMS service to access voicemail messages. The subscriber normally inputs commands to the VMS service by pressing keys on the telephone to send dual-tone multifrequency (“DTMF”) codes. Alternatively, a VMS service may use voice-recognition systems to receive audible commands from subscribers.
Conventional VMS systems are generally capable of delivering the calling party number for stored messages. Thus, a subscriber may receive an announcement from the VMS service such as, “You have one new voicemail message, received from telephone number 111-222-3333.” However, voicemail systems cannot provide the calling name associated with voicemail messages unless an extensive calling name database is created and maintained.
Some VMS services can provide limited calling name services when a private branch exchange (“PBX”) is used to provide internal telephone systems within an organization. For example, such a private VMS service provide a name associated with a voicemail message, provided the message was left by a caller using a telephone served by the PBX. However, such a VMS service cannot provide the calling name for external callers unless a database of external calling numbers and associated names is maintained. Such calling name databases are well known in the art. However, most calling name databases are maintained by common carrier telecommunications services (“telcos”).
Thus a system and method is needed for providing calling name delivery service on a per call basis for subscribers of VMS services.
SUMMARY OF THE INVENTION
The present invention utilizes an Advanced Intelligent Network (“AIN”) to provide a system and method for delivering the calling name information associated with a voicemail message to a voicemail system subscriber. AIN systems are described in U.S. Pat. Nos. 5,701,301, 5,774,533, Bellcore Specification TR-NWT-001284, Switching Systems Generic Requirements for AIN 0.1 which are incorporated herein by reference in their entirety.
The present invention provides a system and method for interfacing a conventional VMS service with a calling name delivery service. The invention advantageously uses a standard call processing model to deliver the calling name information directly to a VMS subscriber. Thus, the present invention obviates the need for external data interfaces between the VMS service and the telco's calling name databases. Functionally, a subscriber, connected by a telephone call to a VMS service, requests the calling name information associated with a voicemail message, by issuing a command to the VMS. Such a command is sent to the VMS using DTMF or voice commands as currently known in the art. The VMS system conferences a service node (“SN”) into the telephone call by dialing a customized dialing plan (“CDP”) code and the telephone number associated with the voicemail message. A CDP trigger on the service switching point (“SSP”) serving the VMS, causes the SSP to launch a query to a service control point (“SCP”) to identify which SN to conference in on the call. The SCP directs the call to a special access number for the appropriate SN based on the telephone number associated with the voicemail message.
Once the SN is conferenced in with the subscriber and the VMS service, the SN immediately provides the calling name for the voicemail message and may receive subsequent commands from the subscriber. For example, the subscriber may wish to have the calling name repeated. After the subscriber is finished listening to the calling name information, the SN hangs up, leaving only the subscriber and the VMS service on the telephone call. The subscriber may continue interacting with the VMS service, and issue commands, including a request for calling name information for the same or subsequent voicemail messages.
The SCP acts as a gatekeeper to restrict access to the SN so that only authorized callers, i.e., authorized VMS services, can obtain calling name information through this system and method. Additionally, the SCP selects the appropriate SN to handle the call based on the telephone number associated with the voicemail message. Due to the large size of a telco's calling name database, the telco may split the database into several parts and store the individual portions of the database on several SNs. Thus, the SCP maintains an index identifying which SN maintains which portion of the database. When a query is sent by the switch to the SCP, the SCP checks this index to determine the new routing instructions for the call. The SCP responds to the query by inserting the special telephone access number for the particular SN in the called party number (“CdPN”) field and inserting the telephone number provided by the VMS service in the calling party number (“CgPN”) field.
The SN is programmed to answer any calls to the special telephone access number as soon as a call comes in. This minimizes any delays for the subscriber requesting the calling name information. The SN uses the CgPN to look up the calling name information in its database. Upon answering the call, the SN plays a computer generated voice response delivering the calling name information, as described above. Thus, the subscriber receives the calling name information through standard call processing techniques. In a preferred embodiment, the SN is programmed to instruct the subscriber to press a pre-determined digit if the name should be repeated, or to press a different pre-defined number to return to the VMS service.
It is an object of the present invention to provide a system and method for interfacing conventional voicemail services with conventional calling name databases.
It is a further object of the present invention to deliver calling name information to a voicemail subscriber using the existing telephone infrastructure.
These and other objects of the present invention are described in greater detail in the detailed description of the invention, the appended drawings and the attached claims.
DESCRIPTION OF THE DRAWINGS
FIGS. 1 a - 1 d are block diagrams showing the interactions between a caller, a voicemail system and a service node when the caller requests and receives a calling name announcement using the present invention.
FIG. 2 is a schematic diagram showing the key components of an AIN used in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The block diagrams in FIGS. 1 a- 1 d provide a functional description of the present invention. As shown in FIG. 1 a, caller 100 connects to a voicemail system, VMS 105 , through a telephone call, i.e., voice channel 110 . Caller 100 communicates with VMS 105 using the voice channel to issue commands to VMS 105 , e.g., play, delete, save, or replay a message. Using the system and method of the present invention, when caller 100 requests the calling name information associated with a voicemail message, VMS 105 conferences SN 120 into the telephone call via voice channel 115 , as shown in FIG. 1 b . Since voice channel 115 represents a conference call, it functionally extends voice channel 110 to a voice channel between caller 100 and SN 120 , shown schematically as voice channel 125 in FIG. 1 c.
When voice channel 125 is established, the telephone number associated with the voicemail message is passed on to SN 120 as described below. Thus, when SN 120 receives the telephone call, SN 120 looks up the calling name in its databases. SN 120 plays a message over voice channel 125 announcing the calling name information to caller 100 . SN 120 remains connected to caller 100 and VMS 105 until caller 100 instructs SN 120 to disconnect voice channel 115 . When voice channel 115 is disconnected, SN 120 drops out of the telephone call leaving only voice channel 110 between caller 100 and VMS 105 , as shown in FIG. 1 d. Caller 100 can continue issuing instructions to VMS 105 , including a new request for calling name information as described above.
FIG. 2 is a schematic diagram showing the interaction between components of the AIN used to implement an embodiment of the present invention. Caller 10 is a subscriber of VMS service provider 21 . The present invention allows caller 10 to request calling name information for any calling parties leaving messages on VMS 21 for caller 10 . In a preferred embodiment, caller 10 calls VMS 21 using telephone 11 and line 12 . As shown in FIG. 2, caller 10 may connect to VMS 21 through public switched telephone network (“PSTN”) 13 . Alternatively, a caller, such as caller 14 , may connect to VMS 21 using telephone 15 and line 16 , connected to PBX 17 as shown in FIG. 2 . In either case, the present invention provides the calling name information to the caller upon request.
The caller requests the calling name information as an option on VMS 21 . That is, upon listening to a voicemail message, if the caller wants to know the identity of the person leaving the message, the caller enters a code recognized by VMS 21 as a request for calling name delivery. Upon receipt of the request, VMS 21 dials the CDP code and the telephone number from which the message was received. For example, suppose a message was left for caller 10 on VMS 21 from a telephone with a calling number of 222-333-444. Suppose further that VMS 21 is programmed to instruct caller 10 to enter the code “3” to receive the calling name information. Finally, suppose the CDP code assigned by the telco for the system of the present invention is “9.” Then, if caller 10 enters “3” during or immediately after listening to the message, VMS 21 initiates a telephone call, i.e., establishes voice channel C, by dialing the following digits:92223334444#. The first digit is the CDP code, the next ten digits are the telephone number to be analyzed, and the # is used to delimit the end of the string.
SSP 22 receives the dialed digits and, in response to the CDP code, sends an Info_Analyzed query, query 1 , to SCP 24 (via Common Channel Signaling System 7 (“SS 7 ”) Network 23 ). Query 1 contains the string of digits received from VMS 21 . SCP 24 uses the information received to determine which SN to direct the call to. As shown in FIG. 2, the calling name database may be divided into one or more parts and housed on multiple SNs. The database master is managed by Service Management System (“SMS”) server 25 which updates the databases maintained on each SN as required. SMS 25 also provides SCP 24 with information needed to maintain an index for tracking the range of calling numbers stored on each SN.
Thus, in the present example, suppose SN 26 has the calling name database for all calling numbers between 000-000-0000 and333-333-3333 and SN 27 has the calling name database for all calling numbers between 777-777-7777 and999-999-9999.The calling name databases for numbers within other ranges would be on other SNs, not shown in FIG. 2 . In this case, SCP 24 would determine that the calling party name information is stored on SN 26 . SCP 24 issues response 2 to SSP 22 directing the telephone call to SN 26 . Response 2 comprises an Analyze_Route message having the telephone access number for SN 26 in the CdPN field and the telephone number to be looked up, i.e., “2223334444,” in the CgPN field.
As shown in FIG. 2, SN 26 is served by SSP 28 . Thus, SSP 22 sends call setup message 3 to SSP 28 via SS 7 network 23 . SSP 28 completes the call setup in response 4 and establishes voice channel C′. As discussed above, SN 26 answers the call as soon as it arrives, thus completing voice channel C″. As discussed above, a telephone call, i.e., voice channel C-C′-C″, is established between caller 10 and SN 26 . In a preferred embodiment, caller 10 hears little or no ringing upon connection of this call. SN 26 uses the CgPN information from the call setup message to look up the calling name information. SN 26 plays a computer generated voice message over voice channel C-C′-C″ to caller 10 . The message is an audible message providing caller 10 with the calling name associated with the voicemail message left on VMS 21 .
In a preferred embodiment, the SN also plays a message informing caller 10 how to repeat the message or how to return to VMS 21 to retrieve more voicemail messages.
The foregoing disclosure of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents. | A system and method for providing calling name delivery to a voicemail service subscriber. The system and method use the features of an advanced intelligent network to provide an interface between a voicemail service and a telephone service provider's calling name databases. The present invention advantageously provides this interface using standard call processing techniques without the need to establish a direct data interface between the systems. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to fluorenyl-type ligands useful in metallocene-type olefin polymerization catalysts and more particularly, to the preparation of such fluorenyl-type ligand structures.
BACKGROUND OF THE INVENTION
[0002] Fluorenyl based metallocene catalysts are effective catalysts in the polymerization, including homopolymerization or copolymerization of olefin polymers such as ethylene, propylene and higher olefins or other ethylenically unsaturated monomers.
[0003] Fluorenyl-type metallocenes are characteristically in the form of metallocene ligand structures characterized by bridged cyclopentadienyl and fluorenyl groups. An example is isopropylidene(cyclopentadienyl)(fluorenyl)zirconium dichloride. The cyclopentadienyl group or the fluorenyl group can be modified by the inclusion of substituent groups in the cyclopentadienyl ring or the fluorenyl group which modifies the structure of the catalyst and ultimately the characteristics of the polymers produced. Thus, olefin polymers such as polyethylene, polypropylene, which may be atactic or stereospecific such as isotactic or syndiotactic, and ethylene-higher alpha olefin copolymers such as ethylene propylene copolymers, can be produced under various polymerization conditions and employing various polymerization catalysts.
[0004] The metallocene catalyst based upon a bridged cyclopentadienylfluorenyl ligand structure can be produced by the reaction of 6,6-dimethyl fulvene, which may be substituted or unsubstituted, with a fluorene, which in turn may be substituted or unsubstituted, to produce the bridged isopropylidene cyclopentadienylfluorenyl ligand structure. This ligand is, in turn, reacted with a transition metal halide such as zirconium tetrachloride to produce the bridged zirconium dichloride.
[0005] Fluorenyl ligands may be characterized by the following numbering scheme for the fluorenyl ligand as indicated in Formula (1):
In this numbering scheme, 9 indicates the bridgehead carbon atom. The remaining carbon atoms available to accept substituents are indicated by numbers 1-4, one phenyl group of the ligand, and numbers 5-8 of the other phenyl group of the fluorenyl ligand.
[0006] Alpha olefin homopolymers or copolymers may be produced using metallocene catalysts under various conditions in polymerization reactors which may be batch type reactors or continuous reactors. Continuous polymerization reactors typically take the form of loop-type reactors in which the monomer stream is continuously introduced and a polymer product is continuously withdrawn. For example, polymers such as polypropylene, polyethylene or ethylene-propylene copolymers involve the introduction of the monomer stream into the continuous loop-type reactor along with an appropriate catalyst system to produce the desired olefin homopolymer or copolymer. The resulting polymer is withdrawn from the loop-type reactor in the form of a “fluff” which is then processed to produce the polymer as a raw material in particulate form as pellets or granules. In the case of C 3+ alpha olefins, such as propylene, or substituted ethylenically unsaturated monomers such as styrene or vinyl chloride, the resulting polymer product may be characterized in terms of stereoregularity, for example, isotactic polypropylene or syndiotactic polypropylene.
[0007] The structure of isotactic polypropylene can be described as one having the methyl groups attached to the tertiary carbon atoms of successive monomeric units falling on the same side of a hypothetical plane through the main chain of the polymer, e.g., the methyl groups are all above or below the plane. Using the Fischer projection formula, the stereochemical sequence of isotactic polypropylene is described as follows:
In Formula (2), each vertical segment indicates a methyl group on the same side of the polymer backbone. Another way of describing the structure is through the use of NMR. Bovey's NMR nomenclature for an isotactic pentad as shown above is . . . mmmm . . . with each “m” representing a “meso” dyad, or successive pairs of methyl groups on the same said of the plane of the polymer chain. As is known in the art, any deviation or inversion in the structure of the chain lowers the degree of isotacticity and crystallinity of the polymer.
[0008] In contrast to the isotactic structure, syndiotactic propylene polymers are those in which the methyl groups attached to the tertiary carbon atoms of successive monomeric units in the chain lie on alternate sides of the plane of the polymer. Syndiotactic polypropylene using the Fisher projection formula can be indicated by racemic dyads with the syndiotactic pentad rrrr as shown by Formula (3):
In Formula (3), the vertical segments indicate methyl groups in the case of syndiotactic polypropylene, or other terminal groups, e.g. chloride, in the case of syndiotactic polyvinyl chloride, or phenyl groups in the case of syndiotactic polystyrene.
[0009] Other unsaturated hydrocarbons which can be polymerized or copolymerized with relatively short chain alpha olefins, such as ethylene and propylene include dienes, such as 1,3-butadiene or 1,4-hexadiene or acetylenically unsaturated compounds, such as methylacetylene.
[0010] Procedures for the synthesis of substituted fluorenes used to produce metallocene polymerization catalysts are influenced by specific features of the fluorene ligand. The direct electrophilic substitutions of fluorene occur predominantly at the 2- or 2,7-positions having the highest electron density. For example, 2,7-di-t-butylfluorene can be prepared from the reaction of fluorene with t-butyl chloride in the presence of AlCl 3 :
As another example, as disclosed in EP1138687, 3,6-di-t-butyl fluorene can be prepared by the reaction of 2,2′-diiodo-4,4′-di-t-butyldipheriylmethane with copper as shown in the following reaction:
This reaction, which occurs at a high temperature (230-250° C.), results in a mixture of products. When using this method, several purification steps are needed in order to obtain the pure 3,6-di-tert-butyl-fluorene.
SUMMARY OF THE INVENTION
[0011] In accordance with the present invention, there are provided methods for the preparation of fluorenyl-type ligand structures and substituted fluorenyl groups which may be employed in metallocene-type olefin polymerization catalysts. In carrying out the present invention, there is provided a 2,2′-dihalogen-diphenylmethylene having a methylene bridge connecting a pair of phenyl groups. Each of the phenyl groups has a halogen on a proximal carbon atom relative to the methylene bridge. The halogenated diphenylmethylene is reacted with a coupling agent comprising a transition metal selected from Groups 2 or 12 of the Periodic Table of Elements. This reaction is carried out in the presence of a nickel or palladium-based catalyst to remove the halogen atoms from the phenyl groups and couple the phenyl groups at the proximal carbon atoms to produce a fluorene ligand structure. In a preferred embodiment of the invention, the coupling agent is selected from the group consisting of zinc, cadmium and magnesium and more specifically, zinc. The catalyst may be a monophosphine nickel complex characterized by the formula:
NiX 2 2(PR 3 ) (6)
or a diphosphine nickel complex characterized by the formula:
NiX 2 [PR 2 —CH 2 ) n —PR 2 ] (7)
wherein X is a halogen, n is a number within the range of 1-10 and R is an alkyl, aryl or cyclic group.
[0012] The halogenated diphenylmethylene may be an unsubstituted ligand structure or a monosubstituted or disubstituted ligand structure. In one embodiment of the invention, the halogenated diphenylmethylene is monosubstituted with an alkyl group, an alicyclic group or an aryl group having from 1 to 20 carbon atoms. In a preferred embodiment of the invention, the halogenated diphenylmethylene is monosubstituted with a tertiary butyl group.
[0013] In a further embodiment of the invention, the halogenated diphenylmethylene is a dialkyl diphenylmethylene having alkyl substituents at the directly distal positions of the phenyl groups relative to the methylene bridge. In this embodiment of the invention, the product produced by the coupling reaction is a 3,6-dialkyl fluorene. Preferably, each of the alkyl substituents is an isopropyl or higher group, having a molecular weight of at least 43. More preferably, the alkyl substituents are tertiary butyl groups.
[0014] In a more specific aspect of the invention, the halogenated diphenylmethylene is a substituted diphenyl methylene characterized by the formula:
In Formula (8), X is a halogen atom. Each of R 1 -R 8 is a hydrogen atom, an aryl group or an alkyl group, which may be the same or different, provided that no more than 3 of the R 1 -R 4 groups or no more than 3 of the R 5 -R 8 groups are hydrogen atoms. Thus, the substituted diphenylmethylene characterized by Formula (8) is at least a disubstituted ligand structure.
[0015] In a preferred embodiment of the invention, R 1 , R 4 , R 5 and R 8 are hydrogen and R 2 , R 3 , R 6 and R 7 are alkyl groups. In one embodiment of the invention, R 3 and R 6 are tertiary butyl groups and R 2 and R 7 are C 1 -C 20 allyl groups. In another embodiment of the invention, R 3 and R 6 are tertiary butyl groups and R 1 , R 2 , R 4 , R 5 , R 7 and R 8 are hydrogen atoms.
[0016] In a preferred embodiment of the invention, the reaction with the coupling agent is carried out at a temperature of less than 100° C. Preferably, the coupling reaction is carried out at temperatures within the range of 20-80° C. for a time period within the range of 2-3 hours.
[0017] Further embodiments of the present invention involve the preparation of substituted fluorenes employing fluorenes or substituted fluorenes as starting materials. In one embodiment of the invention, there is provided a 3,6-disubstituted fluorene characterized by the formula:
In Formula (9), R 1 and R 2 are C 1 -C 20 alkyl groups which may be the same or different.
[0018] The disubstituted fluorene is reacted with a brominating agent to produce 2,7-dibromo-3,6-disubstituted fluorene characterized by the formula:
wherein R 1 and R 2 are as defined above.
[0019] The 2,7-dibromo-3,6-disubstituted fluorene is reacted with a magnesium or zinc-based Grignard reagent characterized by the formula:
RMX (11)
wherein R is a C 1 -C 20 alkyl or a C 6 -C 20 alicyclic or aryl group, M is magnesium or zinc, and X is a halogen.
The product of this reaction is a 2,7,3,6-tetrasubstituted fluorene characterized by the formula:
Alternatively, the 2,7-dibromo-3,6-disubstituted fluorene characterized by Formula (10) is reacted in the presence of a palladium-based catalyst with an arylboronic acid characterized by the formula:
wherein A r is a phenyl or a naphthyl group which may be substituted or unsubstituted and R a is a C 1 -C 20 alkyl group.
The result of this reaction is a 2,3,6,7-substituted fluorene characterized by the formula:
In a preferred embodiment of the invention, Ar is a phenyl group and R 1 and R 2 are tertiary butyl groups.
[0020] In a further aspect of the invention, a 3,6-disubstituted fluorene characterized by Formula (9) above is reacted with a chloromethylating agent to produce a 2(7)-monochloromethylene-3,6-disubstituted fluorene, a 2,7-dichloromethylene-3,6-disubstututed fluorene or a 2,4,7-trichloromethylene-3,6-disubstituted fluorene characterized by Formulas (15) through (17), respectively.
The chloromethylene disubstituted fluorene characterized by the above Formulas (15)-(17) is reacted with a reducing agent to produce the corresponding monomethyl, dimethyl or trimethyl-disubstituted fluorene as characterized by Formulas (18), (19) or (20), respectively.
Preferably, the groups R 1 and R 2 are tertiary butyl groups.
[0021] Yet a further embodiment of the invention employs as a starting material a 2,7-disubstituted fluorene characterized by the formula:
wherein R 1 and R 2 are C 1 -C 20 alkyl or alicyclic groups which may be the same or different. The disubstituted fluorenyl group is reacted with a brominating agent to produce a 4-bromo-3,6-disubstituted fluorene characterized by the formula:
The 4-bromo-3,6-disubstituted fluorene is reacted in the presence of a nickel or palladium catalyst with a magnesium or zinc-based Grignard reagent as characterized by Formula (11) above to produce a 2,4,7-substituted fluorene characterized by the formula:
Alternatively, the 4-bromo-3,6-disubstituted fluorene is reacted in the presence of a palladium-based catalyst with an arylboronic acid characterized by Formula (13) above to produce a 2,4,7-substituted fluorene characterized by the formula:
In a preferred embodiment of the invention, R 1 and R 2 are tertiary butyl groups.
[0022] In yet a further aspect of the invention, fluorene is reacted with a tertiary butylating agent to produce a 2,7-ditertiarybutyl fluorene which is reacted with a brominating agent to produce a 4-bromo-2,7-ditertiarybutyl fluorene characterized by the formula:
This brominated fluorene is reacted with aluminum chloride and benzene to dealkylate the fluorene ligand to produce a 4-bromo fluorene characterized by the formula:
This 4-bromo fluorene ligand is reacted in the presence of a nickel or palladium-based catalyst with a magnesium or zinc Grignard reagent as characterized by Formula (11) above or with an arylboronic acid as characterized by Formula (13) above to produce a 4-substituted fluorene characterized by the formula:
DETAILED DESCRIPTION OF THE INVENTION
[0023] In accordance with the present invention, provided are methods for the preparation of fluorenyl-type ligand structures by a protocol which employs readily available reactants and provides a fluorenyl ligand in high yields, in contrast to the use of a copper agent as described previously. The process of the present invention can be carried out under moderate temperature conditions and is not attended by laborious and time consuming purification procedures.
[0024] As noted previously, in a typical numbering scheme applied to fluorenyl groups, the central carbon atom (the bridgehead carbon atom) extending between the phenylene groups, is numbered 9 and the carbon atoms of the phenylene groups are numbered 1-8. In the diphenylmethylene group from which the fluorenyl group may be derived, the carbon atoms in one phenyl group are numbered 1-6 and the counterpart carbon atoms of the other phenyl group are numbered 1′-6′. These numbering schemes are shown in the following reaction illustrating the reaction of a halogenated diphenylmethylene with a coupling agent to produce a corresponding fluorenyl ligand.
[0025] This reaction indicates the basic reaction employed in the present invention in which the 2,2-dihalogen diphenylmethylene is reacted with a zinc, cadmium or magnesium coupling agent over a nickel or palladium-based catalyst. In Reaction (28), X is a halogen, preferably chlorine, bromine or iodine, and more preferably, iodine. In Reaction (28), the carbon atom in the methylene bridge of the diphenylmethylene corresponds to the bridgehead carbon atom 9 of the fluorenyl group. The carbon atoms 3, 4, 5 and 6 correspond respectively to carbon atoms 4, 3, 2 and 1 of the fluorenyl group and the carbon atoms 3′, 4′, 5′ and 6′ correspond respectively to carbon atoms 8, 7, 6 and 5 of the fluorenyl group. In the case where the fluorenyl group is only monosubstituted, it will be recognized that 2-substitution is equivalent to 7-substitution, 3-substitution is equivalent to 6-substitution and so on.
[0026] The foregoing reaction is carried out in the presence of nickel(II) catalysts, preferably phosphine nickel(II) complexes, specifically, Ni[(PPh 3 ) 2 ]Cl 2 , [Ph 2 PC 2 H 4 PPh 2 ]NiCl 2 and [Ph 2 PC 3 H 6 PPh 2 ]NiCl 2 or palladium (0) catalyst, preferably Pd(PPh 3 ) 4 . Preferably, at least 0.5 mol. %, and more preferably 0.5-2.0 mol. %, of catalyst is employed. According to a preferred embodiment of the invention, the process is carried out in the presence of a polar solvent, such as tetrahydrofuran (THF) or N,N-dimethylformamide. The reaction is preferably carried out at a temperature within the range of 20-80° C., for a period of 1-48 hours, and more preferably for 2-3 hours.
[0027] Examples of reaction routes which may be employed in carrying out the invention are as follows, with | indicating a methyl group and indicating a tertiary butyl group.
[0028] The reaction involves the use of a brominating reagent and a Grignard reagent or an arylboronic acid as described previously. The term “Grignard reagent” as used herein, is meant to denote a conventional Grignard reagent characterized by the formula:
RMgX (35)
and also the zinc equivalent in which the magnesium atom is replaced with a zinc atom to provide the reagent:
RZnX (36)
X is a halogen, typically chlorine or bromine.
[0029] Another reaction route can be used to make tetra-substituted fluorenes. This procedure includes reacting a 3,6-substituted fluorene having the same or different substituent groups with at least 2 equivalents and preferably 2.0-2.2 equivalents of a brominating agent, preferably N-bromosuccinimide in propylene oxide at 60-80° C. for 2-6 hours to produce a 2,7-dibromo-3,6-disubstituted fluorene as follows:
[0030] The 2,7-dibromo-3,6-disubstituted fluorene is reacted with a Grignard compound RMgX or RZnX in the presence of a nickel or palladium-based catalyst to produce a 2,3,6,7-susbstituted fluorene:
Alternatively, the 2,7-dibromo-3,6-disubstituted fluorene is reacted with an arylboronic acid as depicted by Formula (13) in which the aryl group may be phenyl, substituted phenyl, naphthyl or substituted naphthyl, in the presence of a palladium-based catalyst to produce 2,3,6,7-susbstituted fluorene as exemplified by the following reaction:
The first procedure comprises reacting the 2,7-dibromo-3,6-disubstituted fluorene with at least 2 equivalents and preferably 2-7 equivalents of the Grignard reagent, magnesium or zinc-organic compound. This reaction is carried out in the presence of a nickel or palladium catalyst, preferably Ni[(PPh 3 ) 2 ]Cl 2 , [Ph 2 PC 2 H 4 PPh 2 ]NiCl 2 , [Ph 2 PC 3 H 6 PPh 2 ]NiCl 2 or Pd(PPh 3 ) 4 , with at least 0.5 mol. %, and preferably 0.5-2.0 mol. % of catalyst. The reaction procedure is preferably carried out in the presence of a polar solvent such as diethyl ether or THF. The reaction is preferably carried out at a temperature within the range of 20-60° C. for a time period of 1 hour to 5 days, and more preferably, for 2-24 hours.
[0031] The alternative procedure involves the reaction 2,7-dibromo-3,6-disubstituted fluorene with at least 2 equivalents and preferably 2-3 equivalents of the arylboronic acid. This reaction is carried out in the presence of a palladium catalyst, preferably Pd(PPh 3 ) 4 , with at least 0.5 mol. %, and preferably 0.5-5.0 mol. % of palladium catalyst, and in the presence of at least 3 equivalents of Na 2 CO 3 or K 2 CO 3 , preferably 3-7 equivalents of Na 2 CO 3 or K 2 CO 3 . Preferably, the alternative reaction procedure is carried out in the presence of toluene, alcohol and water at ratios of 10:(1-2):(1-0.1), respectively. The reaction is preferably carried out at a temperature ranging from 20-150° C. for a period of 1-24 hours, and more preferably, 2-3 hours. The resulting fluorene product can be purified by any suitable procedure such as by crystallization or by column chromatography.
[0032] Another reaction route which can be used to make tri-, tetra- and penta-substituted fluorenes includes reacting a 3,6-substituted fluorene having same or different groups with an chloromethylation agent to produce a 2(7)-monochloromethylene-3,6-disubstituted fluorene, 2,7-di-chloromethylene-3,6-disubstituted fluorene, and 2,4,7-tri-chloromethylene-3,6-disubstituted fluorene in accordance with the following reactions:
The chloromethylene fluorene derivatives are reacted with a reduction agent to produce the corresponding tri-, tetra- and penta-substituted fluorenes as follows:
[0033] The reaction of 3,6-disubstituted fluorene producing the monochloromethylene derivative is carried out with at least 1 equivalent and preferably 1-2 equivalents of chloromethyl methyl ether to produce the 2(7)-monochloromethylene-3,6-disubstituted fluorene. This reaction is carried out in the presence of at least 1 mol. % and preferably 5-30 mol. % of MCI 4 (M=Ti, Zr, Hf) or MCl 2 (M=Zn, Cd), preferably TiCl 4 or ZnCl 2 . The reaction is carried out at a temperature within the rang of 0-40° C., preferably 0-10° C. for a period of 1-72 hours, and more preferably for 1-5 hours.
[0034] The 2,7-dichloromethylene-3,6-disubstituted fluorene is produced under similar condition using at least 2 equivalents and preferably 2-7 equivalents of chloromethyl methyl ether, 10-30 mol. % of MCl 4 (M=Ti, Zr, Hf) or MCl 2 (M=Zn, Cd), preferably TiCl 4 or ZnCl 2 , at a temperature within the range of 0-40° C., preferably 20° C., for a period of 3-72 hours, and more preferably for about 24 hours. The 2,4,7-trichloromethylene-3,6-disubstituted fluorene is produced under conditions involving at least 3 equivalents and preferably 5-7 equivalents of chloromethyl methyl ether, 10-30 mol. % of MCl 4 (M=Ti, Zr, Hf) or MCl 2 (M=Zn, Cd), preferably TiCl 4 or ZnCl 2 , at a temperature within the range of 0-40° C., preferably 20° C., for a period of 3-72 hours, and more preferably for about 24 hours. The reactions are carried out in an organic solvent, preferable carbon disulfide or without solvent. The products are purified by crystallization from hot heptanes.
[0035] An alternate procedure involves reacting the chloromethylene derivatives with at least 0.5 equivalent and preferably 0.5-1.0 equivalent per each chloromethylene unit of LiAiH 4 in THF for 1-5 hours at 20-60° C. to produce the corresponding methyl-fluorenes.
[0036] Another process which can be used to make 2,4,7-substituted fluorenes involves the following procedure. A 2,7-substituted fluorene having the same or different substituent groups (alkyl or cyclic, C 1 -C 20 ) is reacted with a bromination agent to produce a 4-bromo-2,7-disubstituted fluorene in accordance with the following reaction:
The 4-bromo-2,7-disubstituted fluorene is reacted with a Grignard reagent RMgX or RZnX (R =Alk, (C 1 -C 20 ), Cyclic (C 6 -C 20 )) in the presence of a nickel or palladium-based catalyst to produce a 2,4,7-susbstituted fluorene in accordance with the following reaction:
Alternatively, the 4-bromo-2,7-disubstituted fluorene is reacted in the presence of a palladium-based catalyst with an arylboronic acid in which the aryl group may be phenyl, substituted phenyl, naphthyl or substituted naphthyl, to produce 2,4,7-susbstituted fluorene as exemplified by the following reaction:
The initial reaction involving the 2,7-disubstituted fluorene is carried out with at least 1.0 equivalent and preferably 1.0-1.2 equivalents of bromine to produce the 4-bromo-2,7-disubstituted fluorene. This reaction is carried out in the presence of iron powder in CCl 4 for 1-5 hours at 60-80° C.
[0037] The next reaction involves reacting 4-bromo-2,7-disubstituted fluorene with at least 1 equivalent and preferably 2-7 equivalents of the Grignard reagent magnesium or zinc-organic compounds. This reaction is carried out in the presence of a nickel or palladium-based catalyst, preferably Ni[(PPh 3 ) 2 ]Cl 2 , [Ph 2 PC 2 H 4 PPh 2 ]NiCl 2 , [Ph 2 PC 3 H 6 PPh 2 ]NiCl 2 or Pd(PPh 3 ) 4 , with at least 0.5 mol. %, and preferably 0.5-2.0 mol. % of catalyst. In a preferred embodiment of the invention, the reaction is carried out in the presence of polar solvent, preferably in diethyl ether or THF. This reaction is preferably carried out at a temperature within the range of 20-60° C. for a period of 1 hour to 5 days, and more preferably for 2-24 hours.
[0038] The alternative reaction involves reacting the 4-bromo-2,7-disubstituted fluorene with at least 1 equivalent and preferably 1.5 equivalents of the arylboronic acid. This reaction is carried out in the presence of a palladium-based catalyst, preferably Pd(PPh 3 ) 4 , and with at least 0.5 mol. %, and preferably 0.5-5.0 mol. % of palladium catalyst, and in the presence of at least 3 equivalents of Na 2 CO 3 or K 2 CO 3 . Preferably, the reaction involves 3-7 equivalents of Na 2 CO 3 or K 2 CO 3 . In a preferred embodiment of the invention, this reaction is carried out in the presence of toluene, alcohol and water, preferably in ratios of 10:(1-2):(1-0.1), respectively. The initial reaction is preferably carried out at a temperature within the range of 20-150° C. for a period of 1-24 hours, and more preferably for a period of 2-3 hours. The resulting fluorene product is purified by crystallization or by column chromatography.
[0039] Another procedure for producing a 4-substituted fluorene involves the following reaction sequence. Fluorene is reacted with a tert-butylation agent to produce a 2,7-di-t-butyl-fluorene as follows:
The 2,7-di-t-butyl-fluorene is reacted with a bromination agent to produce a 4-bromo-2,7-di-t-butyl-fluorene in accordance with the following reaction:
The 4-bromo-2,7-di-t-butyl-fluorene is then reacted with benzene and AlCl 3 to produce 4-bromo-fluorene as follows:
The 4-bromo-fluorene is reacted with a Grignard reagent RMgX or RZnX (R=Alk, (C 1 -C 20 ), cyclic (C 6 -C 20 ) as defined above in the presence of a nickel or palladium-based catalyst, or with an arylboronic acid in which the aryl group may be phenyl, substituted phenyl, naphthyl or substituted naphthyl, to produce 4-R-fluorene as exemplified by the following reaction:
[0040] The reaction of fluorene with the tert-butylating agent involves the reaction of at least 1.0 equivalent of and preferably 1.0-1.2 equivalents of 2,6-di-t-butyl-p-cresol to provide a protection of the 2- and 7-positions of the fluorene. This reaction can be carried out in the presence of AlCl 3 in nitromethane. The reaction of 2,7-di-t-butyl-fluorene with bromine is carried out under the conditions as described previously.
[0041] The next reaction is a deprotection reaction carried out with benzene in the presence of AlCl 3 . The benzene functions as a solvent and a reactant. The reaction temperature ranges from 20-80° C., preferably 50° C. The reaction is carried out over a period of 0.5-5 hours, and preferably for 1-2 hours. The final reaction involves reacting 4-bromo-fluorene with the Grignard alkylation reagent or the arylboronic acid under the conditions described above to produce the 4-substituted fluorene.
[0042] For a further description of the invention, reference is made to the following illustrative examples.
EXAMPLE 1
Synthesis of 3,6-di-tert-butyl-fluorene
a) Synthesis of 4,4′-di-tert-butyldiphenylmethane
[0043] To a solution of diphenylmethane (20.0 g, 0.119 mol) and 2,6-di-t-butyl-4-methylphenol (54.4 g, 0.238 mol) in nitromethane (300 ml) was added AlCl 3 (31.7 g, 0.238 mol) in nitromethane (100 ml) at 0° C. The reaction mixture was stirred for 120 min at 0° C. and then poured into ice water and extracted with ether (50 ml×2). The organic phase was washed with 10% NaOH (40 ml×5) and dried over MgSO 4 . The solvents (nitromethane and ether) were evaporated using a rotary evaporator. The solid was washed with EtOH and dried. The yield was 17.1 g. 1 HNMR (CDCl 3 ): δ 7.31 (d, J=7.8 Hz, 4H, H arom ), 7.14 (d, J=7.8 Hz, 4H, H arom ), 4.06 (s, impurity), 3.93 (s, 2H, CH 2 ), 1.32 (s, 18H, t-Bu).
b) Synthesis of 2,2′-diiodo-4,4′-di-t-butyldiphenylmethane
[0044] To a solution of 4,4′-di-t-butyldiphenylnethane (9.17 g, 32.7 mmol), periodic acid dihydrate (4.47 g, 19.6 mmol) and iodine (8.30 g, 32.7 mmol) in glacial acetic acid (100 ml) was added H 2 O 4 (2 ml, 95%) and water (7 ml). The mixture was stirred at 85-90° C. for 20 hours and then poured into ice water and extracted with ether. The ether layer was washed with a NaHSO 3 solution, Na 2 CO 3 , followed by water and brine. The organic phase was dried over MgSO 4 . The solvent was distilled off to obtain a yellow oil. The oil was chromatographed through Al 2 O 3 provide 15.3 g of product.
c) Coupling reaction of 2,2′-diiodo-4,4′-di-t-butyldiphenylmethane to produce 3,6-di-tert-butyl-fluorene
[0045]
[0046] Twelve replications of reaction (51) were carried out under the reaction conditions and with the fluorene yields set forth in Table I. N,N-dimethylformamide was used as a solvent.
TABLE I 2,2′-Diiodo- Reaction 4,4′-di-t- Coupling Reaction temperature, Fluorene Replication # butyldiphenylethane (mg) reagent (mg) Catalyst (mg) time, hs ° C. yield, % 1 409 Zn (125) Ni(Ph 3 P) 2 Cl 2 (50) 20 75 25.8 2 409 Zn (125) Ni(Ph 3 P) 2 Cl 2 (50) 40 75 32.9 3 409 Zn (125) Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10) 20 75 40.3 4 409 Zn (125) Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10) 48 75 57.7 5 409 Zn* (125) Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10) 3 75 59.0 6 409 Zn* (125) Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10) 20 75 65.1 7 409 Zn* (125) Ni[Ph 2 P(CH 2 ) 2 PPh 2 )]Cl 2 (10) 48 75 78.1 8 888 Zn (250) Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (18) 3 75 75.0 9 888 Zn (250) Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (18) 20 75 81.2 10 888 Zn (250) Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (18) 48 75 96.2 11 409 Zn (125 mg) Pd(Ph 3 P) 4 (20) 20 75 8.1 12 409 Cd (250) Ni[Ph 2 P(CH 2 ) 3 PPh 2 )]Cl 2 (10) 3 75 65.0 *activated zinc (zinc powder was treated with 10% HCl, washed with water, EtOH and dried)
EXAMPLE 2
Synthesis of 2,7-dimethyl-3,6-di-tert-butyl-fluorene
[0047] The same procedures as in Example 1, replications 1-10 were repeated except that the reaction was carried out with 2,2′-diiodo-4,4′-di-t-butyl-5,5′-dimethyl-diphenylmethane in accordance with the following reaction:
The results in terms of yield of the fluorenyl compound were roughly equivalent to those of Example 1.
EXAMPLE 3
Synthesis of 3-tert-butyl-fluorene
[0048] The same procedures as in Example 1, replications 1-10 were repeated except that the reaction was carried out with 2,2′-diiodo-4-t-butyl-diphenylmethane in accordance with the following reaction:
The results in terms of yield of the fluorenyl compound were roughly equivalent to those of Example 1.
EXAMPLE 4
Synthesis of 2,7-dimethyl-3,6-di-tert-butyl-fluorene
a) Bromination of 3,6-di-t-butyl-fluorene
[0049] To a solution of 3,6-di-t-butylfluorene (2.10 g, 7.55 mmol) in propylene carbonate (60 ml) was added NBS (2.70 g). The reaction mixture was stirred for 6 hours at 70-75° C. The mixture was then poured into water, and the precipitated solid was filtered, washed with water and dried to yield 2.71 g at a purity of 82%. 1 H NMR (CDCl 3 ): δ 7.80 and 7.72 (each s, 2H, 1,8- and 4,5-H (Flu), 3.74 (s, 2H, H 9 ), 1.59 (s, 18H, t-Bu).
b) Coupling reaction of 2,7-dibromo-3,6-di-t-butyl-fluorene with Zn-Grignard reagent
[0050] To a solution of ZnCl 2 (545 mg, 4.00 mmol) in THF (20 ml) was added MeMgBr (1.3 ml, 3M in Et 2 O, 4.90 mmol). A mixture of 2,7-dibromo-3,6-di-t-butyl-fluorene (0.65 g, 1.50 mmol) and 1,2-bis(diphenyl phosphine)ethane nickel dichloride (0.110 g, 0.20 mmol) in THF (10 ml) was added to the prepared MeZnBr solution. The mixture was stirred at 25° C. for 6 hours. The reaction mixture was quenched with water, extracted with ether, dried over MgSO 4 , and evaporated under vacuum to produce a residue which was purified by column chromatography (silica gel, hexane/CH 2 Cl 2 =5/1) to give 2,7-dimethyl-3,6-di-t-butyl-fluorene at a yield of 10%.
EXAMPLE 5
Synthesis of 2,7-diphenyl-3,6-di-tert-butyl-fluorene
a) Bromination of 3,6-di-t-butyl-fluorene
[0051] The bromination of 3,6-di-t-butyl-fluorene was carried out following the procedure of Example 4a in accordance with reaction (54).
b) 2,7-Diphenyl-3,6-di-t-butyl-fluorene
[0052] To a mixture of 2,7-dibromo-3,6-di-t-butylfluorene (0.96 g, 2.20 mmol) and Pd(PPh 3 ) 4 (260 mg, 0.22 mmol) in toluene (50 ml) was added a solution of phenylboronic acid (0.81 g, 6.63 mmol) in EtOH (10 ml) and a solution of Na 2 CO 3 (1.5 g) in water (10 ml). The reaction mixture was stirred for 6 hours under reflux. The reaction mixture was quenched with water, extracted with ether, dried over MgSO 4 , and evaporated under vacuum to produce a residue which was purified by column chromatography (silica gel, hexane/CH 2 Cl 2 =5/1) to yield 2,7-diphenyl-3,6-di-t-butyl-fluorene (0.85 g, 90%). 1 H NMR (CDCl 3 ): δ 7.96 and 7.15 (each s, 2H, 1,8- and 4,5-H (Flu), 7.33 (m, 10H, Ph), 3.77 (s, 2H, H9), 1.27 (s, 18H, t-Bu).
EXAMPLE 6
Synthesis of 2-methyl-3,6-di-tert-butyl-fluorene
a) Chloromethylation of 3,6-di-t-butyl fluorene
[0053] To a solution of 3,6-di-t-buthyl fluorene (2.00 g, 7.19 mmol) and chloromethyl methyl ether (2.5 ml) in CS 2 (15 ml) was added at 0° C. a solution of TiCl 4 (0.4 ml) in CS 2 (5 ml). The reaction mixture was stirred for 3 hours at room temperature. The mixture was poured into ice water and extracted with ether. The ether extract was dried over sodium sulfate and evaporated under vacuum to leave a residue, which was purified by column chromatography (hexane/CH 2 Cl 2 =10/1) and crystallization from hot heptanes. 2-Chloromethyl-3,6-di-t-butylfluorene (Yield 0.75 g) 1 H NMR (CDCl 3 ): δ 7.80 and 7.78 (each d, 1H, 4,5-H), 7.47 (d, 1H, J=8.1 Hz, H8), 7.34 (dd, 1H, J=8.1 Hz, J=1.5 Hz, H7), 7.31 (d, 1H, 1H, J=1.5 Hz, H1), 4.72 (s, 2H, CH 2 Cl), 3.87 (s, 2H, H9), 1.41 (s, 18H, t-Bu). 2,7-Dichloromethyl-3,6-di-t-butylfluorene (Yield 0.63 g) 1 H NMR (CDCl 3 ): δ 7.87 (br s, 2H, 4,5-H), 7.34 (br s, 2H, 1,8-H), 4.75 (s, 4H, CH 2 Cl), 3.95 (s, 2H, H9), 1.42 (s, 18H, t-Bu).
b) Reduction of 2-chloromethyl-3,6-di-t-butylfluorene
[0054] To a solution of 2-chloromethyl-3,6-di-t-butylfluorene (0.74 g, 2.26 mmol) in THF (15 ml) was added a small portion of LiAlH 4 (129 mg, 3.39 mmol) under stirring and the mixture was refluxed for 5 hours. The reaction was quenched with water and NaOH and extracted with ether. The ether solution was evaporated under vacuum to give a white solid yield of 0.68 g. 1 H NMR (CDCl 3 ): δ 7.80 and 7.66 (each d, 1H, 4,5-H), 7.45 (d, 1H, J=8.1 Hz, H8), 7.31 (dd, 1H, J=8.1 Hz, J=1.5 Hz, H7), 7.14 (br s, 1H, 1H, H1), 3.69 (s, 2H, H9), 2.40 (s, 3H, Me), 1.41 (s, 18H, t-Bu).
EXAMPLE 7
Synthesis of 2,7-dimethyl-3,6-di-tert-butyl-fluorene
a) Chloromethylation of 3,6-di-t-butyl fluorene
[0055] The same procedure as in Example 6a was repeated.
b) Reduction of 2,7-di-chloromethyl-3,6-di-t-butylfluorene
[0056] To a solution of 2,7-dichloromethyl-3,6-di-t-butylfluorene (0.75 g, 2.0 mmol) in THF (15 ml) was added a small portion of LiAlH 4 (220 mg, 5.8 mmol) under stirring and the mixture was refluxed for 4 hours. The reaction was quenched with water and NaOH and extracted with ether. The ether solution was evaporated under vacuum to give a white solid of 2,7-di-methyl-3,6-di-tert-butyl-fluorene with a yield of 85%.
EXAMPLE 8
Synthesis of 2,4,7-tri-methyl-3,6-di-tert-butyl-fluorene
[0057] The same procedure as in Example 6 was repeated except the chloroalkylation reaction was run for 24 hours to provide a yield of 10%.
[0058] Having described specific embodiments of the present invention, it will be understood that modifications thereof may be suggested to those skilled in the art, and it is intended to cover all such modifications as fall within the scope of the appended claims. | Methods for the preparation of fluorenyl-type ligand structures and substituted fluorenyl groups which may be employed in metallocene-type olefin polymerization catalysts. There is provided a 2,2′-dihalogen-diphenylmethylene having a methylene bridge connecting a pair of phenyl groups. Each phenyl group has a halogen on a proximal carbon atom relative to the methylene bridge. The halogenated diphenylmethylene is reacted with a coupling agent comprising a Group 2 or 12 transition metal in the presence of a nickel or palladium-based catalyst to remove the halogen atoms from the phenyl groups and couple the phenyl groups at the proximal carbon atoms to produce a fluorene ligand structure. The coupling agent may be zinc, cadmium or magnesium and the catalyst may be a monophosphene nickel complex. The halogenated diphenylmethylene may be an unsubstituted ligand structure or a monosubstituted or disubstituted ligand structure. The halogenated diphenylmethylene may be monosubstituted with a tertiary butyl group or may be a dialkyl diphenylmethylene having alkyl substituents at the directly distal positions of the phenyl groups relative to the methylene bridge. | 2 |
This application claims priority to and benefit of U.S. Provisional Application Nos. 60/655,265, filed Feb. 22, 2005, the disclosures of each of which are incorporated herein for all purposes.
FIELD OF THE INVENTION
The present invention relates to dimethicone copolyol sulfosuccinates that contain alkyl groups having between 8 and 40 carbon atoms. More specifically, the invention relates to silicone-based sulfosuccinates that exhibit increased detergency while still maintaining mildness and foaming properties when used as surfactants in shampoos and other personal care products.
BACKGROUND OF THE INVENTION
Sulfosuccinate surfactants have been used in the cosmetic industry primarily to improve the mildness of shampoos and other personal care products. Such surfactants are usually diesters or monoesters, with the monoester being preferred because of its mildness and foam enhancement properties. Heretofore, primarily two half ester or monoester derivatives have been used for shampoos which include derivatives of monoalcohol amides, such as oleamide MEA, oleamide IPA and undecylenamide MEA, and derivatives of fatty alcohols and ethoxylated alcohols, such as lauryl, laureth and oleyl alcohols.
The sulfosuccinates obtained from diesters and monoesters vary considerably in their foaming, viscosity building, solubility and conditioning properties. In general, they are gentle to the skin and eyes when compared to high foaming surfactants, and are usually blended with such high foaming surfactants to obtain surfactants which exhibit some degree of both mildness and foaming properties.
U.S. Pat. No. 4,849,127 issued Jul. 18, 1989 to Maxon incorporated herein by reference teaches Dimethicone copolyol sulfosuccinate compounds obtained from silicone-based monoesters. The dimethicone copolyol sulfosuccinates are obtained by reacting the ethoxylated polyether side chains of dimethicone copolyol with maleic anhydride to form a monoester and then converting the monoester to a sulfosuccinate by sulfonation of the double bond with a metallic sulfite, an amine or with a combination of a metallic sulfite and an amine. Dimethicone copolyol sulfosuccinates are silicone-based compounds which are useful as surfactants for improving the mildness and foam enhancing and stabilizing properties of shampoos and other personal care products. The patent is a division of co-pending application Ser. No. 000,479, filed on Jan. 5, 1987, now U.S. Pat. No. 4,717,498.
While silicone sulfosuccinate surfactants having mildness and foaming properties useful in the industry have been known and used, the preparation of such surfactants having both detergency and mildness in a silicone containing product has not been accomplished. The present invention is directed generally to alkyl silicone sulfosuccinate surfactants derived from alkyl silicone-based esters which demonstrate improved mildness, foam enhancing and stabilizing properties over known surfactants.
SUMMARY OF THE INVENTION
The present invention relates to a series of silicone based sulfosuccinates that contain an alkyl group that provides outstanding detergency as well as mildness to the skin and eye. While not wanting to be bound to any one theory, it is generally thought the compounds of the present invention function as follows: Consider the Maxon compounds (U.S. Pat. No. 4,894,127). The presence of only the sulfocuccinate on the silicone backbone results in a product that has surface active activity. This is because the hydrophobe is silicone based and is referred to as siliphilic (silicone loving). The alkoxylate and the sulfosuccinate group result in a hydrophilic and anionic group respectively. At the surface the water loving portion orients itself into the water phase and the silicone provides outstanding feel on the skin. What is missing is an oil soluble group to provide detergency, emulsifying and oils on the substrate into a micelle. By providing such a molecule, an outstanding detergent that is exceptionally mild and providing a good skin feel is achieved. The Maxon product lacks the desired detergency.
OBJECTS OF THE INVENTION
It is, an object of the present invention therefore, to prepare novel alkyl dimethicone copolyol sulfosuccinates having silicone-based compositions having improved detergency properties while maintaining good skin feel and mildness to the eye and skin.
Further objects of this invention are to prepare novel alkyl dimethicone copolyol sulfosuccinates which can be used as surfactants in shampoo and other personal care products and to provide novel multi-functional surfactants which exhibit improved detergency while still providing mildness and foam stabilizing properties.
These and other objects of the present invention together with the advantages thereof will become apparent to those skilled in the art from the detailed disclosure of preferred embodiments of the present invention as set forth below.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates generally to alkyl dimethicone copolyol sulfosuccinates of the formula:
wherein;
a is an integer ranking from 1 to 20;
b is an integer ranging from 1 to 20;
c is an integer ranging from 0 to 200;
d, e and f are each independently integers ranging from 0 to 20;
g is an integer ranging from 7 to 39;
M is selected from the group consisting of sodium, potassium and ammonium.
The compositions of the present invention are generally prepared by reacting the ethoxylated polyether side chains of an alkyl dimethicone copolyol with maleic anhydride to form a monoester and then converting the monoester to a sulfosuccinate by sulfonation of the double bond with a metallic sulfite. Metallic sulfite and amine salts may also be used either alone or in combination for sulfonation of the double bond. The resulting sulfosuccinate is a silicone-based surfactant which exhibits highly improved mildness and foam stabilizing properties.
The alkyl dimethicone copolyol sulfosuccinate compositions of the present invention generally are prepared by reacting the ethoxylated polyether side chains of dimethicone copolyol with maleic anhydride to form a monoester. The side chains involved in this reaction are polymers or copolymers of ethylene or propylene oxide.
wherein;
a is an integer ranging from 1 to 20;
b is an integer ranging from 1 to 20;
c is an integer ranging from 0 to 200;
d, e and f are each independently integers ranging from 0 to 20;
g is an integer ranging from 7 to 39;
M is selected from the group consisting of sodium, potassium and ammonium.
In the first step a preferred condensation reaction proceeds by reacting 1.00 moles of alkyl dimethicone copolyol with 1.0 to 1.30 moles of maleic anhydride. The dimethicone copolyol is heated to a temperature of 60°-100° C., with the preferred temperature ranging between 70°-90° C. The maleic anhydride is completely dissolved and dispersed and the reaction product, the maleic monoester of dimethicone copolyol, is then maintained at a temperature of 60°-100° C., preferably between 70°-90° C., under conditions and according to practices known to those skilled in the art until a constant acid value or number is obtained.
In the second step, the metallic sulfite is dissolved in water at a temperature of about 40° to 95° C., preferably between about 50° to 70° C. After the metallic sulfite is thoroughly dissolved, the maleic monoester of dimethicone copolyol is added to the solution, with the reaction product maintained in a fluid state. The product is allowed to react for approximately one half hour to three hours, until the concentration of the free metallic sulfite is between about 0 and 3%, with the preferred concentration less than about 2%.
PREFERRED EMBODIMENTS
In a preferred embodiment g is 7.
In a preferred embodiment g is 9.
In a preferred embodiment g is 11.
In a preferred embodiment g is 13
In a preferred embodiment g is 15.
In a preferred embodiment g is 17.
In a preferred embodiment g is 19.
In a preferred embodiment g is 21.
In a preferred embodiment g is 23
In a preferred embodiment g is 39.
In a preferred embodiment d+e+f is greater than 5.
In a preferred embodiment d+e+f is greater than 10.
In a preferred embodiment c is less than 100.
In a preferred embodiment c is less than 50.
In a preferred embodiment c is less than 20.
EXAMPLES
Alkyl Dimethicone Copolyols
The alkyl dimethicone copolyols useful as raw materials in the practice of the compounds of the present invention are available from Siltech LLC in Dacula Ga and conform to the following structure:
Examples 1-10
Example
a
b
c
d
e
f
g
1
1
1
0
8
5
5
7
2
5
1
5
0
0
0
11
3
10
5
10
3
5
6
9
4
4
5
15
10
0
0
13
5
15
10
5
0
10
0
15
6
17
20
1
0
5
10
17
7
15
1
200
20
20
20
19
8
20
3
5
8
8
8
21
9
6
1
1
0
20
20
39
10
2
1
0
5
5
5
23
Maleic Anhydride
Maleic anhydride is an item of commerce and conforms to the following structure:
Metallic Sulfite Salts
Metallic sulfite salts are items of commerce and include:
Sodium sulfite (Na 2 SO 3 )
Potassium sulfite (K 2 SO 3 )
Ammonium sulfite (NH 4 ) 2 SO 3
General Procedure
Maleamic Reaction
The reaction is carried out under anhydrous conditions with maleic anhydride and alkyl dimethicone copolyol. The reaction is generally carried out at 80-90° C., with a slight excess of maleic anhydride. A mole ratio of 1:1.05 is preferred.
To the specified number of grams of the specified alkyl dimethicone copolyol is added 103 grams of maleic anhydride under good agitation. The reaction mass is heated to 80° C. whereupon the maleic anhydride melts and begins to react. Care is taken to control the exotherm that ensues to keep the temperature below 95° C. The reaction mass is held for 8 hours and the reaction is complete when the acid value run in water is within 3 acid value units of the acid value run in anhydrous isopropanol.
Alkyl Dimethicone Copolyol
Example
Example
Grams
11
1
1174.0
12
2
242.6
13
3
370.6
14
4
846.3
15
5
383.3
16
6
552.3
17
7
1326.3
18
8
254.8
19
9
581.5
20
10
693.0
Sulfonation
The sulfonation reaction is carried out under aqueous conditions at a concentration of between 50% and 70% water by weight. The preferred amount of water is 65% by weight.
To the specified amount of water is added the specified number of grams of the specified metallic sulfite. The reaction mass is heated to 70° C. and the molten maleamic intermediated (Examples 11-20) is slowly added. Once the addition is complete the reaction mass is heated to 80-90° C. and held 3-5 hours. During that time the residual sulfite drops to very low levels as determined by titration with iodine.
Malemic Derivative
Metallic Sulfite
Water
Example
Example
Grams
Type
Grams
Grams
21
11
1274.0
Sodium Sulfite
132.3
2611.7
22
12
342.6
Sodium Sulfite
132.3
882.0
23
13
470.6
Ammonium Sulfite
121.8
1100.2
24
14
946.3
Ammonium Sulfite
121.8
1983.6
25
15
483.3
Potassium Sulifite
168.0
1209.6
26
16
654.3
Sodium Sulfite
132.3
1460.8
27
17
1326.3
Ammonium Sulfite
121.8
2689.3
28
18
354.8
Potassium Sulfite
168.0
970.9
29
19
681.5
Sodium Sulfite
132.3
1511.3
30
20
793.0
Potassium Sulfite
168.0
1784.7
The compounds of the present invention are used as prepared without additional purification.
Applications Examples
Unlike the products made that lack the alkyl group, the compounds of the present invention are outstanding detergents and emulsifiers, not just foaming compositions. This makes them multi-functional and highly desirable in personal care applications.
The compounds of the present invention can be used as primary surfactants in baby shampoos, body washes and in bubble bath compositions, where very mild, sodium lauryl sulfate free products are desired. The use of these materials result in exceptionally mild detersive systems having outstanding mildness, wet comb and cleansing properties, while still supporting a no more tears claim.
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth hereinabove but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which the invention pertains. | The present invention relates to dimethicone copolyol sulfosuccinates that contain alkyl groups having between 8 and 40 carbon atoms. More specifically, the invention relates to silicone-based sulfosuccinates that exhibit increased detergency while still maintaining mildness and foaming properties when used as surfactants in shampoos and other personal care products. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending application Ser. No. 10/259,139, filed on Sep. 27, 2002, which is a continuation-in-part of co-pending application Ser. No. 10/123,389, filed on Apr. 16, 2002, both of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to novel arylindenopyridines and arylindenopyrimidines and their therapeutic and prophylactic uses. Disorders treated and/or prevented using these compounds include neurodegenerative and movement disorders ameliorated by antagonizing Adenosine A2a receptors.
BACKGROUND OF THE INVENTION
[0000] Adenosine A2a Receptors
[0003] Adenosine is a purine nucleotide produced by all metabolically active cells within the body. Adenosine exerts its effects via four subtypes of cell-surface receptors (A1, A2a, A2b and A3), which belong to the G protein coupled receptor superfamily (Stiles, G. L. Journal of Biological Chemistry, 1992, 267, 6451). A1 and A3 couple to inhibitory G protein, while A2a and A2b couple to stimulatory G protein. A2a receptors are mainly found in the brain, both in neurons and glial cells (highest level in the striatum and nucleus accumbens, moderate to high level in olfactory tubercle, hypothalamus, and hippocampus etc. regions) (Rosin, D. L.; Robeva, A.; Woodard, R. L.; Guyenet, P. G.; Linden, J. Journal of Comparative Neurology , 1998, 401, 163).
[0004] In peripheral tissues, A2a receptors are found in platelets, neutrophils, vascular smooth muscle and endothelium (Gessi, S.; Varani, K.; Merighi, S.; Ongini, E.; Borea, P. A. British Journal of Pharmacology, 2000, 129, 2). The striatum is the main brain region for the regulation of motor activity, particularly through its innervation from dopaminergic neurons originating in the substantia nigra. The striatum is the major target of the dopaminergic neuron degeneration in patients with Parkinson's Disease (PD). Within the striatum, A2a receptors are co-localized with dopamine D2 receptors, suggesting an important site for the integration of adenosine and dopamine signaling in the brain (Fink, J. S.; Weaver, D. R.; Rivkees, S. A.; Peterfreund, R. A.; Pollack, A. E.; Adler, E. M.; Reppert, S. M. Brain Research Molecular Brain Research, 1992, 14, 186).
[0005] Neurochemical studies have shown that activation of A2a receptors reduces the binding affinity of D2 agonist to their receptors. This D2R and A2aR receptor-receptor interaction has been demonstrated in striatal membrane preparations of rats (Ferre, S.; von Euler, G.; Johansson, B.; Fredholm, B. B.; Fuxe, K. Proceedings of the National Academy of Sciences of the United States of America, 1991, 88, 7238) as well as in fibroblast cell lines after transfected with A2aR and D2R cDNAs (Salim, H.; Ferre, S.; Dalal, A.; Peterfreund, R. A.; Fuxe, K.; Vincent, J. D.; Lledo, P. M. Journal of Neurochemistry, 2000, 74, 432). In vivo, pharmacological blockade of A2a receptors using A2a antagonist leads to beneficial effects in dopaminergic neurotoxin MPTP(1-methyl-4-pheny-1,2,3,6-tetrahydropyridine)-induced PD in various species, including mice, rats, and monkeys (Ikeda, K.; Kurokawa, M.; Aoyama, S.; Kuwana, Y. Journal of Neurochemistry, 2002, 80, 262). Furthermore, A2a knockout mice with genetic blockade of A2a function have been found to be less sensitive to motor impairment and neurochemical changes when they were exposed to neurotoxin MPTP (Chen, J. F.; Xu, K.; Petzer, J. P.; Staal, R.; Xu, Y. H.; Beilstein, M.; Sonsalla, P. K.; Castagnoli, K.; Castagnoli, N., Jr.; Schwarzschild, M. A. Journal of Neuroscience, 2001, 21, RC143).
[0006] In humans, the adenosine receptor antagonist theophylline has been found to produce beneficial effects in PD patients (Mally, J.; Stone, T. W. Journal of the Neurological Sciences, 1995, 132, 129). Consistently, recent epidemiological study has shown that high caffeine consumption makes people less likely to develop PD (Ascherio, A.; Zhang, S. M.; Hernan, M. A.; Kawachi, I.; Colditz, G. A.; Speizer, F. E.; Willett, W. C. Annals of Neurology, 2001, 50, 56). In summary, adenosine A2a receptor blockers may provide a new class of antiparkinsonian agents (Impagnatiello, F.; Bastia, E.; Ongini, E.; Monopoli, A. Emerging Therapeutic Targets, 2000, 4, 635).
SUMMARY OF THE INVENTION
[0007] This invention provides a compound having the structure of Formula I or II
or a pharmaceutically acceptable salt thereof, wherein
(a) R 1 is selected from the group consisting of
(i) —COR 5 , wherein R 5 is selected from H, optionally substituted C 18 straight or branched chain alkyl, optionally substituted aryl and optionally substituted arylalkyl;
wherein the substituents on the alkyl, aryl and arylalkyl group are selected from C 18 alkoxy, phenylacetyloxy, hydroxy, halogen, p-tosyloxy, mesyloxy, amino, cyano, carboalkoxy, or NR 7 R 8 wherein R 7 and R 8 are independently selected from the group consisting of hydrogen, C 1-8 straight or branched chain alkyl, C 3-7 cycloalkyl, benzyl, aryl, or heteroaryl or NR 7 R 8 taken together form a heterocycle or heteroaryl;
(ii) COOR 5 , wherein R 5 is as defined above; (ii) cyano; (iii) —CONR 9 R 10 wherein R 9 and R 10 are independently selected from H, C 1-8 straight or branched chain alkyl, C 3-7 cycloalkyl, trifluoromethyl, hydroxy, alkoxy, acyl, alkylcarbonyl, carboxyl, arylalkyl, aryl, heteroaryl and heterocyclyl;
wherein the alkyl, cycloalkyl, alkoxy, acyl, alkylcarbonyl, carboxyl, arylalkyl, aryl, heteroaryl and heterocyclyl groups may be substituted with carboxyl, alkyl, aryl, substituted aryl, heterocyclyl, substituted heterocyclyl, heteroaryl, substituted heteroaryl, hydroxamic acid, sulfonamide, sulfonyl, hydroxy, thiol, amino, alkoxy or arylalkyl, or R 9 and R 10 taken together with the nitrogen to which they are attached form a heterocycle or heteroaryl group;
(v) optionally substituted C 1-8 straight or branched chain alkyl;
wherein the substituents on the alkyl, group are selected from C 1-8 alkoxy, phenylacetyloxy, hydroxy, halogen, p-tosyloxy, mesyloxy, amino, cyano, carboalkoxy, carboxyl, aryl, heterocyclyl, heteroaryl, sulfonyl, thiol, alkylthio, or NR 7 R 8 wherein R 7 and R 8 are as defined above;
(b) R 2 is selected from the group consisting of optionally substituted alkyl, optionally substituted aryl, optionally substituted heteroaryl, optionally substituted heterocyclyl and optionally substituted C 3-7 cycloalkyl, C 1-8 alkoxy, aryloxy, C 1-8 alkylsulfonyl, arylsulfonyl, arylthio, C 1-8 alkylthio, or —NR 24 R 25
wherein R 24 and R 25 are independently selected from H, C 1-8 straight or branched chain alkyl, arylalkyl, C 3-7 cycloalkyl, carboxyalkyl, aryl, heteroaryl, and heterocyclyl or R 24 and R 25 taken together with the nitrogen form a heteroaryl or heterocyclyl group,
(c) R 3 is from one to four groups independently selected from the group consisting of:
hydrogen, halo, C 1-8 straight or branched chain alkyl, arylalkyl, C 3-7 cycloalkyl, C 1-8 alkoxy, cyano, C 1-4 carboalkoxy, trifluoromethyl, C 1-8 alkylsulfonyl, halogen, nitro, hydroxy, trifluoromethoxy, C 1-8 carboxylate, aryl, heteroaryl, and heterocyclyl, —NR 11 R 12 ,
wherein R 11 and R 12 are independently selected from H, C 1-8 straight or branched chain alkyl, arylalkyl, C 3-7 cycloalkyl, carboxyalkyl, aryl, heteroaryl, and heterocyclyl or R 10 and R 11 taken together with the nitrogen form a heteroaryl or heterocyclyl group,
—NR 13 COR 14 ,
wherein R 13 is selected from hydrogen or alkyl and R 14 is selected from hydrogen, alkyl, substituted alkyl, C 1-3 alkoxyl, carboxyalkyl, aryl, arylalkyl, heteroaryl, heterocyclyl, R 15 R 16 N (CH 2 ) p —, or R 15 R 16 NCO(CH 2 ) p —, wherein R 15 and R 16 are independently selected from H, OH, alkyl, and alkoxy, and p is an integer from 1-6, wherein the alkyl group may be substituted with carboxyl, alkyl, aryl, substituted aryl, heterocyclyl, substituted heterocyclyl, heteroaryl, substituted heteroaryl, hydroxamic acid, sulfonamide, sulfonyl, hydroxy, thiol, alkoxy or arylalkyl, or R 13 and R 14 taken together with the carbonyl form a carbonyl containing heterocyclyl group;
(d) R 4 is selected from the group consisting of hydrogen, C 1-6 straight or branched chain alkyl, benzyl
wherein the alkyl and benzyl groups are optionally substituted with one or more groups selected from C 3-7 cycloalkyl, C 1-8 alkoxy, cyano, C 1-4 carboalkoxy, trifluoromethyl, C 1-8 alkylsulfonyl, halogen, nitro, hydroxy, trifluoromethoxy, C 1-8 carboxylate, amino, NR 17 R 18 , aryl and heteroaryl, —OR 17 , and —NR 17 R 18 ,
wherein R 17 and R 18 are independently selected from hydrogen, and optionally substituted C 16 alkyl or aryl; and
(e) X is selected from C═S, C═O; CH 2 , CHOH, CHOR 19 ; or CHNR 20 R 21 where R 19 , R 20 , and R 21 are selected from optionally substituted C 1-8 straight of branched chain alkyl, wherein the substituents on the alkyl group are selected from C 1-8 alkoxy, hydroxy, halogen, amino, cyano, or NR 22 R 23 wherein R 22 and R 23 are independently selected from the group consisting of hydrogen, C 1-8 straight or branched chain alkyl, C 3-7 cycloalkyl, benzyl, aryl, heteroaryl, or NR 22 R 23 taken together from a heterocycle or heteroaryl; with the proviso that in a compound of Formula II when R 1 is a cyano, then R 2 is not phenyl.
[0030] This invention also provides a pharmaceutical composition comprising the instant compound and a pharmaceutically acceptable carrier.
[0031] This invention further provides a method of treating a subject having a condition ameliorated by antagonizing Adenosine A2a receptors, which comprises administering to the subject a therapeutically effective dose of the instant pharmaceutical composition.
[0032] This invention further provides a method of preventing a disorder ameliorated by antagonizing Adenosine A2a receptors in a subject, comprising of administering to the subject a prophylactically effective dose of the compound of claim 1 either preceding or subsequent to an event anticipated to cause a disorder ameliorated by antagonizing Adenosine A2a receptors in the subject.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Compounds of Formula I are potent small molecule antagonists of the Adenosine A2a receptors that have demonstrated potency for the antagonism of Adenosine A2a, A1, and A3 receptors.
[0034] Preferred embodiments for R 1 are COOR 5 wherein R 5 is an optionally substituted C 1-8 straight or branched chain alkyl. Preferably the alkyl chain is substituted with a dialkylamino group.
[0035] Preferred embodiments for R 2 are optionally substituted heteroaryl and optionally substituted aryl. Preferably, R 2 is an optionally substituted furan.
[0036] Preferred substituents for R 3 include hydrogen, halo, hydroxy, amino, trifluoromethyl, alkoxy, hydroxyalkyl chains, and aminoalkyl chains, Preferred substituents for R 4 include NH 2 and alkylamino.
[0037] In a preferred embodiment, the compound is selected from the group of compounds shown in Tables 1 and 2 hereinafter.
[0038] More preferably, the compound is selected from the following compounds:
[0039] The compound of claim 1 , formula 1, wherein R 4 is amino.
2-amino-4-furan-2-yl-indeno[1,2-d]pyrimidin-5-one
2-amino-4-phenyl-indeno[1,2-d]pyrimidin-5-one
[0042] 1 2-amino-4-thiophen-2-yl-indeno[1,2-d]pyrimidin-5-one
2-amino-4-(5-methyl-furan-2-yl)-indeno[1,2-d]pyrimidin-5-one
2,6-diamino-4-furan-2-yl-indeno[1,2-d]pyrimid in-5-one
9H-indeno[2,1 -c]pyridine-4-carbonitrile, 3-amino-1-furan-2-yl-9-oxo-
9H-indeno[2,1-c]pyridine-4-carboxylic acid, 3-amino-1-furan-2yl-9-oxo-, 2-dimethylamino-ethyl ester
9H-indeno[2,1-c]pyridine-4-carboxylic acid, 3-amino-1-phenyl-9-oxo-, 2-dimethylamino-ethyl ester
9H-indeno[2,1 -c]pyridine-4-carboxylic acid, 3-amino1-furan-2-yl-9-oxo-, (2-dimethylamino-1-methyl-ethyl)-amide
9H-indeno[2,1-c]pyridine-4-carboxylic acid, 3-amino-1-furan-2-yl-9-oxo-, (2-dimethylamino-ethyl)-methyl-amide
9H-indeno[2, 1 -c]pyridine-4-carboxylic acid, 3-amino-1-furan-2-yl-9-oxo-, 1-methyl-pyrrolidin-2-ylmethyl ester
[0051] The instant compounds can be isolated and used as free bases. They can also be isolated and used as pharmaceutically acceptable salts. Examples of such salts include hydrobromic, hydroiodic, hydrochloric, perchloric, sulfuric, maleic, fumaric, malic, tartaric, citric, benzoic, mandelic, methanesulfonic, hydroethanesulfonic, benzenesulfonic, oxalic, palmoic, 2-naphthalenesulfonic, p-toluenesulfonic, cyclohexanesulfamic and saccharic.
[0052] This invention also provides a pharmaceutical composition comprising the instant compound and a pharmaceutically acceptable carrier.
[0053] Pharmaceutically acceptable carriers are well known to those skilled in the art and include, but are not limited to, from about 0.01 to about 0.1 M and preferably 0.05 M phosphate buffer or 0.8% saline. Such pharmaceutically acceptable carriers can be aqueous or non-aqueous solutions, suspensions and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, ethanol, alcoholic/aqueous solutions, glycerol, emulsions or suspensions, including saline and buffered media. Oral carriers can be elixirs, syrups, capsules, tablets and the like. The typical solid carrier is an inert substance such as lactose, starch, glucose, methyl-cellulose, magnesium stearate, dicalcium phosphate, mannitol and the like. Parenteral carriers include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's and fixed oils. Intravenous carriers include fluid and nutrient replenishers, electrolyte replenishers such as those based on Ringer's dextrose and the like. Preservatives and other additives can also be present, such as, for example, antimicrobials, antioxidants, chelating agents, inert gases and the like. All carriers can be mixed as needed with disintegrants, diluents, granulating agents, lubricants, binders and the like using conventional techniques known in the art.
[0054] This invention further provides a method of treating a subject having a condition ameliorated by antagonizing Adenosine A2a receptors, which comprises administering to the subject a therapeutically effective dose of the instant pharmaceutical composition.
[0055] In one embodiment, the disorder is a neurodegenerative or movement disorder. Examples of disorders treatable by the instant pharmaceutical composition include, without limitation, Parkinson's Disease, Huntington's Disease, Multiple System Atrophy, Corticobasal Degeneration, Alzheimer's Disease, and Senile Dementia.
[0056] In one preferred embodiment, the disorder is Parkinson's disease.
[0057] As used herein, the term “subject” includes, without limitation, any animal or artificially modified animal having a disorder ameliorated by antagonizing adenosine A2a receptors. In a preferred embodiment, the subject is a human.
[0058] Administering the instant pharmaceutical composition can be effected or performed using any of the various methods known to those skilled in the art. The instant compounds can be administered, for example, intravenously, intramuscularly, orally and subcutaneously. In the preferred embodiment, the instant pharmaceutical composition is administered orally. Additionally, administration can comprise giving the subject a plurality of dosages over a suitable period of time. Such administration regimens can be determined according to routine methods.
[0059] As used herein, a “therapeutically effective dose” of a pharmaceutical composition is an amount sufficient to stop, reverse or reduce the progression of a disorder. A “prophylactically effective dose” of a pharmaceutical composition is an amount sufficient to prevent a disorder, i.e., eliminate, ameliorate and/or delay the disorder's onset. Methods are known in the art for determining therapeutically and prophylactically effective doses for the instant pharmaceutical composition. The effective dose for administering the pharmaceutical composition to a human, for example, can be determined mathematically from the results of animal studies.
[0060] In one embodiment, the therapeutically and/or prophylactically effective dose is a dose sufficient to deliver from about 0.001 mg/kg of body weight to about 200 mg/kg of body weight of the instant pharmaceutical composition. In another embodiment, the therapeutically and/or prophylactically effective dose is a dose sufficient to deliver from about 0.05 mg/kg of body weight to about 50 mg/kg of body weight. More specifically, in one embodiment, oral doses range from about 0.05 mg/kg to about 100 mg/kg daily. In another embodiment, oral doses range from about 0.05 mg/kg to about 50 mg/kg daily, and in a further embodiment, from about 0.05 mg/kg to about 20 mg/kg daily. In yet another embodiment, infusion doses range from about 1.0 μg/kg/min to about 10 mg/kg/min of inhibitor, admixed with a pharmaceutical carrier over a period ranging from about several minutes to about several days. In a further embodiment, for topical administration, the instant compound can be combined with a pharmaceutical carrier at a drug/carrier ratio of from about 0.001 to about 0.1.
[0000] Definitions and Nomenclature
[0061] Unless otherwise noted, under standard nomenclature used throughout this disclosure the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment.
[0062] As used herein, the following chemical terms shall have the meanings as set forth in the following paragraphs: “independently”, when in reference to chemical substituents, shall mean that when more than one substituent exists, the substituents may be the same or different;.
[0063] “Alkyl” shall mean straight, cyclic and branched-chain alkyl. Unless otherwise stated, the alkyl group will contain 1-20 carbon atoms. Unless otherwise stated, the alkyl group may be optionally substituted with one or more groups such as halogen, OH, CN, mercapto, nitro, amino, C 1 -C 8 -alkyl, C 1 -C 8 -alkoxyl, C 1 -C 8 -alkylthio, C 1 -C 8 -alkyl-amino, di(C 1 -C 8 -alkyl)amino, (mono-, di-, tri-, and per-) halo-alkyl, formyl, carboxy, alkoxycarbonyl, C 1 -C 8 -alkyl-CO—O—, C 1 -C 8 -alkyl-CO—NH—, carboxamide, hydroxamic acid, sulfonamide, sulfonyl, thiol, aryl, aryl(c 1 -c 8 )alkyl, heterocyclyl, and heteroaryl.
[0064] “Alkoxy” shall mean —O-alkyl and unless otherwise stated, it will have 1-8 carbon atoms.
[0065] The term “bioisostere” is defined as “groups or molecules which have chemical and physical properties producing broadly similar biological properties.” (Burger's Medicinal Chemistry and Drug Discovery, M. E. Wolff, ed. Fifth Edition, Vol. 1, 1995, Pg. 785).
[0066] “Halogen” shall mean fluorine, chlorine, bromine or iodine; “PH” or “Ph” shall mean phenyl; “Ac” shall mean acyl; “Bn” shall mean benzyl.
[0067] The term “acyl” as used herein, whether used alone or as part of a substituent group, means an organic radical having 2 to 6 carbon atoms (branched or straight chain) derived from an organic acid by removal of the hydroxyl group. The term “Ac” as used herein, whether used alone or as part of a substituent group, means acetyl.
[0068] “Aryl” or “Ar,” whether used alone or as part of a substituent group, is a carbocyclic aromatic radical including, but not limited to, phenyl, 1- or 2-naphthyl and the like. The carbocyclic aromatic radical may be substituted by independent replacement of 1 to 5 of the hydrogen atoms thereon with halogen, OH, CN, mercapto, nitro, amino, C 1 -C 8 -alkyl, C 1 -C 8 -alkoxyl, C 1 -C 8 -alkylthio, C 1 -C 8 -alkyl-amino, di(C 1 -C 8 -alkyl)amino, (mono-, di-, tri-, and per-) halo-alkyl, formyl, carboxy, alkoxycarbonyl, C 1 -C 8 -alkyl-CO—O—, C 1 -C 8 -alkyl-CO—NH—, or carboxamide. Illustrative aryl radicals include, for example, phenyl, naphthyl, biphenyl, fluorophenyl, difluorophenyl, benzyl, benzoyloxyphenyl, carboethoxyphenyl, acetylphenyl, ethoxyphenyl, phenoxyphenyl, hydroxyphenyl, carboxyphenyl, trifluoromethylphenyl, methoxyethylphenyl, acetamidophenyl, tolyl, xylyl, dimethylcarbamylphenyl and the like. “Ph” or “PH” denotes phenyl.
[0069] Whether used alone or as part of a substituent group, “heteroaryl” refers to a cyclic, fully unsaturated radical having from five to ten ring atoms of which one ring atom is selected from S, O, and N; 0-2 ring atoms are additional heteroatoms independently selected from S, O, and N; and the remaining ring atoms are carbon. The radical may be joined to the rest of the molecule via any of the ring atoms. Exemplary heteroaryl groups include, for example, pyridinyl, pyrazinyl, pyrimidinyl, pyridazinyl, pyrroyl, pyrazolyl, imidazolyl, thiazolyl, oxazolyl, isoxazolyl, thiadiazolyl, triazolyl, triazinyl, oxadiazolyl, thienyl, furanyl, quinolinyl, isoquinolinyl, indolyl, isothiazolyl, 2-oxazepinyl, azepinyl, N-oxo-pyridyl, 1-dioxothienyl, benzothiazolyl, benzoxazolyl, benzothienyl, quinolinyl-N-oxide, benzimidazolyl, benzopyranyl, benzisothiazolyl, benzisoxazolyl, benzodiazinyl, benzofurazanyl, benzothiopyranyl, indazolyl, indolizinyl, benzofuryl, chromonyl, coumarinyl, cinnolinyl, quinoxalinyl, indazolyl, pyrrolopyridinyl, furopyridinyl (such as furo[2,3-c]pyridinyl, furo[3,2-b]pyridinyl, or furo[2,3-b]pyridinyl), imidazopyridinyl (such as imidazo[4,5-b]pyridinyl or imidazo[4,5-c]pyridinyl), naphthyridinyl, phthalazinyl, purinyl, pyridopyridyl, quinazolinyl, thienofuryl, thienopyridyl, thienothienyl, and furyl. The heteroaryl group may be substituted by independent replacement of 1 to 5 of the hydrogen atoms thereon with halogen, OH, CN, mercapto, nitro, amino, C 1 -C 8 -alkyl, C 1 -C 8 -alkoxyl, C 1 -C 8 -alkylthio, C 1 -C 8 -alkyl-amino, di(C 1 -C 8 -alkyl)amino, (mono-, di-, tri-, and per-) halo-alkyl, formyl, carboxy, alkoxycarbonyl, C 1 -C 8 -alkyl-CO—O—, C 1 -C 8 -alkyl-CO—NH—, or carboxamide. Heteroaryl may be substituted with a mono-oxo to give for example a 4-oxo-1H-quinoline.
[0070] The terms “heterocycle,” “heterocyclic,” and “heterocyclo” refer to an optionally substituted, fully or partially saturated cyclic group which is, for example, a 4- to 7-membered monocyclic, 7- to 11 -membered bicyclic, or 10- to 15-membered tricyclic ring system, which has at least one heteroatom in at least one carbon atom containing ring. Each ring of the heterocyclic group containing a heteroatom may have 1, 2, or 3 heteroatoms selected from nitrogen atoms, oxygen atoms, and sulfur atoms, where the nitrogen and sulfur heteroatoms may also optionally be oxidized. The nitrogen atoms may optionally be quaternized. The heterocyclic group may be attached at any heteroatom or carbon atom.
[0071] Exemplary monocyclic heterocyclic groups include pyrrolidinyl; oxetanyl; pyrazolinyl; imidazolinyl; imidazolidinyl; oxazolyl; oxazolidinyl; isoxazolinyl; thiazolidinyl; isothiazolidinyl; tetrahydrofuryl; piperidinyl; piperazinyl; 2-oxopiperazinyl; 2-oxopiperidinyl; 2-oxopyrrolidinyl; 4-piperidonyl; tetrahydropyranyl; tetrahydrothiopyranyl; tetrahydrothiopyranyl sulfone; morpholinyl; thiomorpholinyl; thiomorpholinyl sulfoxide; thiomorpholinyl sulfone; 1,3-dioxolane; dioxanyl; thietanyl; thiiranyl; and the like. Exemplary bicyclic heterocyclic groups include quinuclidinyl; tetrahydroisoquinolinyl; dihydroisoindolyl; dihydroquinazolinyl (such as 3,4-dihydro-4-oxo-quinazolinyl); dihydrobenzofuryl; dihydrobenzothienyl; dihydrobenzothiopyranyl; dihydrobenzothiopyranyl sulfone; dihydrobenzopyranyl; indolinyl; isochromanyl; isoindolinyl; piperonyl; tetrahydroquinolinyl; and the like.
[0072] Substituted aryl, substituted heteroaryl, and substituted heterocycle may also be substituted with a second substituted-aryl, a second substituted-heteroaryl, or a second substituted-heterocycle to give, for example, a 4-pyrazol-1-yl-phenyl or 4-pyridin-2-yl-phenyl.
[0073] Designated numbers of carbon atoms (e.g., C 1-8 ) shall refer independently to the number of carbon atoms in an alkyl or cycloalkyl moiety or to the alkyl portion of a larger substituent in which alkyl appears as its prefix root.
[0074] Unless specified otherwise, it is intended that the definition of any substituent or variable at a particular location in a molecule be independent of its definitions elsewhere in that molecule. It is understood that substituents and substitution patterns on the compounds of this invention can be selected by one of ordinary skill in the art to provide compounds that are chemically stable and that can be readily synthesized by techniques known in the art as well as those methods set forth herein.
[0075] Where the compounds according to this invention have at least one stereogenic center, they may accordingly exist as enantiomers. Where the compounds possess two or more stereogenic centers, they may additionally exist as diastereomers. Furthermore, some of the crystalline forms for the compounds may exist as polymorphs and as such are intended to be included in the present invention. In addition, some of the compounds may form solvates with water (i.e., hydrates) or common organic solvents, and such solvates are also intended to be encompassed within the scope of this invention.
[0076] Some of the compounds of the present invention may have trans and cis isomers. In addition, where the processes for the preparation of the compounds according to the invention give rise to mixture of stereoisomers, these isomers may be separated by conventional techniques such as preparative chromatography. The compounds may be prepared as a single stereoisomer or in racemic form as a mixture of some possible stereoisomers. The non-racemic forms may be obtained by either synthesis or resolution. The compounds may, for example, be resolved into their components enantiomers by standard techniques, such as the formation of diastereomeric pairs by salt formation. The compounds may also be resolved by covalent linkage to a chiral auxiliary, followed by chromatographic separation and/or crystallographic separation, and removal of the chiral auxiliary. Alternatively, the compounds may be resolved using chiral chromatography.
[0077] This invention will be better understood by reference to the Experimental Details which follow, but those skilled in the art will readily appreciate that these are only illustrative of the invention as described more fully in the claims which follow thereafter. Additionally, throughout this application, various publications are cited. The disclosure of these publications is hereby incorporated by reference into this application to describe more fully the state of the art to which this invention pertains.
[0000] Experimental Details
[0000] I. General Synthetic Schemes
[0078] Representative compounds of the present invention can be synthesized in accordance with the general synthetic methods described below and illustrated in the following general schemes. The products of some schemes can be used as intermediates to produce more than one of the instant compounds. The choice of intermediates to be used to produce subsequent compounds of the present invention is a matter of discretion that is well within the capabilities of those skilled in the art.
[0079] Procedures described in Schemes 1 to 7, wherein R 3a , R 3b , R 3c , and R 3d are independently any R 3 group, and R 1 , R 2 , R 3 , and R 4 are as described above, can be used to prepare compounds of the invention.
[0080] The substituted pyrimidines 1 can be prepared as shown in Scheme 1. The indanone or indandione 2 or the indene ester 3 can be condensed with an aldehyde to yield the substituted benzylidenes 4 (Bullington, J. L; Cameron, J. C.; Davis, J. E.; Dodd, J. H.; Harris, C. A.; Henry, J. R.; Pellegrino-Gensey, J. L.; Rupert, K. C.; Siekierka, J. J. Bioorg. Med. Chem. Lett. 1998, 8, 2489; Petrow, V.; Saper, J.; Sturgeon, B. J. Chem. Soc. 1949, 2134). This is then condensed with guanidine carbonate to form the indenopyrimidine 1.
[0081] Alternatively, the pyrimidine compounds can be prepared as shown in Scheme 2. Sulfone 6 can be prepared by oxidation of the thiol ether 5 and the desired amines 7 can be obtained by treatment of the sulfone with aromatic amines.
[0082] Pyrimidines with substituents on the fused aromatic ring could also be synthesized by the following procedure (Scheme 3). The synthesis starts with alkylation of furan with allyl bromide to provide 2-allylfuran. Diels-Alder reaction of 2-allylfuran with dimethylacetylene dicarboxylate followed by deoxygenation (Xing, Y. D.; Huang, N. Z. J. Org. Chem. 1982, 47, 140) provided the phthalate ester 8. The phthalate ester 8 then undergoes a Claisen condensation with ethyl acetate to give the styryl indanedione 9 after acidic workup (Buckle, D. R.; Morgan, N. J.; Ross, J. W.; Smith, H.; Spicer, B. A. J. Med. Chem. 1973, 16, 1334). The indanedione 9 is then converted to the dimethylketene dithioacetal 10 using carbon disulfide in the presence of KF. Addition of Grignard reagents to the dithioacetal 10 and subsequent reaction with guanidine provides the pyrimidines 11 as a mixture of isomers.
[0083] Dihydroxylation and oxidation give the aromatic aldehydes 13 that can be reductively aminated to provide amines 14. The other isomer can be treated in a similar manner.
[0084] 3-Dicyanovinylindan-1-one (15) (Scheme 5) was obtained using the published procedure (Bello, K. A.; Cheng, L.; Griffiths, J. J. Chem. Soc., Perkin Trans. II 1987, 815). Reaction of 3-dicyanovinylindan-1-one with an aldehyde in the presence of ammonium hydroxide produced dihydropyridines 16 (El-Taweel, F. M. A.; Sofan, M. A.; E.-Maati, T. M. A.; Elagamey, A. A. Boll. Chim. Farmac. 2001, 140, 306). These compounds were then oxidized to the corresponding pyridines 17 using chromium trioxide in refluxing acetic acid.
[0085] The ketone of pyridines 17 can be reduced to provide the benzylic alcohols 18. Alternatively, the nitriles can be hydrolyzed with sodium hydroxide to give the carboxylic acids 19 (Scheme 6).
[0086] The acids can then be converted to carboxylic esters 20 or amides 21 using a variety of methods. In general, the esters 20 are obtained by treatment with silver carbonate followed by an alkyl chloride or by coupling with diethylphosphoryl cyanide (DEPC) and the appropriate alcohol (Okawa, T.; Toda, M.; Eguchi, S.; Kakehi, A. Synthesis 1998, 1467). The amides 21 are obtained by coupling the carboxylic acid with the appropriate amine in the presence of DEPC or 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDCI). Esters 20 can also be obtained by first reacting the carboxylic acids 19 with a dibromoalkane followed by displacement of the terminal bromide with an amine (Scheme 7).
II. Specific Compound Syntheses
[0087] Specific compounds which are representative of this invention can be prepared as per the following examples. No attempt has been made to optimize the yields obtained in these reactions. Based on the following, however, one skilled in the art would know how to increase yields through routine variations in reaction times, temperatures, solvents and/or reagents.
[0088] The products of certain syntheses can be used as intermediates to produce more than one of the instant compounds. In those cases, the choice of intermediates to be used to produce compounds of the present invention is a matter of discretion that is well within the capabilities of those skilled in the art.
EXAMPLE 1
Synthesis of Benzylidene 4
(R 2 =2-furyl, R 3a ═F, R 3b , R 3c , R 3d ═H)
[0089] A mixture of 3 (3.0 g, 11.69 mmol) and 2-furaldehyde (1.17 g, 12.17 mmol) in 75 mL of ethanol and 3 mL of concentrated hydrogen chloride was allowed to stir at reflux for 16 hours. The reaction was then cooled to room temperature, and the resulting precipitate was filtered off, washed with ethanol, diethyl ether, and air dried to afford 1.27 g (45%) of product.
EXAMPLE 2
Synthesis of Indenopyrimidine 1
(R 2 =2-furyl, R 3a ═F, R 3b , R 3c ,R 3d ═H)
[0090] A mixture of 4 (0.5 g, 2.06 mmol), guanidine carbonate (0.93 g, 5.16 mmol), and 20.6 mL of 0.5 M sodium methoxide in methanol was stirred at reflux for 16 hours. The reaction mixture was cooled to room temperature, and diluted with water. The resulting precipitate was collected, washed with water, ethanol, diethyl ether, and then dried. Crude material was then purified over silica gel to afford 0.024 g (4%) of product. MS m/z 282.0 (M+H).
EXAMPLE 3
Synthesis of 2-Amino-4-methanesulfonyl-indeno[1,2-d]pyrimidin-5-one
[0091] To a suspension of 5 (Augustin, M.; Groth, C.; Kristen, H.; Peseke, K.; Wiechmann, C. J. Prakt. Chem. 1979, 321, 205) (1.97 g, 8.10 mmol) in MeOH (150 mL) was added a solution of oxone (14.94 g, 24.3 mmol) in H 2 O (100 mL). The mixture was stirred at room temperature overnight then diluted with cold H 2 O (500 mL), made basic with K 2 CO 3 and filtered. The product was washed with water and ether to give 0.88 g (40%) of sulfone 6. MS m/z 297.9 (M+Na).
EXAMPLE 4
Synthesis of Aminopyrimidine 7
(R 2 ═NHPh, R 3 ═H)
[0092] A mixture of sulfone 6 (0.20 g, 0.73 mmol) and aniline (0.20 g, 2.19 mmol) in N-methylpyrrolidinone (3.5 mL) was heated to 100° C. for 90 minutes. After cooling to room temperature, the mixture was diluted with EtOAc (100 mL), washed with brine (2×75 mL) and water (2×75 mL), and dried over Na 2 SO 4 . After filtration and concentration in vacuo, the residue was purified by column chromatography eluting with 0-50% EtOAc in hexane to yield 0.0883 g (42%) of product 7. MS m/z 289.0 (M+H).
EXAMPLE 5
Synthesis of Phthalate Ester 8
[0093] A 1.37 M hexanes solution of n-BuLi (53.6 mL, 73.4 mmol) was added to a cold, −78° C., THF solution (100 mL) of furan (5.3 mL, 73.4 mmol) and the reaction was then warmed to 0° C. After 1.25 h at 0° C. neat allyl bromide (7.9 mL, 91.8 mmol) was added in one portion. After 1 h at 0° C., saturated aqueous NH 4 Cl was added and the layers were separated. The aqueous phase was extracted with EtOAc and the combined organics were washed with water and brine, dried over Na 2 SO 4 , and concentrated to give 4.6 g (58%) of 2-allylfuran which was used without further purification.
[0094] The crude allyl furan (4.6 g, 42.6 mmol) and dimethylacetylene dicarboxylate (5.2 mL, 42.6 mmol) were heated to 90° C. in a sealed tube without solvent. After 6 h at 90° C. the material was cooled and purified by column chromatography eluting with 25% EtOAc in hexanes to give 5.8 g (54%) of the oxabicycle as a yellow oil. MS m/z 251 (M+H).
[0095] Tetrahydrofuran (60 mL) was added dropwise to neat TiCl 4 (16.5 mL, 150.8 mmol) at 0° C. A 1.0 M THF solution of LiAlH 4 (60.3 mL, 60.3 mmol) was added dropwise, changing the color of the suspension from yellow to a dark green or black suspension. Triethylamine (2.9 mL, 20.9 mmol) was added and the mixture was refluxed at 75-80° C. After 45 min, the solution was cooled to rt and a THF solution (23 mL) of the oxabicycle (5.8 g, 23.2 mmol) was added to the dark solution. After 2.5 h at rt, the solution was poured into a 20% aq. K 2 CO 3 solution (200 mL) and the resulting suspension was filtered. The precipitate was washed several times with CH 2 Cl 2 and the filtrate layers were separated. The aqueous phase was extracted with CH 2 Cl 2 and the combined organics were washed with water and brine, dried over Na 2 SO 4 , concentrated, and purified by column chromatography eluting with 25% EtOAc in hexanes to give 3.5 g (64%) of the phthalate ester 8 as a yellow oil. MS m/z 235 (M+H).
EXAMPLE 6
Synthesis of Indanedione 9
[0096] A 60% dispersion of sodium hydride in mineral oil (641 mg, 16.0 mmol) was added to an EtOAc solution (3.5 mL) of the phthalate ester 8 (2.5 g, 10.7 mmol), and the resulting slurry was refluxed. After 1 h the solution became viscous so an additional 7.5 mL of EtOAc was added. After 4 h at reflux the suspension was cooled to rt and filtered to give a yellow solid. This solid was added portionwise to a solution of HCl (25 mL water and 5 mL conc. HCl) at 80° C. The suspension was heated for an additional 30 min at 80° C., cooled to rt, and filtered to give 1.2 g (60%) of the indanedione 9 as a yellow solid. MS m/z 187 (M+H).
EXAMPLE 7
Synthesis of Dimethylketene Dithioacetal 10
[0097] Solid potassium fluoride (7.5 g, 129.1 mmol) was added to a 0° C. solution of indanedione 9 (1.2 g, 6.5 mmol) and CS 2 (0.47 mL, 7.8 mmol) in DMF (10 mL). The cold bath was removed and after 30 min neat iodomethane (1.00 mL, 16.3 mmol) was added. After 5 h at rt, the suspension was diluted with EtOAc and then washed with water and brine. The organic layer was dried over Na 2 SO 4 , concentrated, and purified by column chromatography eluting with 20% EtOAc in hexanes to give 1.4 g (75%) of the dimethylketene dithioacetal 10 as a yellow solid. MS m/z 291 (M+H).
EXAMPLE 8
Synthesis of Pyrimidine 11
(R 2 =Ph, R 3a ═CHCHCH 3 , R 3d ═H)
[0098] A 2.0 M solution of PhMgCl in THF (13 mL, 25.7 mmol) was added to a −78° C. solution of dimethylketene dithioacetal 10 (5.7 g, 19.8 mmol) in 200 mL of THF. After 3 h at −78° C., saturated aqueous NH 4 Cl was added and the layers were separated. The aqueous layer was extracted with EtOAc and the combined organic extracts were washed with water and brine, dried over Na 2 SO 4 , concentrated, and purified by column chromatography eluting with 20% EtOAc in hexanes to give 4.9 g (77%) of the thioenol ether as a yellow solid. MS m/z 321 (M+H).
[0099] Solid guanidine hydrochloride (1.5 g, 15.3 mmol) was added to a solution of the thioenol ether (4.9 g, 15.3 mmol) and K 2 CO 3 (2.6 g, 19.1 mmol) in 30 mL of DMF and the solution was heated to 80° C. After 6 h at 80° C., the solution was diluted with EtOAc and washed with water and brine. The organic layer was dried over Na 2 SO 4 , concentrated, and purified by column chromatography eluting with 40% EtOAc in hexanes to give 4.6 g (96%) of the pyrimidine regioisomers 11 as yellow solids. MS m/z 314 (M+H).
EXAMPLE 9
Synthesis of Aldehyde 13
(R 2 =Ph)
[0100] Solid MeSO 2 NH 2 (277 mg, 2.9 mmol) was added to a t-BuOH:H 2 O (1:1) solution (30 mL) of AD-mix-α (4.0 g). The resulting yellow solution was added to an EtOAc solution (15 mL) of the pyrimidine (910 mg, 2.9 mmol). After 3 days, solid sodium sulfite (4.4 g, 34.9 mmol) was added. After stirring for 1.5 h, the heterogeneous solution was diluted with EtOAc and the layers were separated. The aqueous phase was extracted with EtOAc and the combined extracts were washed with water and brine, dried over Na 2 SO 4 , concentrated, and purified by column chromatography eluting with 100% EtOAc to give 710 mg (70%) of the intermediate diol 12. MS m/z 348 (M+H).
[0101] Solid HIO 4 -2H 2 O (933 mg, 4.1 mmol) was added to a 0° C. solution of diol 12 (710 mg, 2.1 mmol) in THF. After 1.5 h at 0° C., the solution was diluted with EtOAc and the organic phase was washed with saturated aqueous NaHCO 3 , water, and brine. The organic layer was dried over Na 2 SO 4 and concentrated to give 603 mg (98%) of aldehyde 13 as a yellow solid that was used without further purification. MS m/z 302 (M+H).
EXAMPLE 10
Synthesis of Amine 14 Via Reductive Amination
[0102] R 3 ═N(—CH 2 CH 2 OCH 2 CH 2 —)
[0103] Solid NaBH(OAc) 3 (53 mg, 0.25 mmol) was added to a solution of aldehyde 13 (50 mg, 0.17 mmol), morpholine (0.034 mL, 0.34 mmol), and AcOH (0.014 mL, 0.25 mmol) in 1 mL of THF. After 3 d the solution was filtered and concentrated. The resulting material was dissolved in CH 2 Cl 2 and washed with saturated aqueous NaHCO 3 and brine, dried over Na 2 SO 4 , concentrated, and purified by column chromatography eluting with 0-10% MeOH in CH 2 Cl 2 to give 38 mg (60%) of the amine 14 as a yellow solid. MS m/z 373 (M+H). The product was dissolved in a minimum amount of CH 2 Cl 2 and treated with 1.0 M HCl in ether to obtain the hydrochloride salt.
EXAMPLE 11
Cyclization to Form Dihydropyridine 16
(R 2 =2-furyl, R 3 ═H)
[0104] To a solution of 3-dicyanovinylindan-1-one (4.06 g, 20.9 mmol) in 200 mL of ethanol was added 2-furaldehyde (3.01 g, 31.4 mmol) and 25 mL of conc. NH 4 OH. The solution was heated to reflux for 2 h and allowed to cool to rt overnight. The mixture was concentrated in vacuo to remove ethanol. The residue was filtered and washed with water. The purple solid obtained was dried to yield 5.92 g (89%). MS m/z 290 (M + +1).
EXAMPLE 12
Oxidation of Dihydropyridine 16 to Pyridine 17
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═CN, X═O)
[0105] To a refluxing solution of dihydropyridine 16 (5.92 g, 20.4 mmol) in acetic acid (100 mL) was added a solution of chromium (VI) oxide (2.05 g, 20.4 mmol) in 12 mL of water. After 10 minutes at reflux, the reaction was diluted with water until a precipitate started to form. The mixture was cooled to room temperature and filtered. The residue was washed with water to give 4.64 g (79%) of a brown solid. MS m/z 288 (M + +1).
EXAMPLE 13
Reduction of Ketone 17 to Alcohol 18
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═CN, X═H, OH)
[0106] To a 0° C. solution of ketone 17 (0.115 g, 0.40 mmol) in 12 mL of THF was added a 1.0 M LiAlH 4 solution in THF (0.40 mL, 0.40 mmol). The reaction was stirred at 0° C. for 1 h. The reaction was quenched by the addition of ethyl acetate (1.5 mL), water (1.5 mL), 10% aq. NaOH (1.5 mL), and saturated aq. NH 4 Cl (3.0 mL). The mixture was extracted with ethyl acetate (3×35 mL), washed with brine, and dried over sodium sulfate. The remaining solution was concentrated to yield 0.083 g (72%) of a yellow solid. MS m/z 290 (M + +1).
EXAMPLE 14
Hydrolysis of Nitrile 17 to Carboxylic Acid 19
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═COOH, X═O)
[0107] To a mixture of nitrile 17 (0.695 g, 2.42 mmol) and ethanol (30 mL) was added 5 mL of 35% aqueous sodium hydroxide. The resulting mixture was heated to reflux overnight. After cooling to rt, the solution was poured into water and acidified with 1 N HCl. The resulting precipitate was isolated by filtration and washed with water to yield 0.623 g (84%) of a brown solid. MS m/z 329 (M + +23).
EXAMPLE 15
Synthesis of Carboxylic Ester 20 with Silver Carbonate
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═CO 2 CH 2 CH 2 NMe 2 , X═O)
[0108] A suspension of carboxylic acid 19 (5.0 g, 16.3 mmol), silver carbonate (5.8 g, 21.2 mmol), and tetrabutylammonium iodide (1.5 g, 4.1 mmol) in 80 mL of DMF was heated to 90° C. After 1 h, the mixture was cooled to rt and 2-(dimethylamino)ethylchloride hydrochloride (2.4 g, 16.3 mmol) was added and the mixture was heated to 100° C. After 7 h, the reaction was filtered while hot, concentrated and purified by column chromatography eluting with 0-10% MeOH/CH 2 Cl 2 to yield 0.160 g (3%) of a yellow solid. MS m/z 378 (M + +1). The product was dissolved in a minimum of dichloromethane and treated with 1.0 M HCl in ether to obtain the hydrochloride salt.
EXAMPLE 16
Synthesis of Carboxylic Ester 20 with DEPC
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═CO 2 CH 2 CH(—CH 2 CH 2 CH 2 (Me)N—), X═O)
[0109] To a mixture of carboxylic acid 19 (0.40 g, 1.3 mmol) and (S)-1-methyl-2-pyrrolidinemethanol (0.50 mL, 3.9 mmol) in DMF (30 mL) was added 0.20 mL (1.3 mmol) of diethylphosphoryl cyanide and triethylamine (0.20 mL, 1.3 mmol). The reaction was stirred at 0° C. for one hour and then heated up to approximately 70° C. overnight. The reaction was then cooled to rt and diluted with ethyl acetate. The organic mixture was washed with saturated aqueous NaHCO 3 , water, and brine. After being dried with sodium sulfate, the solution was concentrated. The residue was purified by column chromatography eluting with 10-100% ethyl acetate in hexane and then preparative TLC eluting with 2% MeOH in dichloromethane to yield 1.9 mg (0.4%) of a yellow solid. MS m/z 404 (M + +1).
EXAMPLE 17
Synthesis of Carboxylic Amide 21 with DEPC
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═CO 2 CH 2 CH(—CH 2 CH 2 CH 2 (Me)N—), X═O)
[0110] To a mixture of carboxylic acid 19 (0.25 g, 0.82 mmol) and N,N,N′-trimethylethylenediamine (0.14 mL, 1.08 mmol) in DMF (20 mL) was added 0.12 mL (0.82 mmol) of diethylphosphoryl cyanide and triethylamine (0.11 mL, 0.82 mmol). The reaction was stirred at 0° C. for one hour and then heated up to approximately 60° C. overnight. The reaction was then cooled to rt and diluted with ethyl acetate. The organic mixture was washed with saturated aqueous NaHCO 3 , water, and brine. After being dried with magnesium sulfate, the solution was concentrated. The residue was purified by column chromatography eluting with 0-10% methanol in dichloromethane and then preparative TLC eluting with 1% MeOH in dichloromethane to yield 3.3 mg (10%) of a yellow solid. MS m/z 391 (M + +1). The product was dissolved in a minimum of diethyl ether and treated with 1.0 M HCl in ether to obtain the hydrochloride salt.
EXAMPLE 18
Synthesis of Carboxylic Amide 21 with EDCI
(R 2 =2-furyl, R 3 ═H, R 4 ═NH 2 , R 5 ═CON(—CH 2 CH 2 NMeCH 2 CH 2 —), X═O)
[0111] A mixture of carboxylic acid 19 (0.300 g, 0.979 mmol), N-methylpiperazine (0.295 g, 2.94 mmol), 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (0.563 g, 2.94 mmol) 1-hydroxybenzotriazole hydrate (0.397 g, 2.94 mmol), triethylamine (0.298 g, 2.94 mmol) in DMF (8 mL) was stirred at rt overnight. The mixture was then diluted with water and extracted several times with ethyl acetate. The combined organics were washed twice with brine and then dried over sodium sulfate. The solution was concentrated and then purified by column chromatography to afford 0.092 g (2%) of solid. MS m/z 389 (M + +1). The product was treated with 1.0 M HCl in ether to obtain the hydrochloride salt.
EXAMPLE 19
Synthesis of Carboxylic Ester 20 Via a Dibromoalkane
(R 2 =Ph, R 3 ═H, R 4 ═NH 2 , R 5 ═CO 2 CH 2 CH 2 CH 2 NMe 2 , X═O)
[0112] To a solution of carboxylic acid 19 (0.100 g, 0.32 mmol) in DMF (1.5 mL) was added 60% NaH dispersion in mineral oil (0.013 g, 0.32 mmol). After 10 min at rt, 1,3-dibromopropane (0.035 mL, 0.35 mmol) was added and the solution was stirred at rt for 17 h. After concentration, the residue was purified via column chromatography eluting with 40% ethyl acetate in hexanes to yield 0.014 g (9%) of a yellow solid. MS m/z 437 (M + +1).
[0113] To a solution of the yellow solid (0.014 mg, 0.03 mmol) in a sealed tube was added a 40% aqueous solution of dimethylamine (0.5 mL, 3.0 mmol). The tube was heated to 75° C. for 2 h before concentrating. The residue was purified by column chromatography eluting with 0-10% methanol in dichloromethane to yield 0.009 g (70%) of a yellow solid. MS m/z 402 (M + +1). The product was dissolved in a minimal amount of CH 2 Cl 2 and treated with 1 N HCl in ether to obtain the hydrochloride salt.
[0114] Following the general synthetic procedures outlined above and in Examples 1-19, the compounds of Table 1 below were prepared.
TABLE 1 MS No. R 2 R 3a R 3b R 3c R 3d R 4 X (M + 1) 1 4-MeOPh H H H H NH 2 CH 2 290 2 4-MeOPh H H H H NH 2 CO 304 3 2-furyl H H H H NH 2 CO 264 4 2-furyl H H H H NH 2 CH 2 250 5 3-pyridyl H H H H NH 2 CO 297 (+Na) 6 4-pyridyl H H H H NH 2 CO 275 7 H H H H NH 2 CO 281 8 4-ClC 6 H 4 H H H H NH 2 CO 308 9 3-NO 2 C 6 H 4 H H H H NH 2 CO 319 10 Ph H H H H NH 2 CO 274 11 3-MeOC 6 H 4 H H H H NH 2 CO 304 12 2-MeOC 6 H 4 H H H H NH 2 CO 304 13 3-HOC 6 H 4 H H H H NH 2 CO 290 14 2-thiophenyl H H H H NH 2 CO 302 15 3-thiophenyl H H H H NH 2 CO 302 16 2-furyl H Br H H NH 2 CO 342 17 2-furyl OH H H H NH 2 CO 280 18 SCH3 NH 2 H H H NH 2 CO 259 19 3-FC 6 H 4 H H H H NCHNMe 2 CO 347 20 2-furyl NH 2 H H H NH 2 CO 279 21 2-furyl H H H NH 2 NH 2 CO 279 22 2-furyl H CF 3 H H NH 2 CO 332 23 2-furyl H H CF 3 H NH 2 CO 332 24 Ph H H H H NHMe CO 288 25 2-furyl H Cl Cl H NH 2 CO 332 26 2-furyl Cl H H Cl NH 2 CO 332 27 Ph H H H H N(CH 2 ) 2 NEt 2 CO 373 28 3,4-F 2 C 6 H 3 H H H H NH 2 CO 310 29 3,5-F 2 C 6 H 3 H H H H NH 2 CO 310 30 H H H H NH 2 CO 305 31 3,4,5-F 3 C 2 H 2 H H H H NH 2 CO 340 (M + Na) 32 Ph H H H NH 2 CO 348 33 Ph H H H NH 2 CO 348 34 H H H H NH 2 CO 333 35 2-furyl H H Br H NH 2 CO 342/344 36 2-furyl H H H F NH 2 CO 282 37 2-furyl MeO H H H NH 2 CO 294 38 4-FC 6 H 4 H H H H NH 2 CO 292 39 3-FC 6 H 4 H H H H NH 2 CO 292 40 SO 2 Me H H H H NH 2 CO 298 41 Sme H H H H NH 2 CO 266 42 Ome H H H H NH 2 CO 477 (2M + Na) 43 NHPh H H H H NH 2 CO 289 44 3-furyl H H H H NH 2 CO 264 45 5-methyl-2- H H H H NH 2 CO 278 furyl 46 2-furyl OCH 2 CH 2 NHCO 2 tBu H H H NH 2 CO 437 47 Ph H H H H Me CO 297 48 Ph H H H H OMe CO 291 49 Ph CH 2 NMeCH 2 CH 2 NMe 2 H H H NH 2 CO 388 50 Ph H H H NH 2 CO 386 51 Ph H H H NH 2 CO 373 52 Ph CH 2 NEt 2 H H H NH 2 CO 359 53 Ph H H H NH 2 CO 371 54 Ph H H H NH 2 CO 429 55 Ph H H H NH 2 CO 443 56 Ph CH 2 NMeCH 2 CO 2 Me H H H NH 2 CO 389 57 Ph H H H NH 2 CO 401 58 Ph H H H NH 2 CO 416 59 Ph H H H NH 2 CO 414 60 Ph H H H NH 2 CO 486 61 Ph H H H NH 2 CO 422 62 Ph H H H NH 2 CO 397
[0115] TABLE 2 MS No. X R 2 R 3a R 3b R 3c R 3d R 1 (M + 1) 63 CO 2-furyl H H H H CN 288 64 CO Ph H H H H CN 298 65 CO Ph H H H H COOH 315 (M − 1) 66 CO 3-furyl H H H H CN 288 67 CO 3-FC 6 H 4 H H H H CN 316 68 CO 3-pyridyl H H H H CN 299 69 CO 2-furyl H H H H COOH 305 (M − 1) 70 CO 2-furyl H H H H CO 2 CH 2 CH 2 NMe 2 378 71 CO 4-FC 6 H 4 H H H H CN 316 72 CO 2-thiophenyl H H H H CN 304 73 CO 3-thiophenyl H H H H CN 304 74 CO 3-MeOC 6 H 4 H H H H CN 328 75 CO 2-imidazolyl H H H H CN 288 76 CO 2-furyl H H H H CONHCH 2 CH 2 NMe 2 377 77 CO 2-furyl H H H H CONMeCH 2 CH 2 NMe 2 391 78 CO 2-furyl H H H H CONHCHMeCH 2 NMe 2 391 79 CO 2-furyl F F F F CN 358 (M − 1) 80 CO 2-furyl H H H H 389 81 CO Ph H H H H CO 2 CH 2 CH 2 NMe 2 388 82 CO 2-furyl H H H H 404 83 CO Ph H H H H 457 84 CO Ph H H H H 444 85 CO Et H H H H CN 250 86 CO i-Bu H H H H CN 278 87 CO Ph H H H H CO 2 CH 2 CH 2 CH 2 NMe 2 402 88 CO Ph H H H H 414 89 CHOH 2-furyl H H H H CN 290 90 CO Ph H H H H 414 91 CO Ph H H H H 430 92 CO Ph H H H H CO 2 CH 2 CHMeCH 2 NMe 2 416 93 CO 3-thiophenyl H H H H CO 2 CH 2 CH 2 NMe 2 394 94 CO CH 2 CH 2 CHCH 2 H H H H CN 276 95 CO c-Hex H H H H CN 302 (M − 1) 96 CO 2-furyl H H H H (S)-CO 2 CHMeCH 2 NMe 2 392
III. Biological Assays and Activity
Ligand Binding Assay for Adenosine A2a Receptor
[0116] Ligand binding assay of adenosine A2a receptor was performed using plasma membrane of HEK293 cells containing human A2a adenosine receptor (PerkinElmer, RB-HA2a) and radioligand [ 3 H]CGS21680 (PerkinElmer, NET1021). Assay was set up in 96-well polypropylene plate in total volume of 200 μL by sequentially adding 20 μL 1:20 diluted membrane, 130 μL assay buffer (50 mM Tris·HCl, pH7.4 10 mM MgCl 2 , 1 mM EDTA) containing [ 3 H] CGS21680, 50 μL diluted compound (4×) or vehicle control in assay buffer. Nonspecific binding was determined by 80 mM NECA. Reaction was carried out at room temperature for 2 hours before filtering through 96-well GF/C filter plate pre-soaked in 50 mM Tris·HCl, pH7.4 containing 0.3% polyethylenimine. Plates were then washed 5 times with cold 50 mM Tris·HCl, pH7.4, dried and sealed at the bottom. Microscintillation fluid 30 μl was added to each well and the top sealed. Plates were counted on Packard Topcount for [ 3 H]. Data was analyzed in Microsoft Excel and GraphPad Prism programs. (Varani, K.; Gessi, S.; Dalpiaz, A.; Borea, P.A. British Journal of Pharmacology, 1996, 117, 1693)
[0000] Adenosine A2a Receptor Functional Assay
[0117] CHO-K1 cells overexpressing human adenosine A2a receptors and containing cAMP-inducible beta-galactosidase reporter gene were seeded at 40-50K/well into 96-well tissue culture plates and cultured for two days. On assay day, cells were washed once with 200 μL assay medium (F-12 nutrient mixture/0.1% BSA). For agonist assay, adenosine A2a receptor agonist NECA was subsequently added and cell incubated at 37° C., 5% CO 2 for 5 hrs before stopping reaction. In the case of antagonist assay, cells were incubated with antagonists for 5 minutes at R.T. followed by addition of 50 nM NECA. Cells were then incubated at 37° C., 5% CO 2 for 5 hrs before stopping experiments by washing cells with PBS twice. 50 μL 1× lysis buffer (Promega, 5× stock solution, needs to be diluted to 1× before use) was added to each well and plates frozen at −20° C. For β-galactosidase enzyme colorimetric assay, plates were thawed out at room temperature and 50 μL 2× assay buffer (Promega) added to each well. Color was allowed to develop at 37° C. for 1 h or until reasonable signal appeared. Reaction was then stopped with 150 μL 1 M sodium carbonate. Plates were counted at 405 nm on Vmax Machine (Molecular Devices). Data was analyzed in Microsoft Excel and GraphPad Prism programs. (Chen, W. B.; Shields, T. S.; Cone, R. D. Analytical Biochemistry, 1995, 226, 349; Stiles, G. Journal of Biological Chemistry, 1992, 267, 6451)
[0000] Haloperidol-Induced Catalepsy Study in C57bl/6 Mice
[0118] Mature male C57bl/6 mice (9-12 week old from ACE) were housed two per cage in a rodent room. Room temperature was maintained at 64-79 degrees and humidity at 30-70% and room lighting at 12 hrs light/12 hrs dark cycle. On the study day, mice were transferred to the study room. The mice were injected subcutaneously with haloperidol (Sigma H1512, 1.0 mg/ml made in 0.3% tartaric acid, then diluted to 0.2 mg/ml with saline) or vehicle at 1.5 mg/kg, 7.5 ml/kg. The mice were then placed in their home cages with access to water and food. 30 minutes later, the mice were orally dosed with vehicle (0.3% Tween 80 in saline) or compounds at 10 mg/kg, 10 ml/kg (compounds, 1 mg/ml, made in 0.3% Tween 80 in saline, sonicated to obtain a uniform suspension). The mice were then placed in their home cages with access to water and food. 1 hour after oral dose, the catalepsy test was performed. A vertical metal-wire grid (1.0 cm squares) was used for the test. The mice were placed on the grid and given a few seconds to settle down and their immobility time was recorded until the mice moved their back paw(s). The mice were removed gently from the grid and put back on the grid and their immobility time was counted again. The measurement was repeated three times. The average of the three measurements was used for data analysis.
[0119] Compound 70 showed 87% inhibition and compound 3 showed 90% inhibition of haloperidol-induced catalepsy when orally dosed at 10 mg/kg.
TABLE 5 Ki (nM) A2a A1 A2a antagonist antagonist No. binding function function 1 44.64 233.7 52.98 2 2.032 6.868 5.32 3 0.26 0.0066 0.288 4 0.885 2.63 15.57 5 5.355 9.64 27.1 6 3.9 4.56 16.44 7 0.26 0.49 6.89 8 58.41 5.5 11.59 9 20.82 4.85 7.69 10 6.1 0.109 1.2 11 8.85 1.63 2.47 12 33.49 32.52 172.3 13 5.16 35.59 10.35 14 2.19 0.59 3.19 15 3.23 0.258 3.46 16 1.75 0.169 5.22 17 6.3 67.14 111.29 18 317.95 >3000 188.99 19 110.73 20.88 21.64 20 0.05 0.126 0.91 21 0.376 0.053 3.51 22 14.16 0.055 2.75 23 13.58 0.55 1.47 24 30.32 >3000 5.99 25 172.85 5.69 17.44 26 34.57 0.88 3.13 27 146.84 68.28 >1000 28 48.9 3.53 5.86 29 20.95 1.42 4.27 30 31.55 10.15 4.05 31 140.68 15.22 17.5 32 3.55 0.634 9.89 33 0.175 0.34 0.021 34 560.13 35 3.49 0.265 7.09 36 4.37 0.052 2.52 37 2.86 0.143 3.07 38 2.34 0.956 9.44 39 4.92 0.926 2.31 40 2720.46 41 88.01 575.43 >3000 42 118.2 782.18 >10000 43 39.9 3.68 2.34 44 3.93 0.208 7.4 45 4.013 0.005 0.016 46 60.56 490.14 32.54 47 1076.76 48 470.84 >1000 >1000 49 51.12 40.13 119.03 50 80.15 11.31 94.24 51 36.81 3.26 32.92 52 94.41 18.33 107.17 53 64.15 14.25 40.82 54 40.79 3.19 19.56 55 32.82 5.84 19.86 56 25.72 6.81 25.76 57 34.02 15.93 39.29 58 30.65 11.65 60.99 59 40.79 7.94 34.11 60 34.29 61 29.83 62 58.39 63 0.59 0.0002 0.18 64 13.09 0.138 4.61 65 574.71 244.96 163.36 66 4.21 0.069 15.59 67 13.4 0.618 4.37 68 7.59 0.73 34.84 69 2261 90.16 >1000 70 9.89 0.44 20.13 71 17.24 3.39 2.42 72 12.64 2.54 6.24 73 4.925 0.06 9.7 74 14.67 5.7 7.28 75 23.72 1.51 78.33 76 33.03 22.13 >500 77 6.254 0.68 >500 78 17.65 1.58 >500 79 8.03 12.48 >1000 80 69.08 15.86 55.99 81 228.7 29.03 33.63 82 20.24 1.36 29.58 83 200.06 74.87 117.05 84 173.98 24.71 27.42 85 507.72 86 244.07 >1000 39.26 87 98.93 39.45 >300 88 129.6 48.87 >300 89 5.85 1.12 11.16 90 202.17 57.7 >300 91 208.32 22.07 14.67 92 38.82 13.9 32.88 93 64.05 23.57 104.31 94 49.55 >1000 35.99 95 338.13 >1000 110.22 96 48.55 10.08 52.45 | This invention provides novel arylindenopyridines and arylindenopyrimidines of the formula:
wherein R 1 , R 2 , R 3 , R 4 , and X are as defined above, and pharmaceutical compositions comprising same, useful for treating disorders ameliorated by antagonizing adenosine A2a receptors. This invention also provides therapeutic and prophylactic methods using the instant compounds and pharmaceutical compositions. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a photographic electrostatic process of making printing plates useful in the lithographic printing process, and to hydrophilizing compositions useful in this process.
2. Description of the Prior Art
Processes for producing lithographic printing plates by means of the electrophotographic process are well known in the art. The common way of producing such a printing plate is to first form an electrostatic plate having an oleophilic toner image deposited on a photoconductive layer such as zinc oxide deposited in an insulating resin binder by means of the electrophotographic process well known in the art. This thus formed electrophotographic plate is then converted into a lithographic printing plate by means of a hydrophilizing composition which is applied to the plate to convert the areas of the plate not containing the toner image to a more hydrophilic state. Numerous conversion baths have been disclosed in the prior art for such processes. See U.S. Pat. Nos. 3,573,041; 3,617,266; 3,001,872; 3,107,169; and 3,323,451, each of which is incorporated herein by reference. The most widely utilized commercial conversion wash is one containing ferrocyanide. Because of the toxic by-products this solution has serious disadvantages. This becomes especially critical as government regulations increasingly prohibit or restrict the use of such toxic materials.
A second lithographic printing plate which is in wide commercial use is the multilayer silver halide diffusion transfer printing plates described in U.S. Pat. No. 3,146,104, incorporated herein by reference. This plate is a camera speed printing plate which gives a somewhat higher quality print on the lithographic printing press than the electrostatic printing plate described above. Also the diffusion transfer printing plate has a somewhat longer run length generally than that of the electrostatic printing plate. Thus the diffusion transfer printing plate often is used for run lengths of 5,000 to 10,000 copies whereas an electrostatic printing plate generally has a run length of no greater than about 200 to 2,000 copies before serious degradation of the image or background occurs.
Many times in in-plant printing facilities and in instant printing shops and the like, it is desirable to make both kinds of printing plates described above depending upon the quality and quantity of print desired by the customer. However, at the present time, one of the serious problems is that the printing plates of the two processes are not compatible on the same press under the same printing conditions. Thus a different fountain solution is needed for each of the two types of printing plates. Thus in order to eliminate the requirement of a separate printing press for each type of printing plate or to eliminate the need to undergo time consuming clean-up operations on the press to change from one type of printing plate to the other, it is desirable to provide an electrostatic lithographic printing plate which is compatible on the same press under the same conditions with the silver halide diffusion transfer plate described above.
SUMMARY OF THE INVENTION
This invention relates to a process for producing a lithographic printing plate comprising the steps of forming a latent electrostatic image on a photoconductive insulating recording layer comprising photoconductive zinc oxide, and developing this image with a toner forming an imagewise deposit on the recording layer and contacting the portions of the recording layer which are not covered with the hydrophobic toner deposit with a hydrophilizing composition comprising the reaction product of (1) phosphoric acid or one of the anions derived from such acid, (2) an organic amine compound, and (3) a hydrophilic metal cation, to form a reaction product with zinc ions from the zinc oxide which reaction product of zinc ions with this composition is substantially insoluble in the composition and is preferentially wetted by water to thereby repel lithographic inks. This thus prepared printing plate is then utilized on a lithographic press, preferably an offset press to produce multiple copies of the original. Preferably, the fountain solution is a diluted form of the hydrophilizing composition of this invention. The printing plate formed by the practice of this invention has the advantage that it can be run on the same press using the same ink and fountain solution as is used for the silver halide diffusion transfer printing plate described above. Furthermore, the electrostatic printing plates of this invention have been shown to wrinkle less in use on the press than prior art electrostatic printing plates thereby providing improved run lengths. Moreover, the conversion wash of this invention is applied to an electrostatic plate by a simple and fast process and eliminates the need for time consuming, messy, swabbing techniques utilized in many prior art processes. Additionally, a dilute solution of the conversion wash of this invention can be utilized as the fountain solution alone or combined with prior art fountain solutions on the lithographic offset press for both the electrostatic plate of this invention and the prior art silver halide diffusion transfer printing plate. This fountain solution has been shown to unexpectedly eliminate the blinding of the diffusion transfer plates by gum arabic. This is a significant advantage since gum arabic is commonly on contaminant of presses which use metal printing plates. Additionally, this same fountain solution can be utilized for diazo printing plates. Therefore, there are at least three different types of lithographic printing plates which can be utilized on the same printing press without the need for completely cleaning the press and changing the fountain solutions. An additional advantage of the conversion wash of this invention is that there is significantly greater stability to aerial oxidation than with prior art ferrocyanide conversion washes. Also this invention eliminates the need for the toxic ferrocyanide conversion washes and fountain solutions of the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The "phosphoric acid or one of the anions derived from such acid" includes metaphosphoric acid, metaphosphate ion, pyrophosphoric acid, pyrophosphate ion, dihydrogen orthophosphate ion, hydrogen orthophosphate ion, and/or orthophosphate ion and is preferably orthophosphoric acid or its derived anions because of the improved results obtained.
The hydrophilic metal cation of this invention is a cation which when added to the conversion wash improves the hydrophilicity of the background of the printing plate. It is theorized that this cation is adsorbed to the reaction product of the zinc cation from the photoconductive zinc oxide copy medium, the organic amine compound and the phosphoric acid or one of the anions derived from such acid. The metal cation preferably is aluminum cation. However, other cations such as those of titanium, zirconium or tin can be used.
The organic amine compound of this invention is an organic amine capable of forming an insoluble salt with zinc ion in combination with the hydrophilic metal cation and phosphoric acid to thereby increase the hydrophilicity of the background areas of the electrophotographic zinc oxide copy medium processed. The preferred amine is an alkylene amine such as diethylene triamine and more preferably a primary alkylene diamine such as ethylene diamine. Ethylene diamine is preferred because of the exceptionally good quality prints obtained with this amine compound. The preferred alkylene diamine is one having from 2-6 carbon atoms between the amine groups. The hydrophilizing composition of this invention is preferably an aqueous solution having a pH lower than 7 and more preferably between about 2 and about 5.
Optionally the hydrophilizing composition may contain mono or poly hydric alcohols such as ethyl alcohol, propyl alcohol, butyl alcohol, ethylene glycol, diethylene glycol, triethylene glycol, and sorbitol.
The hydrophilizing composition of this invention is preferably applied by dipping the imaged electrostatic recording medium in the solution and then removing excess solution from the surface of the sheet. Preferably, the excess solution is removed from the sheet by means of a pair of squeegee rollers. When utilized as a conversion wash for an electrophotographic zinc oxide plate, the hydrophilizing composition of this invention preferably is an aqueous solution of the following composition:
grams/ liter of solution______________________________________(1) phosphoric acid 50-350(2) organic amine compound 50-150(3) salt of hydrophilic metal cation 10-250______________________________________
When the hydrophilizing composition of this invention is utilized as a fountain solution, it may be utilized in the concentrated form or in a diluted form. If the composition is too concentrated, the background of the plate begins to break down and scumming occurs. On the other hand, if the fountain solution is too dilute, the background of the plate is not sufficiently wetted and scumming occurs. A preferred dilution of the hydrophilizing composition is from about 1 to 5 parts of this composition per 20 parts of water.
The preferred fountain solution of this invention is one comprising the composition of the conversion wash of this invention mixed with the fountain solution utilized for the silver halide diffusion transfer printing plate mentioned above. This silver halide diffusion transfer plate in the market place utilizes a fountain solution on the lithographic printing plate composed of alkylene glycol such as propylene or ethylene glycol combined with phosphoric acid in an aqueous solution. A preferred concentration of this combined fountain solution is from about 1 to 6 parts of the hydrophilizing solution to 20 parts of the diluted fountain solution utilized for the above-mentioned silver halide diffusion transfer printing plate.
The following examples illustrate this invention:
EXAMPLE 1
A conversion wash is prepared in accordance with the teachings of this invention by first preparing Solutions I and II as follows:
Solution I
250 grams of 85% H 3 PO 4
150 grams Al 2 (SO 4 ).sup.. 18 H 2 O
water to 750 mls -- cool to approximately 20°C
Solution II
60 mls of 98% H 2 NCH 2 CH 2 NH 2
100 mls H 2 O
Solution II is added to Solution I while cooling and stirring. The pH is adjusted to 2.4 by adding sodium hydroxide. Water is then added to make up 1 liter of solution. This solution is then applied to an electrophotographic zinc oxide copy medium which had previously been imaged by electrophotographic means. The solution is applied by dipping the copy medium in the solution and then removing any excess by means of a rubber squeegee. The dwell time in the solution is about 1.0 to about 2.5 seconds. Thereafter the printing plate produced is mounted on the cylinder of a conventional lithographic duplicator such as Model 360 Offset Duplicator manufactured by A.B. Dick where the fountain solution is delivered to the plate over the ink roller. A fountain solution was prepared by adding one part of the fountain concentrate used with the silver halide diffusion transfer printing plate described in U.S. Pat. No. 3,146,104 and one part of the conversion wash to 15 parts of water. 2,000 good, clean copies of an original are produced.
EXAMPLE 2
The procedure of Example 1 is repeated except that the fountain solution was prepared by diluting one part of the conversion wash with nine parts of water. 1,000 good clean copies of an original are produced.
EXAMPLE 3
A test was devised to differentiate between amines which are useful in the practice of this invention and amines which are not. A solution of 50 grams of 85% orthophosphoric acid and 30 grams of Al 2 (SO 4 ) 3 . 18H 2 O was dissolved in sufficient water to give a final volume of from 100 - 150 ml. The quantity of organic amine described in Table 1 was added with stirring and the pH was adjusted to 2.4 after the volume had been made up to 200 ml. with distilled water. A cotton swab was wetted with the solution and rubbed on an electrophotographic printing plate bearing an image, covering both imaged area and background area. Next, the swab was dipped in an offset printing ink such as Colitho All Purpose Black CO-1-C and rubbed over the area treated with the solution to see if the ink adheres to the imaged area or to the background or to both or to neither. The results of this test are described in Table 1. The control described in Table 1 utilized the composition described in Example 1.
The most promising compositions were used to treat electrostatic lithographic plates which were then run on an Itek Model 180 offset duplicator using Colitho All Purpose Black CO-1-C ink and the fountain solution described in Example 1. The results are described in Table 2 and the compositions referred to in Table 2 correspond to those described in Table 1.
TABLE 1__________________________________________________________________________CompositionNumber Organic Amine, g. Results__________________________________________________________________________1 Control Background rejects ink completely. Image accepts ink readily.2 Triethyl Amine, 36.4 Background accepts some ink. Image accepts ink readily.3 Diethylene Triamine, 12.4 Background rejects ink completely. Image accepts ink readily.4 Methyl Amine, 29 g. of 40% solution in Background heavily inked. Image area rejected ink. water5 Dimethyl Amine, 64.8 g. of 25% solution Background heavily inked. in water__________________________________________________________________________
TABLE 2__________________________________________________________________________CompositionNumber Results of Printing Tried__________________________________________________________________________1 Image area dark black, background clean, halftones reproduced faithfully.2 Some toning of the background occurred, image areas were dark black, halftones were slightly filled in.3 Background very clean, as good as with composition 1. Image area is gray, not as black as composition 14 Background accepted ink as readily as the image area and the plate scummed completely.__________________________________________________________________________
EXAMPLE 4
A test was devised to identify hydrophilic metal cations which are useful in the practice of this invention. The following solutions were prepared:
Solution I
50 grams 85% H 3 PO 4
12 ml 98% H 2 NCH 2 CH 2 NH 2
Water to 150 ml
Solution II
8.0 grams Ti(SO 4 ) 2 .sup.. 9H 2 O
Water to 50 ml
Solution III
4.1 grams SnSO 4
Water to 50 ml
Solution IV
30 grams Al 2 (SO 4 ) 2 .sup.. 18 H 2 O
Water to 50 ml
The solutions were mixed as indicated in Example 1 and a cotton swab was wetted with the mixture and rubbed on an electrophotographic printing plate bearing an image, covering both the image area and the background. The cotton swab was then covered with an offset printing ink such as Colitho All Purpose Black CO-1-C and rubbed over the area treated with solution to see if the ink adheres to the image area or to the background or to both or to neither. The results of this test are described in Table 1. The control described in Table 1 utilized plain water only.
TABLE 1__________________________________________________________________________CompositionNumber Mixture Result__________________________________________________________________________1 Control (plain Both the background and the image water) area readily accepted ink and scummed heavily.2 Solution I and The background scummed slightly, Solution II less than the control, composi- tion 1.3 Solution I and The background scummed less than Solution III composition 2, but still accepted some ink; the image area readily accepted ink.4 Solution I and The background remained very clean. Solution IV The image area accepted ink. Background cleaner than composi- tions 2 and 3.__________________________________________________________________________
EXAMPLE 5
The procedure of Example 1 is repeated except that the treated plate was placed on an Itek 11.sup.. 15 Duplicator (offset lithographic press) which is equipped with a molleton fountain system. 1,000 good clean copies of an original were produced.
EXAMPLE 6
A conversion wash is prepared with the following composition:
85% H.sub.3 PO.sub.4 75 gramsWater 600 ml.98% H.sub.2 NCH.sub.2 CH.sub.2 NH.sub.2 to pH = 3.5Al.sub.2 (SO.sub.4).sub.3 . 18H.sub.2 O 100 gramsHOCH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.2 OH 125 ml.NaOH to pH = 2.2Water to 1 liter
This solution is then applied to an electrophotographic zinc oxide printing plate which had previously been imaged by electrophotographic means by rubbing it with a cotton swab which had been saturated with the solution. The plate was mounted on an Itek Model 180 tabletop offset lithographic duplicator. The fountain solution used was prepared by diluting one part of the fountain concentrate normally employed with the Itek Project-A-Lith silver halide diffusion transfer printing plate of U.S. Pat. No. 3,146,104 with 10 parts of water. 800 good, clean copies of an original were obtained.
EXAMPLE 7
A conversion wash is prepared with the following composition:
85% H.sub.3 PO.sub.4 375 gramsWater 1800 ml.98% H.sub.2 NCH.sub.2 CH.sub.2 NH.sub.2 to pH 3.5Al.sub.2 (SO.sub.4).sub.3 . 18H.sub.2 O 300 grams(HOCH.sub.2 CH.sub.2).sub.2 O 375 mlNaOH to pH 2.2Water to 3 liters
This solution was applied to an electrophotographic zinc oxide printing plate which had been previously imaged by electrophotographic means by rubbing it with a cotton swab which had been saturated with the solution. The plate was mounted on an A.B. Dick Model 360 offset lithographic duplicator. A fountain solution was prepared by diluting one part of the conversion wash with ten parts of distilled water, and Itek ADS Ink, product code 40994, was used. 1,000 good, clean copies of an original were obtained.
EXAMPLE 8
The procedure of Example 7 was repeated except that the conversion wash was applied to the electrophotographic zinc oxide printing plate using a paint roller. Using the fountain solution and the ink described in Example 7, 1,000 good, clean copies of an original were obtained on an A.B. Dick Model 360 offset lithographic duplicator.
EXAMPLE 9
A fountain solution was prepared by diluting one part of the fountain concentrate normally employed with the silver halide diffusion transfer plate with 15 parts of water, then adding six parts of this solution to one part of the conversion wash described in Example 7. An electrophotographic zinc oxide printing plate which had been previously imaged by electrophotographic means was treated with the conversion wash described in Example 7 and was mounted on an Itek Model 180 tabletop offset lithographic duplicator charged with the above described fountain solution and Itek ADS Ink, product code 40994. 2,000 good, clean copies of an original were obtained.
EXAMPLE 10
An image was produced on an Itek Project-A-Lith silver halide diffusion transfer plate prepared by the process of U.S. Pat. No. 3,146,104, referred to as a PAL plate, and it was mounted on the Itek Model 180 tabletop offset lithographic duplicator charged with the ink and fountain solution described in Example 9. 5,000 good, clean copies of an original were obtained.
EXAMPLE 11
An Itek 11.sup.. 15 offset lithographic duplicator press was charged with the ink and fountain solutions described in Example 9 and a silver halide diffusion transfer plate prepared as described in Example 10 was mounted. 5,000 good, clean copies of an original were obtained.
EXAMPLE 12
An Itek 11.sup.. 15 offset lithographic duplicator press was charged with the ink and fountain solution described in Example 9. An electrophotographic zinc oxide printing plate which had been previously imaged by electrophotographc means was treated with the conversion wash as described in Example 7 was mounted. 1,000 good, clean copies of an original were obtained.
EXAMPLE 13
An Itek 11.sup.. 15 offset duplicator was charged with GPI Split-Sec Black Ink and the fountain solution described in Example 9. An aluminum metal plate with a diazo coating sold by Minnesota Mining and Manufacturing Co. as the 3M-R plate was exposed imagewise to light and developed. This plate was mounted on the duplicator and 5,000 good, clean copies of an original were obtained.
EXAMPLE 14
A conversion wash is prepared with the following composition:
85% H.sub.3 PO.sub.4 250 grams98% H.sub.2 NCH.sub.2 CH.sub.2 NH.sub.2 60 ml.Al.sub.2 (SO.sub.4).sub.3. 18H.sub.2 O 150 gramsCH.sub.3 CH.sub.2 OH 100 ml.Water to 1 literNaOH to pH 2.2
This solution is then applied to an electrophotographic zinc oxide printing plate which had previously been imaged by electrophotographic means. The solution is applied by dipping the copy medium in the solution and then removing any excess by means of a rubber squeegee. The dwell time in the solution is about 2.5 seconds. Thereafter the printing plate produced is mounted on the cylinder of an Itek Model 180 Tabletop Duplicator offset lithographic press. The duplicator is charged with Itek ADS Ink, Product Code 40994, and a fountain solution prepared by diluting one part of the conversion wash with 10 parts of water. 1,000 good clean copies of an original were obtained.
EXAMPLE 15
An Itek Project-A-Lith silver halide diffusion transfer printing plate prepared by the procedure of U.S. Pat. No. 3,146,104 bearing an image was mounted on an Itek Model 180 tabletop duplicator offset lithographic press charged with the ink and fountain solution described in Example 14. 5,000 good clean copies of an original were obtained.
EXAMPLE 16
A line copy original with a grey scale paste up was placed on the copy board of an Itek Model 175 Electrostatic Platemaker. Two exposures were made, one for 25 seconds at a lens setting at f 16 and a second for 12 seconds at a lens setting at f 11. Both plates were treated by immersing them in the conversion wash described in Example 1 and the excess was removed by squeegeeing. The dwell time in the solution was about 2.5 seconds. The plates were mounted separately on an A.B. Dick Model 360 offset duplicator charged with Itek ADS ink and the fountain solution described in Example 1. 500 good, clean copies of the original were obtained, and in both cases the same number of solid steps on the grey scale step wedge were printed. This kind of exposure latitude is not possible using conventional ferrocyanide conversion washes as is evidenced by the fact that any variation from a 15 second exposure at a lens setting of f 16. This example thus shows the unexpectedly improved exposure latitude using the conversion wash of this invention in an electrophotographic proces for preparing lithographic printing plates.
We claim: | A lithographic printing plate is produced by the steps of forming a latent electrostatic image on a photoconductive zinc oxide insulating layer and developing this layer with a toner which forms an imagewise deposit on the recording layer. Applicants' invention relates to contacting the portions of the recording layer which are not covered with the hydrophobic deposit with a hydrophilizing composition (commonly called a conversion wash) comprising the reaction product of (1) phosphoric acid or one of the anions derived from such acid, (2) an organic amine compound, and (3) a hydrophilic metal cation, to form a reaction product with zinc ions from the zinc oxide which reaction product of zinc ions with said composition is substantially insoluble in said composition and is preferentially wetted by water thereby repelling lithographic inks. The plate produced by this process is especially useful for use on a lithographic offset press to produce multiple copies of an original. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit and priority of United Kingdom Patent Application No. 1512450.6 filed on Jul. 16, 2015. The entire disclosure of the above application is incorporated herein by reference.
[0002] The subject application includes subject matter similar to U.S. patent application Ser. No. ______, (Attorney Docket 6000-000049-US), entitled “A Method of Augmenting an Audio Content”, filed concurrently herewith; and U.S. patent application Ser. No. ______, (Attorney Docket 6000-000050-US), entitled “Personal Audio Mixer”, filed concurrently herewith, both of which are incorporated herein by reference.
FIELD
[0003] The present invention relates to a method of synchronising an audio signal. A device and system for performing the method are also provided.
BACKGROUND
[0004] Music concerts and other live events are increasingly being held in large venues such as stadiums, arenas and large outdoor spaces such as parks. With increasingly large venues being used, the challenge of providing a consistently enjoyable audio experience to all attendees at the event, regardless of their location within the venue, is becoming increasingly challenging.
[0005] All attendees at such events expect to experience a high quality of sound, which is either heard directly from the acts performing on the stage, or reproduced from speaker systems at the venue. Multiple speaker systems distributed around the venue may often be desirable to provide a consistent sound quality and volume for all audience members. In larger venues, the sound reproduced from speakers further from the stage may be delayed such that attendees, who are standing close to distant speakers, do not experience an echo or reverb effect as sound from speakers nearer the stage reaches them.
[0006] In some cases such systems may be unreliable and reproduction of the sound may be distorted due to interference between the sound produced by different speaker systems around the venue. Additionally, if multiple instrumentalists and/or vocalists are performing simultaneously on the stage, it may be very challenging to ensure the mix of sound being projected throughout the venue is correctly balanced in all areas to allow the individual instruments and/or vocalists to be heard by each of the audience members. Catering for all the individual preferences of the attendees in this regard may be impossible.
SUMMARY
[0007] According to an aspect of the present disclosure, there is provided a method of synchronising one or more wirelessly received audio signals with an acoustically received audio signal, the method comprising: receiving an electromagnetic signal using a first wireless communication method, the electromagnetic signal comprising: the one or more wirelessly received audio signals and a wirelessly received metadata relating to a remote audio content, determining a delay between the acoustically received audio signal and the one or more wirelessly received audio signals by referring the acoustically received audio signal to the wirelessly received metadata and delaying the one or more audio signals by the determined delay.
[0008] The acoustically received audio signal may be recorded, e.g. by a transducer, such as a microphone, configured to convert an ambient audio content, into the acoustically received audio signal. The remote audio content may be configured to correspond to the ambient audio content and/or the acoustically received audio signal.
[0009] According to an aspect of the present disclosure, there is provided a method of synchronising one or more wirelessly received audio signals with an acoustically received audio signal, the method comprising: recording the acoustically received audio signal from an ambient audio content, receiving an electromagnetic signal using a first wireless communication method, the electromagnetic signal comprising: the one or more wirelessly received audio signals and a wirelessly received metadata relating to a remote audio content, determining a delay between the acoustically received audio signal and the one or more wirelessly received audio signals by referring the acoustically received audio signal to the wirelessly received metadata and delaying the one or more audio signals by the determined delay.
[0010] The method may further comprise processing the acoustically received audio signal to determine an acoustic metadata. The delay between the acoustically received audio signal and the one or more wirelessly received audio signals may be determined by comparing the acoustic metadata with the wirelessly received metadata.
[0011] The wirelessly received metadata may comprise timing information relating to the remote audio content. Additionally or alternatively, the wirelessly received metadata may comprise information relating to a waveform of the remote audio content.
[0012] The electromagnetic signal may comprise a multiplexed audio signal. Additionally or alternatively, the wireless signal may be a modulated signal, e.g. a digitally modulated signal. The method may further comprise demultiplexing and/or demodulating (e.g. decoding) the electromagnetic audio signal to obtain the one or more wirelessly received audio signals and/or the wirelessly received metadata.
[0013] The electromagnetic signal may comprise a plurality of wirelessly received audio signals. The method may further comprise receiving an audio content setting from a user interface device and adjusting the relative volumes of the wirelessly received audio signals, according to the audio content setting, to provide a plurality of adjusted audio signals. The adjusted audio signals may be combined to generate a custom audio content.
[0014] At least one of the wirelessly received audio signals may correspond to the remote audio content.
[0015] The audio content setting may be received using a second wireless communication method. The first wireless communication method may have a longer range than the second wireless communication method.
[0016] According to another aspect of the present disclosure, there is provided an audio synchroniser comprising: a wireless receiver configured to receive an electromagnetic signal using a first wireless communication method, the signal comprising one or more wirelessly received audio signals and a wirelessly received metadata relating to a remote audio content, and a controller configured to perform the method, for example according to a previously mentioned aspect of the disclosure.
[0017] According to another aspect of the disclosure, there is provided a system for synchronising one or more wirelessly received audio signals with an acoustically received audio signal, the system comprising: an audio workstation configured to generate a metadata relating to an audio content and provide a signal comprising one or more audio signals and the metadata, a transmitter configured to receive the signal from the audio workstation and transmit the signal using a first wireless communication method, and the audio synchroniser according to a previously mentioned aspect of the disclosure.
[0018] The audio workstation may be configured to generate the audio content from a plurality of audio channels provided to the audio workstation. Additionally or alternatively, the audio workstation may be configured to generate the one or more audio signals from the plurality of audio channels provided to the audio workstation. At least one of the audio signals may correspond to the audio content. The audio content may be configured to correspond to the acoustically received audio signal and/or an ambient audio content at the location of the audio synchroniser.
[0019] The system may further comprise a speaker system configured to provide the ambient audio content.
[0020] According to another aspect of the present disclosure, there is provided software configured to perform the method according to a previously mentioned aspect of the disclosure.
[0021] To avoid unnecessary duplication of effort and repetition of text in the specification, certain features are described in relation to only one or several aspects or embodiments of the disclosure. However, it is to be understood that, where it is technically possible, features described in relation to any aspect or embodiment of the disclosure may also be used with any other aspect or embodiment of the disclosure.
DRAWINGS
[0022] For a better understanding of the present disclosure, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
[0023] FIG. 1 is a schematic view of a previously proposed arrangement of sound recording, mixing and reproduction apparatus for a large outdoor event;
[0024] FIG. 2 is a schematic view showing the process of recording, processing and reproducing sound within the arrangement shown in FIG. 1 ;
[0025] FIG. 3 is a schematic view of an arrangement of sound recording, mixing and reproduction apparatus, according to an embodiment of the present disclosure, for a large outdoor event;
[0026] FIG. 4 is a schematic view showing the process of recording, processing and reproducing sound within the arrangement shown in FIG. 3 ;
[0027] FIG. 5 is a schematic view of a system for mixing a custom audio content according to an embodiment of the present disclosure;
[0028] FIG. 6 shows a previously proposed method of synchronising an audio signal; and
[0029] FIG. 7 shows a method of synchronising an audio signal, according to an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0030] With reference to FIG. 1 , a venue for a concert or other live event comprises a performance area, such as a stage 2 , and an audience area 4 . The audience area may comprise one or more stands of seating in a venue such as a theatre or arena. Alternatively, the audience area may be a portion of a larger area such as a park, within which it is desirable to see and/or hear a performance on the stage 2 . In some cases the audience area 4 may be variable, being defined by the crowd of people gathered for the performance.
[0031] With reference to FIGS. 1 and 2 , the sound produced by instrumentalists and vocalists performing on the stage 2 is picked up by one or more microphone 6 and/or one or more instrument pick-ups 8 provided on the stage 2 . The microphones 6 and pick-ups 8 convert the acoustic audio into a plurality of audio signals 20 . The audio signals 20 from the microphones 6 and pick-ups 8 are input as audio channels into a stage mixer 10 , which adjusts the relative volumes of each of the channels.
[0032] The relative volumes of each of the audio channels mixed by the stage mixer 10 are set by an audio technician prior to and/or during the performance. The relative volumes may be selected to provide what the audio technician considers to be the best mix of instrumental and vocal sounds to be projected throughout the venue. In some cases performers may request that the mix is adjusted according to their own preferences.
[0033] The mixed, e.g. combined, audio signal 22 output by the stage mixer 10 is input into a stage equaliser 12 , which can be configured to increase or decrease the volumes of certain frequency ranges within the mixed audio signal. The equalisation settings may be selected by the audio technician and/or performers according to their personal tastes and may be selected according to the acoustic environment of the venue and the nature of the performance.
[0034] The mixed and equalised audio signal 24 is then input to a stage amplifier 14 which boosts the audio signal to provide an amplified signal 26 , which is provided to one or more front speakers 16 a , 16 b to project the audio signal as sound. Additional speakers 18 a , 18 b are often provided within the venue to project the mixed and equalised audio to attendees located towards the back of the audience area 4 . Sound from the front speakers 16 a , 16 b reaches audience members towards the back of the audience area 4 a short period of time after the sound from the additional speaks 18 a , 18 b . In large venues, this delay may be detectable by the audience members and may lead to echoing or reverb type effects. In order to avoid such effects, the audio signal provided to the additional speakers 18 a 18 b is delayed before being projected into the audience area 4 . The signal may be delayed by the additional speakers 18 a , 18 b , the stage amplifier 14 , or any other component or device within the arrangement 1 . Sound from the speakers 16 a , 16 b and the additional speakers 18 a , 18 b will therefore reach an attendee towards the rear of the audience area 4 at substantially the same time, such that no reverb or echoing is noticeable.
[0035] Owing to the mixed and equalised sounds being reproduced by multiple speaker systems throughout the venue, some of which are configured to delay the signal before reproducing the sound, interference may occur between the projected sounds waves in certain areas of the venue which deteriorates the quality of audible sound. For example, certain instruments and/or vocalists may become indistinguishable, not clearly audible or substantially inaudible within the overall sound. In addition to this, the acoustic qualities of the venue may vary according to the location within the venue and hence the equalisation of the sound may be disrupted for some audience members. For example, the bass notes may become overly emphasised.
[0036] As described above, the mix and equalisation of the sound from the performance may be set according to the personal tastes of the audio technician and/or the performers. However, the personal tastes of the individual audience members may vary from this and may vary between the audience members. For example a certain audience member may prefer a sound in which the treble notes are emphasised more than in the sound being projected from the speakers, whereas another audience member may be particularly interested in hearing the vocals of a song being performed and may prefer a mix in which the vocals are more distinctly audible over the sounds of other instruments.
[0037] With reference to FIGS. 3 and 4 , in order to provide an improved quality and consistency of audio experienced for each audience member attending a performance and to allow the mix and equalisation of the audio to be individually adjusted by each audience member, an arrangement 100 of sound recording, mixing and reproduction apparatus, according to an embodiment of the present disclosure, is provided. The apparatus within the arrangement 100 is configured to record, mix and reproduce audio signals following a process.
[0038] The arrangement 100 comprises the microphones 6 , instrument pick-ups 8 , stage mixer 10 , stage equaliser 12 and stage amplifier 14 , which provide audio signals to drive the front speakers 16 a , 16 b and additional speakers 18 a , 18 b as described above with reference to the arrangement 1 . The arrangement 100 further comprises a stage audio splitter 120 , an audio workstation 122 , a multi-channel transmitter 124 and a plurality of personal audio mixing devices 200 .
[0039] The stage audio splitter 120 is configured to receive the audio signals 20 from each of the microphones 6 and instrument pick-ups 8 , and split the signals to provide inputs 120 a to the stage mixer 10 and the audio workstation 122 . The inputs 120 a received by the stage mixer 10 and the audio workstation 122 are substantially the same as each other, and are substantially the same as the inputs 20 received by the stage mixer 10 in the arrangement 1 , described above. This allows the stage mixer 10 and components which receive their input from the stage mixer 10 to operate as described above.
[0040] The audio workstation 122 comprises one or more additional audio splitting and mixing devices, which are configured such that each mixing device is capable of outputting a combined audio signal 128 comprising a different mix of each of the audio channels 120 a , e.g. the relative volumes of each of the audio signals 120 a within each one or the combined audio signals 128 are different to within each of the other combined audio signals 128 output by the other mixing devices. At least one of the combined audio signals 128 generated by the audio workstation 122 may correspond to the stage mix being projected from the speakers 16 and additional speakers 18 .
[0041] The audio workstation 122 may comprise a computing device, or any other system capable of processing the audio signal inputs 120 a from the stage audio splitter 120 to generate the plurality of combined audio signals 128 .
[0042] The audio workstation 122 is also configured to generate an audio content that is substantially the same as the stage mix generated by the stage mixer 10 . The audio content may be configured to correspond to the sound projected from the speakers 16 and the additional speakers 18 . The audio workstation 122 is configured to process the audio content to generate metadata 129 , e.g. a metadata stream, corresponding to the audio content. The metadata may relate to the waveform of the audio content. Additionally or alternatively, the metadata may comprise timing information relating to the audio content. The metadata may be generated by the audio workstation 122 substantially in real time, such that the stream of metadata 129 is synchronised with the combined audio signals 128 output from the audio workstation 122 .
[0043] The combined audio signals 128 and metadata 129 output by the audio workstation 122 are input to a multi-channel transmitter 124 . The multi-channel transmitter 124 is configured to transmit the combined audio signals 128 and metadata 129 as one or more wireless signal 130 , using wireless communication, such as radio, digital radio, Wi-Fi (such as RTM), or any other wireless communication method. The multi-channel transmitter 124 is also capable of relaying the combined audio signals 128 and metadata 129 to one or more further multi-channel transmitters 124 ′ using a wired or wireless communication method. Relaying the combined audio signals and metadata allows the area over which the combined audio signals and metadata is transmitted to be extended.
[0044] Each of the combined audio signals 128 and the metadata 129 may be transmitted separately using a separate wireless communication channel, bandwidth, or frequency. Alternatively, the combined audio signals 128 and metadata 129 may be modulated, e.g. digitally modulated, and/or multiplexed together and transmitted using a single communication channel, bandwidth or frequency. For example, the combined audio signals 128 and metadata 129 may be encoded using a Quadrature Amplitude Modulation (QAM) technique, such as 16-bit QAM. The wireless signals 130 transmitted by the multi-channel transmitter 124 are received by the plurality of personal audio mixing devices 200 .
[0045] With reference to FIG. 5 , the personal audio mixing devices 200 , according to an arrangement of the present disclosure, comprise an audio signal receiver 202 , a decoder 204 , a personal mixer 206 , and a personal equaliser 208 .
[0046] The audio signal receiver 202 is configured to receive the wireless signal 130 comprising the combined audio signals 128 and the metadata 129 transmitted by the multi-channel transmitter 124 . As described above, the multi-channel transmitter 124 may encode the signal, for example using a QAM technique. Hence, the decoder 204 may be configured to demultiplex and/or demodulate (e.g. decode) the received signal as necessary to recover each of the combined audio signals 128 and the metadata 129 , as one or more decoded audio signals 203 , and wirelessly received metadata 205 .
[0047] As described above, the combined audio signals 128 each comprise a different mix of audio channels 20 recorded from the instrumentalists and/or vocalists performing on the stage 2 . For example, a first combined audio signal may comprise a mix of audio channels in which the volume of the vocals has been increased with respect to the other audio channels 20 ; in a second combined audio signal the volume of an audio channel from the instrument pick-up of a lead guitarist may be increased with respect to the other audio channels 20 . The decoded audio signals 203 are provided as inputs to the personal mixer 206 .
[0048] The personal mixer 206 may be configured to vary the relative volumes of each of the decoded audio signals 203 . The mix created by the personal mixer 206 may be selectively controlled by a user of the personal audio mixer device 200 , as described below. The user may set the personal mixer 206 to create a mix of one or more of the decoded audio signals 203 .
[0049] In a particular arrangement, each of the combined audio signals 128 is mixed by the audio workstation 122 such that each signal comprises a single audio channel 20 recorded from one microphone 6 or instrument pick-up 8. The personal mixer 206 can therefore be configured by the user to provide a unique personalised mix of audio from the performers on the stage 2 . The personal audio mix may be configured by the user to improve or augment the ambient sound, e.g. from the speakers and additional speakers 16 , 18 , heard by the user.
[0050] A mixed audio signal 207 output from the personal mixer 206 is processed by a personal equaliser 208 . The personal equaliser 208 is similar to the stage equaliser 12 described above and allows the volumes of certain frequency ranges within the mixed audio signal 207 to be increased or decreased. The personal equaliser 208 may be configured by a user of the personal audio mixer device 200 according to their own listening preferences.
[0051] An equalised audio signal 209 from the personal equaliser 208 is output from the personal audio mixing device 200 and may be converted to sound, e.g. by a set of personal head phones or speakers (not shown), allowing the user, or a group of users to listen to the personal audio content created on the personal audio mixing device 200 .
[0052] Each member of the audience may use their own personal audio mixing device 200 to listen to a personal, custom audio content at the same time as listening to the stage mix being projected by the speakers 16 and additional speakers 18 . The pure audio reproduction of the performance provided by the personal audio mixing device 200 may be configured as desired by the user to complement or augment the sound being heard from the speaker systems 16 , 18 , whilst retaining the unique experience of the live event.
[0053] If desirable, the user may listen to the personal, custom audio content in a way that excludes other external noises, for example by using noise cancelling/excluding headphones.
[0054] In order for the user of the personal audio mixing device 200 to configure the personal mixer 206 and personal equaliser 208 according to their preferences, the personal audio mixing device 200 may comprise one or more user input devices, such as buttons, scroll wheels, or touch screen devices (not shown). Additionally or alternatively, the personal audio mixing device 200 may comprise a user interface communication module 214 .
[0055] As shown in FIG. 5 , the user interface communication module 214 is configured to communicate with a user interface device 216 . The user interface device 216 may comprise any portable computing device capable of receiving input from a user and communicating with the user interface communication module 214 . For example, the user interface device 216 may be a mobile telephone or tablet computer. The user interface communication module 214 may communicate with the user interface device 216 using any form of wired or wireless communication methods. For example, the user interface communication module 214 may comprise a Bluetooth communication module and may be configured to couple with, e.g. tether to, the user interface device 216 using Bluetooth.
[0056] The user interface device 216 may run specific software, such as an app, which provides the user with a suitable user interface, such as a graphical user interface, allowing the user to easily adjust the settings of the personal mixer 206 and personal equaliser 208 . The user interface device 216 communicates with the personal audio mixer device 200 via the interface communication module 214 to communicate any audio content settings, which have been input by the user using the user interface device 216 .
[0057] The user interface device 216 and the personal audio mixing device 200 may communicate in real time to allow the user to adjust the mix and equalisation of the audio delivered by the personal audio mixing device 200 during the concert. For example, the user may wish to adjust the audio content settings according to the performer or the stage on a specific song being performed.
[0058] The personal audio mixer device 200 also comprises a Near Field Communication (NFC) module 218 . The NFC module 218 may comprise an NFC tag which can be read by an NFC reader provided on the using interface device 216 . The NFC tag may comprise authorisation data which can be read by the user interface device 216 , to allow the user interface device 216 to couple with the personal audio mixing device 200 , e.g. with the user interface communication module 214 . Additionally or alternatively, the authorisation data may be used by the user interface device 216 to access another service provided at the performance venue.
[0059] The NFC module 218 may further comprise an NFC radio. The radio may be configured to communicate with the user interface device 216 to receive an audio content setting from the user interface device 216 . Alternatively, the NFC radio may read an audio content setting from another source such as an NFC tag provided on a concert ticket, or smart poster at the venue.
[0060] The personal audio mixer device 200 further comprises a microphone 210 . The microphone 210 may be a single channel microphone. Alternatively the microphone 210 may be a stereo or binaural microphone. The microphone 210 is configured to record an ambient sound at the location of the user, for example the microphone may record the sound of the crowd and the sound received by the user from the speakers 16 and additional speakers 18 . The sound is converted by the microphone 210 to an acoustic audio signal 211 , which is input to the personal mixer 206 . The user of the personal audio mixing device can adjust the relative volume of the acoustic audio signal 211 together with the decoded audio signals 203 . This may allow the user of the device 200 to continue experiencing the sound of the crowd at a desired volume whilst listening to the personal audio mix created on the personal audio mixing device 200 .
[0061] Prior to being input to the personal mixer 206 , the acoustic audio signal 211 is input to an audio processor 212 . The audio processor 212 also receives the decoded audio signals 203 from the decoder 204 . The audio processor 212 may process the acoustic audio signal 211 and the decoded audio signals 203 to determine a delay between the acoustic audio signal 211 recorded by the microphone 210 and the decoded audio signals received and decoded from the wireless signal 130 transmitted by the multi-channel transmitter 124 .
[0062] With reference to FIG. 6 , in a previously proposed arrangement the audio processor 121 is configured to processes the acoustic audio signal 211 and the decoded audio signals 203 according to a method 600 . In a first step 602 , the acoustic audio signal 211 and the decoded audio signals 211 are processed to produce one or more metadata streams relating the acoustic audio signal 211 and the decoded audio signals 203 respectively. The metadata streams may contain information relating to the waveforms of the acoustic audio signal and/or the decoded audio signals. Additionally or alternatively, the metadata streams may comprise timing information.
[0063] In a second step 604 , the previously proposed audio processor combines the metadata streams relating to one or more of the decoded audio channels to generate a combined metadata steam, which corresponds to the metadata steam generated from the acoustic audio signal. The audio processor 212 may combine different combinations of metadata streams before selecting a combination which it considered to correspond. It will be appreciated that the audio processor 212 may alternatively combine the decoded audio signals 203 prior to generating the metadata streams in order to provide the combined metadata steam.
[0064] In a third step 606 , the previously proposed audio processor compares the combined metadata stream with the metadata stream relating to the acoustic audio signal 211 to determine a delay between the acoustic audio signal 211 recorded by the microphone 210 , and the decoded audio signals 203 .
[0065] The audio processor 212 may delay one, some or each of the decoded audio signals 203 by the determined delay and may input one or more delayed audio signals 213 to the personal mixer 206 . This allows the personal audio content being created on the personal audio mixing device 200 to be synchronised with the sounds being heard by the user from the speakers 16 and additional speakers 18 , e.g. the ambient audio at the location of the user.
[0066] As the user moves around the audience area 4 , and the distance between the audience member and the speakers 16 , 18 varies, the required delay may vary also. Additionally or alternatively, environmental factors such as changes in temperature and humidity may affect the delay between the acoustic audio signal 211 and the decoded audio signals 203 . These effects may be emphasised the further an audience member is from the speakers 16 , 18 .
[0067] In order to maintain synchronisation of the personal audio content created by the device, with the ambient audio, the audio processor 212 may continuously update the delay being applied to the decoded audio signals 203 . It may therefore be desirable for the audio processor 212 to reduce the time taken for the audio processor 212 to perform the steps to determine the delay.
[0068] In some cases, the time taken for the audio processor 212 , following the previously proposed method 600 , to process the decoded audio signals 203 and the acoustic audio signal 211 to generate the metadata, produce the necessary combined metadata, and compare the metadata to determine the delay, may exceed the length of the delay required. During the time taken to determine the delay to be applied, the required delay may vary by a detectable amount, e.g. detectable by the user, such that applying the determined delay does not correctly synchronise the personal audio content created by the personal audio mixing device 200 with the ambient audio content at the location of the user, e.g. the sound received from the speakers 16 , 18 .
[0069] In order to reduce the time taken by the audio processor to determine the required delay, the audio workstation may be configured to generate at least one of the combined audio signals 128 , such that it corresponds to the acoustic audio signal. For example, the combined audio signal 128 may be configured to correspond to the stage mix being projected by the speakers 16 , 18 . The audio processor 212 may then process only the acoustic audio signal 211 and the decoded audio signal 203 that corresponds to the stage mix, and hence the ambient audio content recorded by the microphone 210 to provide the acoustic audio signal 211 .
[0070] In order to further reduce the time taken by the audio processor 212 to determine the delay, the audio processor 212 may be configured to receive the metadata 129 , which is transmitted wirelessly from the multi-channel transmitter 124 . With reference to FIG. 7 , the audio processor 212 may determine a required delay using a method 700 , according to an arrangement of the present disclosure.
[0071] In a first step 702 , the acoustic audio signal 211 is processed to produce a metadata stream. In a second step 704 the metadata stream relating to the acoustic audio signal is compared with the wirelessly received metadata 205 , to determine a delay between the acoustic audio signal 211 and the decoded audio signals 203 .
[0072] As described above, the metadata 129 transmitted by the multi-channel transmitter 124 and received wirelessly by the personal audio mixer 200 may relate to an audio content generated by the audio workstation that corresponds to the stage mix being projected by the speakers 16 , 18 . Hence, the wirelessly received metadata 205 may be suitable for comparing with the metadata stream generated from the acoustic audio signal 211 to determine the delay. In addition, by applying the wirelessly received metadata 205 to determine the required delay, rather than processing the decoded audio signals 203 to generate one or more metadata streams, the audio processor 212 may calculate the delay faster. This may lead to improved synchronisation between the personal audio content and the ambient audio heard by the user.
[0073] It will be appreciated that the personal audio mixing device 200 may comprise one or more controllers configured to perform the functions of one or more of the audio signal receiver 202 , the decoder 204 , the personal mixer 206 , the personal equaliser 208 , the user interface communication module 214 and the audio processor 212 , as described above. The controllers may comprise one or more modules. Each of the modules may be configured to perform the functionality of one of the above-mentioned components of the personal audio mixing device 200 . Alternatively, the functionality of one or more of the components mentioned above may be split between the modules or between the controllers. Furthermore, the or each of the modules may be mounted in a common housing or casing, or may be distributed between two or more housings or casings.
[0074] Although the disclosure has been described by way of example, with reference to one or more examples, it is not limited to the disclosed examples and other examples may be created without departing from the scope of the disclosure, as defined by the appended claims. | A method of synchronising one or more wirelessly received audio signals with an acoustically received audio signal is provided. The method comprises: receiving an electromagnetic signal using a first wireless communication method, the electromagnetic signal comprising: the one or more wirelessly received audio signals and a wirelessly received metadata relating to a remote audio content, determining a delay between the acoustically received audio signal and the one or more wirelessly received audio signals by referring the acoustically received audio signal to the wirelessly received metadata; and delaying the one or more audio signals by the determined delay. A device and system for performing the method are also provided. | 7 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of international app. No. PCT/FI2004/000058, filed Feb. 5, 2004, the disclosure of which is incorporated by reference herein, and claims priority on Finnish App. No. 20030205, Filed Feb. 11, 2003.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The invention relates to an apparatus and a method in the treatment of the stock passed to a headbox of a paper machine or equivalent.
[0004] Centrifugal cleaning is needed in paper machines for separation of sand and contaminants. With today's technology, the cleaning efficiency of centrifugal cleaning deteriorates when the fiber consistency of the pulp suspension exceeds 1 percent. This limits the increasing of the feed consistency of the stock to be fed to the headbox. In practice, the slotted screen technique has made it unnecessary to use centrifugal cleaning for separating reject fibers, such as shives. A hydrocyclone plant is placed in the short circulation of the paper machine, where the flow rates are high, as high as 2000 l/s. To be operative, centrifugal cleaning requires a pressure difference of 120-150 kPa. In that connection, all (about 5) steps of the hydrocyclone plant require pumps, which represent as much as about 25 percent of the energy consumption of the short circulation. At a flow rate of 2000 l/s, the power consumption of centrifugal cleaning is about 1200 kW. A typical amount of fiber reject from centrifugal cleaning is about 0.1-0.2 percent of production. The loss of the filler pigments coming with coated broke is at its worst about 0.5 percent of machine production.
[0005] A filler recovery system is often incorporated in connection with the centrifugal cleaning of the short circulation. In addition to filler, the system must also process other rejects, such as fiber reject and sand, coming from the short circulation. In that case, the efficiency of the filler recovery system is not best possible.
[0006] Concepts are known in which the cleaning of the stock has been transferred from the short circulation to pulp lines. The consistency (about 3 percent) of the broke system is, however, not suitable for separation of sand with hydrocyclones.
[0007] When centrifugal cleaning is in the pulp line (e.g. chemical pulp, DIP or TMP), these pulps need not be cleaned again any more, but the debris, sand and non-disintegrating coating sheets of paper coming to the broke system via pulpers should be treated by means of hydrocyclones.
SUMMARY OF THE INVENTION
[0008] By placing a hydrocyclone plant in accordance with the invention in a broke system line in the short circulation, the problem is solved. The fiber consistency in the headbox can be increased, when needed, to a level of over 2 percent without the fiber consistency in the centrifugal cleaning exceeding the limit of 1 percent.
[0009] The size and the energy consumption of the hydrocyclone plant would be only about one third of the present size and energy consumption. The size is determined based on the maximal broke percentage.
[0010] At the same time, better selectivity is achieved in the filler recovery process.
[0011] In the invention, a hydrocyclone plant is placed in a stock line which is in the short circulation and uses broke, and it is connected with another stock line, so that the bulk of the stock flow (the purer stock) bypasses centrifugal cleaning.
[0012] The proposal reduces the energy consumption of centrifugal cleaning by about 65 percent, which means a saving of about 17 percent in the energy need of the short circulation. On a large machine the saved power is about 800 kW.
[0013] The amount of reject from centrifugal cleaning is reduced to a fraction, which means that the amount of reject from centrifugal cleaning would be in its entirety less than 0.05 percent of production. In practice, it could halve the amount of reject in the area of the paper mill, thus reducing the handling capacity associated with fiber recovery.
[0014] The investment in equipment is reduced by about 65 percent in centrifugal cleaning and by about 10 percent in respect of the short circulation. A hydrocyclone plant is a subprocess that takes up much space. By means of the arrangement in accordance with the invention, the paper machine hall is shortened by 3 m, with the result that the saving in building costs is considerable.
[0015] In accordance with the invention, a system is formed that includes at least two stock chests. The first stock chest comprises a stock composition M 1 containing pulp that requires centrifugal cleaning before it is passed to the headbox of the paper machine. The stock composition M 1 contains broke pulp passed from the paper machine and, in addition, it can contain pulp coming from fiber recovery and further mechanical pulp. The second stock chest comprises a stock composition M 2 containing pulp that has already undergone centrifugal cleaning, such as recycled fiber and/or chemical pulp and/or TMP. Thus, it does not contain any broke coming from the paper machine. In the arrangement in accordance with the invention, only the stock M 1 of the first stock chest is treated in the hydrocyclone plant and at least one accept is passed from it into connection with a second stock chest line and its stock M 2 . There can be more stock chests than two.
[0016] The apparatus in accordance with the invention thus includes a hydrocyclone plant that is much cheaper in capital expenditure and takes up less space than that of the prior art because its capacity need not be as high as that of the prior art arrangements in which all stock is passed through a hydrocyclone plant. In the arrangement in accordance with the invention, it is only the stock M 1 which has come as broke that is passed through the hydrocyclone plant in the short circulation of the headbox.
[0017] In the following, the invention will be described with reference to some advantageous embodiments of the invention shown in the figures of the appended drawings, but the invention is not meant to be exclusively limited to them.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A shows a prior art apparatus for passing stock to a headbox of a paper machine.
[0019] FIG. 1B shows an arrangement in accordance with the invention.
[0020] FIG. 2A shows a first embodiment of the invention in which broke-containing stock is passed from a first stock chest to a hydrocyclone plant, and in which embodiment the stock is passed through a wire pit.
[0021] FIG. 2B shows a second embodiment of the invention.
[0022] FIG. 3 is an illustration of principle of the operation of a hydrocyclone plant.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] FIG. 1A shows a prior art stock system in which all stock M 1 +M 2 +M 3 is passed to a hydrocyclone plant 20 , which means that a high capacity is required from the hydrocyclone plant.
[0024] FIG. 1B shows an arrangement in accordance with the invention. A stock chest 10 a , contains stock, i.e. a pulp fraction M 1 , which contains broke passed from a paper machine and said pulp fraction M 1 is treated in a hydrocyclone plant 20 . The cleaned stock, its accepts are passed further into connection with stocks M 2 and M 3 that do not contain broke and further to a headbox 100 . The pulp fractions M 2 and M 3 that do not contain broke in stock chests 10 a 2 and 110 a 3 thus bypass the centrifugal cleaning 20 , and the accept of the stock M 1 from the hydrocyclone plant 20 is passed into connection with said stocks M 2 and M 3 . The hydrocyclone plant 20 is not required to have as high a capacity as that of the embodiment of FIG. 1A .
[0025] In the embodiment of FIG. 2A , stock M 1 , or a pulp fraction, of a first stock chest 10 a 1 also comprises a stock composition that requires centrifugal cleaning before it is passed to a headbox of a paper machine. The stock M 1 contains broke coming from the paper machine and, in addition, it may contain pulp coming from fiber recovery, and further mechanical pulp.
[0026] Stock M 2 of a second stock chest 10 a 2 comprises a stock composition that has already undergone centrifugal cleaning, such as recycled fiber and/or chemical pulp and/or TMP.
[0027] In the embodiment of FIG. 2A , the stock M 1 is passed from the stock chest 10 a 1 through a stock line a 1 to a lower part of a wire pit 11 . The line a 1 includes a pump P 1 . In the lower part of the wire pit, the stock M 1 is diluted with wire water obtained from a wire section of a paper machine (not shown) along a line d 1 to a consistency required by a hydrocyclone plant 20 . A line a 2 leads from the lower part of the wire pit 11 to the suction side of a pump P 2 and a line a 2 leads from the pressure side of the pump P 2 to a first centrifugal cleaning step 20 a 1 of the hydrocyclone plant 20 situated in the short circulation of the paper machine. In the figure, the centrifugal cleaning steps are designated with 20 a 1 , 20 a 2 , 20 a 3 . . . An accept line from the centrifugal cleaning step 20 a 1 of the hydrocyclone plant 20 ; a line a 3 is passed further to join a line b, of the stock M 2 of the second stock chest 10 a 2 via a mixing device 12 . The mixing device 12 is also supplied with wire water from the wire pit 11 along a line e 1 for diluting the stock M 2 to be fed to the headbox 100 to a suitable consistency.
[0028] From the upper part of the wire pit 11 there is further a line c 1 for dilution water, said line c 1 including a pump P 3 . The line c 1 leads further from the discharge side of the pump P 3 to a deaeration tank 13 a 1 . The dilution water passed through the deaeration tank 13 a 1 is conducted further after the deaeration treatment to a discharge line f 1 and further while pumped by a pump P 4 to a machine screen 14 a 1 , whose accepted fraction, i.e. accept, is passed to a dilution inlet header J 2 in the headbox 100 .
[0029] The stock chest 10 a 2 is provided with the line b 1 for the stock and further to the suction side of a pump P 5 . On the discharge side of the pump P 5 , the line b 1 is connected to the mixing device 12 , after which there is a pump P 6 in a line b 2 for pumping the combined stock further along the line b 2 to a deaeration tank 13 a 2 , from which a discharge line f 2 leads further to the suction side of a pump P 7 . On the discharge side of the pump P 7 , in the line f 2 there is a machine screen 14 a 2 , from which an accepted fraction, i.e. accept, is passed to a stock inlet header J 1 of the headbox 100 .
[0030] In the device arrangement in accordance with the invention, only the broke-containing stock M 1 passed from the stock chest 10 a , is treated in the hydrocyclone plant 20 . An accept line a 3 leads from said hydrocyclone plant further into connection with the stock line b, of the stock M 2 of the second stock chest 10 a 2 . Since the stock M 2 of the second stock chest 110 a 2 comprises stock that has already previously undergone centrifugal cleaning, said line can be connected directly to the headbox 100 of the paper machine, via its deaeration tank 13 a 2 and machine screen 14 a 2 .
[0031] In the embodiment of FIG. 2B , stock M 1 , i.e. a pulp fraction, of a first stock chest 10 a 1 also comprises a stock composition that requires centrifugal cleaning before it is passed to a headbox of a paper machine. The stock M 1 contains broke coming from the paper machine and it can additionally contain pulp coming from fiber recovery and further mechanical pulp.
[0032] Stock M 2 of a second stock chest 10 a 2 comprises pulp that has already undergone centrifugal cleaning, such as recycled fiber and/or chemical pulp and/or TMP.
[0033] Also in this embodiment of the invention, only the stock M 1 passed from the stock chest 10 a 1 is treated in a hydrocyclone plant 20 . In the embodiment of the figure, the stock is passed from the stock chest 10 a 1 through a line a 1 while pumped by a pump P 10 to a mixing device 120 , in which the stock is diluted to a centrifugal cleaning consistency with wire water obtained from a line f 4 , and the stock M 1 is passed further through a line a 2 to the suction side of a pump P 20 . The line a 2 on the pressure side of the pump P 20 is connected to the hydrocyclone plant 20 to form the feed of its first centrifugal cleaning step 20 a 1 .
[0034] In the embodiment of FIG. 2B , the hydrocyclone plant 20 situated in the short circulation of the paper machine includes centrifugal cleaning steps 20 a 1 , 20 a 2 and 20 a 3 . An accept line a 3 leads further from the first hydrocyclone, i.e. the centrifugal cleaning step 20 a 1 of the hydrocyclone plant 20 into connection with a stock line b 1 of a second stock chest 10 a 2 .
[0035] In the embodiment, wire water from the paper machine is passed to a wire pit 110 through a line d 1 , which wire pit 110 in this embodiment is formed by a planar wire pit structure, a so-called flume, which comprises a horizontal flow path for wire water. Said wire pit 110 removes effectively air in bubble form from the wire water, and pre-deaeration of the wire water is accomplished by means of said wire pit type. The wire water is passed from the wire pit 110 through a discharge line d 2 and a pump P 30 to a deaeration tank 13 a 3 , from which there is further a discharge line f 3 leading into connection with the line b, of the stock M 2 of the second stock chest 10 a 2 via a mixing device 12 . The line f 4 leads further from the discharge line f 3 of the deaeration tank 13 a 3 into connection with the line a 1 of the stock M 1 of the first stock chest 10 a 1 via the mixing device 120 . A branch line f 5 leads further from the line f 3 to a pump P 40 and further from the pressure side of the pump P 40 to a machine screen 14 a 3 , which conducts the wire water further as accept from the machine screen 14 a 3 to a dilution water inlet header J 2 of a headbox 100 .
[0036] The stock M 2 is passed from the stock chest 10 a 2 through a pump P 50 along the line b 1 to the mixing device 12 in order to be combined with the stock coming as accept along the line a 3 from the hydrocyclone plant 20 and with the dilution water coming along the line f 3 . After that the diluted stock is pumped by means of a headbox feed pump P 60 through a machine screen 14 a 4 to a stock inlet header J 1 of the headbox 100 .
[0037] As shown in FIG. 3 , the hydrocyclone plant 20 includes several centrifugal cleaning steps 20 a 1 , 20 a 2 , 20 a 3 , so that, as shown in the figure, accept from the first step 20 a 1 is passed through the line a 3 further into connection with the line b, of the stock M 2 of the second chest 10 a 2 . As shown in FIG. 3 , the stock is passed through the line a 1 as a feed to the first centrifugal cleaning step of the hydrocyclone plant 20 , i.e. to the hydrocyclone 20 a 1 . The stock flows along a spiral-shaped path inside the hydrocyclone 20 a 1 and heavier particles separate as reject from the bottom of the hydrocyclone and lighter particles rise as accept further through the line a 3 into the line b 1 of the stock M 2 passed from the second stock chest 10 a 2 . There can be several hydrocyclones 20 a 1 , 20 a 2 , 20 a 3 . . . and the reject from the first hydrocyclone 20 a 1 can be passed further to the second hydrocyclone 20 a 2 as its feed and the accept from it in one embodiment can be passed further to the line b, of the stock M 2 of the second stock chest 10 a 2 .
[0038] The figure shows a headbox 100 . The headbox 100 in accordance with the invention is advantageously a so-called dilution headbox, which means that the dilution water passed to the dilution water inlet header J 2 is passed further across the width of the headbox to different points of the stock passed from the stock inlet header J 1 In this way, dilution makes it possible to regulate the basis weight of the web across the width of the web. The dilution water passed from the dilution water inlet header J 2 is passed to ducts which are provided with dilution water valves, by means of which the supply of dilution water can be regulated as desired across the width of the headbox, thus enabling the basis weight of the web to be regulated to be even across the entire width of the web.
[0039] As shown in the figure, the hydrocyclone plant can also include several accept lines, the stock passed through them being conducted into connection with another stock or with stocks passed from other chests. In accordance with the invention, it is also possible to use several stock chests, but in the invention only that stock, such as the broke-containing stock M 1 , which shall be treated in the hydrocyclone plant is circulated through the hydrocyclone plant 20 . The pulp fraction M 2 which need not be cleaned with hydrocyclones is passed directly to deaeration and, after a machine screen, to the stock inlet header J 1 of the headbox 100 . The accept derived from the stock M 1 in the centrifugal cleaning 20 is conducted into connection with said stock.
[0040] When the stocks M 1 and M 2 of the chests 10 a 1 , 10 a 2 are referred to in this application, it is also possible to call them a pulp fraction M, and a pulp fraction M 2 . In this application, the paper machine is understood to mean paper, board and tissue machines.
[0041] The broke can be formed of paper broke, which can include trimmings or paper passed to a pulper in connection with web breaks.
[0042] The present application refers to lines by which are meant stock lines, pipes, ducts along which stock/wire water is passed. | An apparatus in the treatment of stock passed to a headbox of a paper machine or equivalent includes at least two stock chests ( 10 a 1 , 10 a 2 ). Stock (M 1 ) from a first stock chest ( 10 a 1 ) is passed along a line (a 1 , a 2 ) to a hydrococyclone plant ( 20 ) in the short circulation of the paper machine or equivalent. An accept line (a 3 ) of the hydrocyclone plant is connected with a stock line (b 1 ) of the stock (M 2 ) fed from a second stock chest ( 10 a 2 ), and a combined stock flow is passed along a line (b 2 ) to the headbox ( 100 ) of the paper machine or equivalent. A method in the treatment of the stock passed to a headbox of a paper machine or equivalent is disclosed. | 3 |
BACKGROUND OF THE INVENTION
[0001] This invention pertains to a fastener driving tool having improved bearing and guide assemblies. More particularly, the present invention pertains to a fastener-driving tool having non-metal contacting bearing assemblies and an enhanced aligning nosepiece guide assembly.
[0002] Fastener driving tools are well known in the art. Such tools are typically powder-actuated or electric-actuated tools for driving fasteners through a surface, such as a metal deck or metal roof The fasteners that are driven are of a known type that include a shank having a self-tapping, self-driving or self-drilling tip at one end and head integral with the other end of the shank. Typically, a sealing washer is positioned on the shank with an interference fit.
[0003] Known fastener-driving tools generally include a driver such as a powder actuated or an electric-actuated driver that is mounted to telescoping tubes. A first tube (upper or outer tube) is stationary relative to the driver and a second (lower or inner tube) telescopes relative to the upper tube. A shaft is mounted to the driver and extends through the tubes. The lower tube telescopes relative to the upper tube to permit movement of the driver shaft relative to a distal end of the lower tube. An end of the shaft includes, for example, a hex or socket-like element to engage the fastener head for driving. The lower tube telescopes to permit movement between a retracted position and a contracted position. In the retracted or extended position, a fastener is loaded onto an end of the shaft for driving into the surface. In the contracted position, the fastener is driven from the tool outwardly, through the distal end of the lower tube, into the surface.
[0004] Known fastener driving tools include a spring positioned between the tubes to urge the tubes and thus the tool into the retracted or loading position. In known driving tools, the lower tube is fitted immediately within the upper tube. Although this assures proper alignment of the tubes relative to one another and straight movement of the fastener, there is surface-to-surface contact of the tubes. In that these tubes are formed of metal this produces metal-to-metal contact between the tubes and can result in high frictional forces and possibly binding of the tubes.
[0005] Generally, a stop is positioned on the end of the upper tube that cooperates with a stop positioned along the length of the lower tube. This limits that travel of the tubes relative to one another and assures that the fastener is properly driven into the surface. That is, the stops are positioned relative to one another so that the fastener is driven a predetermined amount into the surface.
[0006] Known fastener driving tools include a nosepiece assembly that supports the fastener prior to and as it is engaged by the driver shaft (e.g., socket-like element). An opening in the nosepiece provides a track or path through which the fastener is driven from the tool. One drawback to known nosepiece assemblies is that while the nosepiece is relatively large, the opening through which the fastener is driven is relatively small. In that some types of roofing systems have preformed holes for receiving the fasteners, it is only with skill, practice and close inspection that the fastener opening is properly aligned with the roof deck panel hole. Other types of roofing systems require fastening roof panels, without these preformed holes, to one another and/or to underlying structural members.
[0007] In addition, many such metal roofing systems are formed having a corrugated profile defined by “peaks” and “valleys”. For those systems that have the preformed holes, the holes are typically formed on the peak portion of the corrugations. This makes it even more difficult to align the tool while maintaining it balanced on top of the corrugation while driving the fastener.
[0008] Accordingly, there is a need for a fastener driving tool that has an improved bearing surface to eliminate the problems associated with metal-to-metal sliding tube contact. Desirably, such a tool includes an enhanced fastener aligning and guide assembly to facilitate proper positioning of the fastener over the surface into which the fastener is driven. Most desirably, these enhanced features are provided in a tool that permits the tool operator to use the tool standing in an erect or near-erect stance to reduce operator fatigue.
BRIEF SUMMARY OF THE INVENTION
[0009] A fastener driving tool for driving fasteners into a workpiece is for use by an operator in a substantially erect position. The tool is configured for use on roof panels to drive fasteners into the panels for panel to panel and panel to structural applications. The panels have a corrugation-like profile defining a peak, a pair of valleys adjacent to the peak and respective walls extending between the peak and the adjacent valleys. Holes may be pre-formed in the panels, along the peak, for fastening the panels to the underlying structure or for joining panels to one another.
[0010] The tool includes a driver, such as an electric motor, telescopic extension members and a fastener receiving member. The telescopic extension members permit driving the fasteners into the roof panel. The fastener receiving member receives a fed fastener, supports the fastener during loading and releases the fastener as it is driven into the roof panel.
[0011] The driver has a driver shaft extending therefrom. The first extension member is operably connected to the driver and the second extension member is operably connected to the first extension member. In a current embodiment, the extension members are formed as tubes, with the first tube being a upper tube and the second member being a lower tube. The lower tube slidingly engages the upper tube between a loading position to load fasteners into the tool and a driving position to drive the fasteners from the tool into the roof panels.
[0012] A bearing assembly operably connects the upper and lower tubes. The bearing assembly is formed from a non-metallic, low-friction material, such as an acetal resin. A portion of the bearing assembly is mounted to one of the upper and lower tubes for sliding engagement with the other tube. The bearing assembly is positioned to prevent direct contact of the tubes with one another.
[0013] In one embodiment, the bearing assembly includes an upper tube bearing mounted to a lower end of the upper tube for slidingly engaging the lower tube. Preferably, the upper tube bearing including a sleeve portion mounted to the upper tube and a bearing portion extending transverse to and inwardly of the sleeve portion for contact with the lower tube.
[0014] The bearing assembly can further include a driver shaft guide mounted to the lower tube at about an upper end thereof. The driver shaft guide carries an upper tube bearing surface for slidingly engaging the upper tube. The upper tube bearing surface and the upper tube bearing maintain the upper and lower tubes concentric with one another during use.
[0015] The fastener receiving member receives fasteners when in the loading position and supporting and releases the fasteners when in the driving position. The fastener receiving member is mounted to the lower tube. The fastener receiving member includes a cradle having a main body portion and a pair of legs extending from the main body portion diverging downwardly and outwardly from the main body, symmetrical to one another.
[0016] The main body defines an upper inside surface extending between and contiguous with the legs, and an opening through the main body portion for passage of the fastener. The cradle is configured for positioning on the panel, straddling the peak with the upper inside surface resting adjacent the peak and the legs extending into the valleys for aligning the opening in the main body portion with a desired location on the roof panel (e.g., the panel hole).
[0017] In one embodiment, the cradle includes an aligning member having a jaw assembly that includes first and second jaw pivotal jaw elements mounted thereto. The jaw elements pivot between a closed position wherein the jaw elements abut one another and support a fastener and an open position wherein the jaw elements are pivoted away from one another by the fastener driven therethrough. The jaw elements are mounted to the cradle by pivot pins.
[0018] Preferably, an upper guide is mounted to the cradle. The upper guide is movable between a loading position that corresponds to the closed position of the jaw elements and a driving position that corresponds to the open position of the jaw elements. The upper guide includes a locking member for interfering with pivoting of the jaw elements when the upper guide is in the loading position and for disengaging from the jaw elements when the upper guide is in the driving position.
[0019] The jaw elements are configured each defining one-half of a cone. When together, the jaw elements define a nadir. In a current embodiment, the nadir extends through the cradle opening beyond the upper inside surface, so that the nadir rests on a desired location (e.g., “falls” into a roof panel hole).
[0020] Alternately, the cradle is formed having a viewing opening formed in at least one of the legs. An aligning marker can be formed as a stylus that extends inwardly of the viewing opening or as indicia on the one of the legs.
[0021] These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0022] The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:
[0023] [0023]FIG. 1 is a front view, shown in partial cross-section, of a fastener driving tool embodying the principles of the present invention showing the tool in the retracted or loading position, in which the outer tube bearing is shown engaging the inner tube stop in phantom lines;
[0024] FIGS. 2 A- 2 C are partial, enlarged cross-sectional views of the fastener driving tool of FIG. 1, the partial figures shown for ease of illustration;
[0025] [0025]FIG. 3 is a front view of one embodiment of a nosepiece assembly for use with the fastener driving tool, which nosepiece assembly embodies the principles of the present invention;
[0026] [0026]FIG. 4 is a side view of the nosepiece assembly of FIG. 3;
[0027] [0027]FIG. 5 is a cross-sectional view of the nosepiece assembly taken along line 5 -- 5 of FIG. 4;
[0028] [0028]FIG. 6 is a side view of another nosepiece assembly illustrating and alternate nosepiece cradle; and
[0029] [0029]FIG. 7 is a front view of the cradle of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
[0030] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed and claimed herein.
[0031] Referring now to the figures and in particular to FIG. 1, there is shown a fastener driving tool 10 embodying the principles of the present invention. The tool 10 includes, generally, a driver 12 such as the illustrated electric, rotating driver 12 . An outer, upper tube 14 is fixedly mounted to the driver 12 by, for example, the exemplary illustrated clamp 16 . The upper tube 14 is mounted to the driver 12 at a driver cap assembly 18 .
[0032] A lower, inner tube 20 is telescopically mounted to the upper tube 14 . The lower tube 20 slides freely within a lower portion of the upper tube 14 , as will be described in more detail below. A bottom or distal end 22 of the lower tube 20 terminates at a juncture, as indicated at 24 , with a feed tube 26 . The feed tube 26 is mounted to the lower tube 20 for feeding individual fasteners F through the feed tube 26 into the distal end 22 of the lower tube 20 . A nosepiece assembly 28 is mounted to an end 30 of the tool 10 at about and adjacent the juncture 24 of the feed tube 26 and lower tube 20 . The nosepiece assembly 28 supports the fasteners F as they are fed into the lower tube 20 and are driven from the tool 10 .
[0033] A driver shaft 32 extends from the driver 12 through the upper and lower tubes 14 , 20 . A bottom end of the driver shaft 32 includes a fastener engaging element 34 , such as the illustrated hexagonal socket-like element for engaging the fastener F head. When the tool 10 is in the retracted (i.e., loading) state, as seen in FIGS. 1 and 2A, the fastener engaging element 34 extends just beyond the distal end 22 of the lower tube 20 . This positioning facilitates loading the fastener F. When the tool 10 is in the contracted (i.e., driving) state, the fastener engaging element 34 extends into the nosepiece assembly 28 to drive the fastener F from the tool 10 into the workpiece.
[0034] A driver shaft guide 36 is positioned at and mounted to an upper end 38 of the lower tube 20 . The guide 36 includes an inner circumferential shoulder 40 . A driver shaft bearing 42 is mounted on the inner shoulder 40 providing a bearing surface for the driver shaft 32 . The guide 36 further includes an outer shoulder 44 at an outer periphery, generally opposing the inner shoulder 40 . A spring 46 is positioned and extends between the outer shoulder 44 and the driver cap assembly 18 . The spring force is exerted against the lower tube 20 (by connection to the guide 36 ) and the driver cap 18 , thus biasing the tubes 14 , 20 into the retracted state. In a current embodiment, the guide outer shoulder 44 includes a spring seat bearing 48 for engaging the spring 46 . The spring seat bearing 48 includes an upper tube bearing surface 50 for slidingly engaging the upper tube 14 .
[0035] In a present embodiment, the driver shaft guide 36 , driver shaft bearing 42 and outer shoulder portion/spring seat bearing 44 / 48 , including the outer tube bearing surface 50 , are formed from a suitable, low friction polymeric material, such as DELRIN®, which is commercially available from E. I. du Pont de Nemours and Company. DELRIN® is an acetal resin based material (more particularly polyoxymethylene) that exhibits numerous advantageous characteristics, including high tensile strength, impact resistance, and stiffness, as well as fatigue endurance, resistance to moisture and chemicals, dimensional stability and natural lubricity. Those skilled in the art will recognize other suitable materials for use in the present invention, which other materials are within the scope and spirit of the present invention.
[0036] As described above, the feed tube 26 is joined with the lower tube 20 at the distal end 22 of the lower tube 20 . As best seen in FIG. 2A, the feed tube 26 enters the lower tube 20 at an angle so that the fasteners F traverse smoothly from the feed tube 26 into the nosepiece 28 . Referring to FIG. 2B, a feed tube mount 52 is positioned on the lower tube 20 and secures the feed tube 26 to the lower tube 20 . The feed tube mount 52 includes a pair of fasteners 54 that extend through an opening 56 in the wall of the upper tube 14 and into the drive shaft guide 36 .
[0037] Unlike known fastener driving tools, the present tool 10 includes an upper tube bearing assembly 58 mounted to the upper tube 14 for guiding that tube 14 along the lower tube 20 . The bearing 58 is mounted to an outer surface 60 of the upper tube 14 and includes a sleeve portion 62 and a bearing portion 64 . In a current embodiment, the bearing portion 64 extends from an end of the sleeve portion 62 generally transverse thereto and contacts the lower tube 20 . In one configuration, the sleeve portion 62 is threadedly mounted to the upper tube 14 at threaded region 66 . In a present embodiment, the upper tube bearing 58 is also formed from an acetal resin, such as DELRIN(, or a like suitable, low friction material.
[0038] Referring now to FIGS. 1 and 2B, the bearing assembly 58 , shown cross-hatched, illustrates the bearing 58 when the tool 10 is in the retracted or loading position. The bearing assembly 58 shown non-cross-hatched at 58 a illustrates the bearing 58 when the tool 10 is in the contracted or driving position. It must also be noted that although the bearing assembly 58 appears to be of a split arrangement, it in fact is not. That is, the bearing halves symmetrically oppose one another and form a single bearing with a single, circular (not skewed or elliptical) bearing portion 64 .
[0039] The sleeve portion 62 includes an outer collar 68 having a groove 70 formed therein into which one or more pliable spheres 72 are fitted to maintain the sleeve portion 62 in a predetermined location along the upper tube threads 66 . In a current embodiment, the spheres 72 are also formed from a polymeric material, such as DELRIN® acetal resin. An O-ring 74 can be positioned around the spheres 72 to maintain the spheres 72 securely in place along the upper tube threads 66 .
[0040] As can be seen from FIGS. 1 and 2B, a gap 76 is defined between the upper and lower tubes 14 , 20 . The gap 76 spaces the tubes 14 , 20 from one another to prevent metal-to-metal contact between the tubes 14 , 20 . The gap 76 is maintained annular by the bearing portion 64 of the upper tube bearing assembly 58 (which is mounted to the upper tube 14 and contacts the lower tube 20 ) and the driver shaft guide 36 upper tube bearing surface 50 . In this manner, the upper and lower tubes 14 , 20 are maintained spaced from one another by a pair of longitudinally spaced, circumferential bearing surfaces 50 , 64 that assure that the tubes 14 , 20 are maintained concentric with one another along their lengths. In addition to the spacing provided, these bearing surfaces 50 , 64 provide low friction, non-binding movement of the tubes 14 , 20 relative to one another. This arrangement further assures that there is no metal-to-metal contact between the upper and lower tubes 14 , 20 during operation of the tool 10 .
[0041] Stops 76 are fixed to an outer surface of the lower tube 20 distally from the upper tube bearing 58 . The stops 76 cooperate with and engage the bearing portion or leg 64 of the upper tube bearing 58 to set a predetermined amount of travel d of the lower tube 20 relative to the upper tube 14 . The amount or distance of travel d is set by threadedly engaging the upper tube bearing 58 along the threaded region 66 of the upper tube 14 . This predetermined amount of travel d limits the travel of the driver shaft 32 and fastener engaging element 34 into the nosepiece 28 , and subsequently, the distance that the fastener F is driven out of the tool 10 into the workpiece. As will be appreciated from a study of the drawings, the distance that the fastener F is driven by the tool 10 is set by the distance or travel d between the upper tube bearing 58 and the stops 76 . As will also be appreciated by those skilled in the art, it is important that the fasteners F be driven into the workpiece surface (such as a roofing deck) a predetermined amount. Under-driving the fastener results in improperly securing the roof deck panels to one another, while over-driving the fastener can result in an improper seal between the fastener and the roof deck panels.
[0042] In a present tool 10 , the travel or distance d can be set between 3.125 inches and 3.625 inches. This corresponds to the depth to which commonly used roofing deck fasteners are specified to be driven. As set forth above, this travel is set by threadedly engaging or disengaging the upper bearing assembly 58 from the upper tube threads 66 . It will be recognized by those skilled in the art that variations can be made to the tool 10 to provide one or more different ranges of travel for the tool 10 , which other ranges are within the scope and spirit of the present invention.
[0043] Referring now to FIGS. 3 - 5 , there is shown one embodiment of a fastener receiving member or nosepiece assembly 28 embodying the principles of the present invention. The nosepiece assembly 28 is mounted to the fastener discharge end of the tool 10 at about the juncture 24 of the feed tube 26 and the lower tube 20 . The nosepiece 28 is configured to receive a fastener F and to guide and align the fastener F into proper position to be driven.
[0044] The nosepiece 28 includes a lower guide or cradle 80 , an upper guide 82 and a nosepiece tube 84 . The cradle 80 is configured to rest on the roof panel (as indicated at R in FIG. 4) to straddle a corrugation. The upper guide 82 and nosepiece tube 84 are fixedly mounted to each other. The nosepiece tube 84 inserts into the distal end 22 of the lower tube 20 and includes an elongated opening 86 in the side wall of the tube 84 that aligns with the feed tube 26 so that fasteners F fed from the feed tube F are directed into the nosepiece tube 84 . An O-ring 88 can be positioned on the nosepiece tube 84 , between the upper guide 82 and the lower tube distal end 22 to reduce rattle of the tool 10 during use.
[0045] The upper guide 82 and nosepiece tube 84 are mounted to the cradle 80 for reciprocal movement within the cradle 80 between a loading position and a driving position, which positions correspond to the loading and driving positions of the tool 10 , generally. A pair of springs 90 are disposed between the upper guide 82 and the cradle 80 to bias the upper guide 82 into the loading position.
[0046] A pair of opposing jaw elements 92 are pivotally mounted to the cradle 80 . The jaws 92 , when in a closed position, support the fastener F and when open, pivot outwardly to permit driving the fastener F into the workpiece (e.g., roof panel R). A pair of pivot pins 94 extend through the cradle 80 for pivotal movement of the jaws 92 .
[0047] The upper guide 82 , as set forth above, is mounted to the cradle 80 for reciprocal movement. A pair of elongated slots 96 are formed in the upper guide 82 , through which the pivot pins 94 traverse. In this manner, the upper guide 82 reciprocates within the cradle 80 , along the pivot pins 94 , independent of the jaws 92 .
[0048] The upper guide 82 further includes a pair of roll pins 98 mounted thereto that are configured to cooperate with the jaws 92 . The roll pins 98 move with the upper guide 82 to move into and out of interfering engagement with the jaws 92 . To this end, when the upper guide 82 is in a retracted position and the jaws 92 are closed, the roll pins 98 engage a camming shoulder 100 on each respective jaw 92 to maintain or lock the jaws 92 closed. When the upper guide 82 is urged downwardly to the driving position, the roll pins 98 are moved out of engagement with the camming shoulders 100 which permits the jaws 92 to pivot outwardly to open. The jaws 92 are, however, biased closed by a pair of return springs 102 . The force of the fastener F against an inner surface 104 of the jaws 92 urges the jaws 92 open when the roll pins 98 are disengaged from their respective jaw camming shoulders 100 . In this manner, the jaws 92 are maintained closed until they are “unlocked” by movement of the roll pins 98 off of the camming shoulders 100 (by downward force on the upper guide 82 ) and urged or forced open by the fastener F being driving through the jaws 92 , out of the nosepiece 28 and into the workpiece.
[0049] As can be seen from FIG. 5, the jaws 92 are configured having a split arrangement. Each half of the split jaw arrangement defines one-half of a downwardly oriented conical element 106 . The conical element 106 halves, when mated, terminate at a nadir 108 . The nadir 108 is disposed slighting below an upper inside surface 110 of the cradle 80 so that as the tool 10 is moved along the surface of the roof panel R, the nadir 108 will essentially drop into the preformed hole (if provided) in the roof panel R. As will be recognized by those skilled in the art, this provides rapid and sure tool 10 alignment over a desired location on the roof panel R.
[0050] The cradle 80 includes a central, main body portion 112 and a pair of legs 114 diverging downwardly and outwardly therefrom. The cradle 80 is configured to rest on and engage a corrugation of the metal roof panel R, with the upper inside surface 110 of the cradle 80 resting on the peak of the corrugation, the legs 114 extending downwardly along the sides of the corrugation, and the leg bases 116 resting on or in the valleys of adjacent corrugations. As such, the cradle 80 is held secure against the deck panel R corrugation. In this manner, the cradle 80 is self-centering along the corrugation peak.
[0051] The present cradle 80 provides for readily aligning the tool 10 along the corrugation peak so that the fasteners F are properly driven into the roof panel R. In use, the tool 10 is slid along the roof panel R with the cradle 80 engaging a corrugation peak. When traversing the tool along the roof panel R, it is in the loading condition with the tubes 14 , 20 and nosepiece 28 retracted. When the jaw nadir 108 “falls” into a roof panel R hole, the tool 10 is stood upright and a fastener F is fed into the feed tube 26 . The fastener F is fed by gravity to the nosepiece 28 . A downward pressure is then applied to the driver 12 handle. The downward pressure moves the upper and lower tubes 14 , 20 into the contracted or driving position which engages the fastener engaging element 34 with the fastener F head. Continued downward pressure urges the nosepiece assembly upper guide 82 down to “unlock” the jaws 92 . As further downward pressure is applied to the driver 12 handle and as the driver 12 is actuated, the fastener F is urged though the jaws 92 and is driven into the roof panel R.
[0052] Those skilled in the art will recognize that the types of metal roof systems available vary. To this end, not all roof panels are formed wit preformed openings along the panel corrugation peaks. As such, the present tool 10 can be use such that the nadir 108 is used to position the tool 10 along the corrugation peak, at a desired location on the roof panel R.
[0053] An alternate cradle 180 is illustrated in FIGS. 6 - 7 . This cradle 180 can be used with or without the nosepiece assembly illustrated in FIGS. 3 - 5 . The cradle 180 includes a central, elongated bore 182 through which the fastener F travels as it is driven from the tool 10 . As seen in FIG. 6, each of the legs 184 includes an opening or viewing window 186 therein. The viewing windows 186 each extend through inner and outer surfaces 188 , 190 of the legs 184 and through a portion of the main body 192 . To this end, when the cradle 180 is resting on a corrugation of the roof panel R the corrugation peak is readily visible through the viewing windows 186 . In addition, in that the present tool 10 is configured for use by an operator standing erect or relatively erect, the viewing window 186 is configured so that central portion of the corrugation peak is readily viewed by the operator standing slightly off-center of the tool 10 when it is positioned for use. As such, there is no longer a need for an operator to constantly crouch and stand while driving fasteners F into the roof deck R.
[0054] The cradle 180 is further provided with aligning markers 194 , such as styli or engraved indicia to align the cradle 180 and thus the tool 10 over the desired location on the panel R (e.g., over the preformed roof panel R holes). The styli 194 can be, for example, wire 196 mounted to the cradle legs 184 by screws, bolts or other mechanical fasteners, such as indicated at 198 . The aligning markers 194 permit properly visually aligning the tool 10 on the roof panel R (e.g., immediately above the roof panel R hole) to properly drive the fastener F. Similar to the cradle 80 illustrated in FIGS. 3 - 5 , this embodiment of the cradle 180 straddles the roof panel R corrugation and is thus self-centering over the roof panel R corrugation.
[0055] Those skilled in the art will recognize that a variety of different types of aligning markers 194 and aligning devices can be used to assure that the tool is properly aligned on the roof panel R. All such aligning devices are within the scope and spirit of the present invention.
[0056] In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.
[0057] From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A fastener driving tool includes a driver having a driver shaft extending therefrom, a first extension member operably connected to the driver and a second extension member operably connected to the first extension member. The tool is for use on roof deck panels. The second extension member slidingly engages the first extension member between a loading position and a driving position. A bearing assembly operably connects the first and second extension members. The bearing assembly is formed from a non-metallic, low-friction material. A portion of the bearing assembly is mounted to one of the first and second extension members for sliding engagement with the other extension member and is disposed to prevent direct contact of the first and second extension members with one another. A fastener receiving member is mounted to the second extension member for receiving fasteners when in the loading position and for supporting and releasing the fasteners when in the driving position. The fastener receiving member includes a cradle having a main body portion and a pair of legs extending from the main body portion diverging downwardly and outwardly. The cradle is configured for positioning on the roof panel, straddling raised portions of the panel for aligning the tool therealong. | 1 |
BACKGROUND OF THE INVENTION
The present invention generally relates to a slip clutch assembly and, in particular, relates to such an assembly wherein the rotated element remains subjected to a torque after the motive force is removed.
In general, a slip clutch is used when the applied force, usually rotational in nature, is not to exceed a preselected torque or when the rotation imparted to a member being rotated is not to exceed a particular angular distance.
One particularly demanding application of mechanisms of this nature is in the operation and control of optical elements such as those used in analytical instruments. A specific application is the redirecting of a precisely aligned light beam either by interposing a mirror in the path of the beam or by rotating a mirror from one angular position in the beam to a second angular position in the beam. In such precisely aligned arrangements it is important to avoid mechanically shocking the optical elements as this could easily result in substantial misalignment thereof.
A conventional system usually includes an electric motor solenoids and/or pneumatic cylinders. However, such systems are difficult to modulate and control. Such systems also frequently respond too rapidly and consequently impart mechanical shocks to the elements. Another commonly used mechanism includes the use of a combination of springs and switches. The springs are positioned in the drive train of the motor to maintain the rotated member in position after the motive force is removed by means of the switches. To date these latter mechanisms have been mechanically complex, expensive and quite difficult to adjust.
In view of the above, what is clearly needed is a slip clutch assembly which is inexpensive, mechanically simplified and accurate.
SUMMARY OF THE INVENTION
Accordingly, it is one object of the present invention to provide a slip clutch assembly which fully meets the above-recited criteria.
This object is achieved, at least in part, by a slip clutch assembly including a spring positioned on a rotatable mandrel, a torque applied to the mandrel is coupled to a driven plate via the spring until a preselected level of torque is reached.
Other objects and advantages will become apparent to those skilled in the art from the following detailed description read in conjunction with the appended claims and the drawing attached hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of slip clutch assembly of this invention being used to control the orientation of a mirror.
FIG. 2 is a cross sectional view of the slip clutch assembly in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A slip clutch assembly, generally indicated at 10 in the drawing and embodying the principles of the present invention, includes a mandrel 12 having a first portion 14 having a comparatively smaller diameter and a second portion 16 having a comparatively larger diameter. Preferably, but not necessarily, the first portion 14 constitutes one end 18 of the mandrel 12 and the second portion 16 constitutes the other end 20 thereof, a single shoulder 22 being formed at the interface of the first and second portions, 14 and 16, respectively. The second portion 16 is adapted to receive a shaft 24, which shaft 24, in the preferred embodiment, is connected to a motor 26 which rotationally drives the shaft 24 and hence the mandrel 12. The motor 26, and the direction of rotation thereof is preferably dictated by a conventional motor control means 28.
A spring 30, having an internal diameter less than the diameter of the first portion 14 of the mandrel 12, is positioned thereon. The ends 32, or tangs, of the spring 30 are arranged such that, when the spring 30 is placed on the mandrel 12 and viewed longitudinally, a gap 34 is formed therebetween. That is, the respective ends 32 of the spring 30 are angularly offset and extend away from the mandrel 12.
The assembly 10 further includes a member 36 having a pair of substantially flat, parallel and opposing faces, 38 and 40. A shaft 42 is provided on one face 38 of the member 36 and extends axially therefrom. The shaft 42 is, in the preferred embodiment, connected to an optical element 44 to be rotated and of a length and diameter that an intermediate shaft support 46 is unnecessary. The opposing face 40 of the member 36 includes a rod 48 extending therefrom. The rod 48 is affixed eccentrically such that it extends away from the face 40 at least the length of the spring and through the gap 34 formed by the tangs 32 thereof.
In one preferred embodiment, a brass block is machined using conventional techniques, to form a mandrel 12 having a first portion 14 length of about 0.8 centimeter and a second portion 16 length about 0.01 centimeter. The diameter of the first portion 14 being about 1.9 centimeters and the second portion 16 diameter being about 2 centimeters. A blind hole 50 is drilled in the end 20 of the second portion 16 to accept the motor shaft 24. Preferably, although not necessarily, the shaft 24 includes a flat, not shown, at the end penetrating the blind hole 50. A radial hole 52 is drilled and threaded to accept, for example, a 6/32 Allen head screw 54 to secure the shaft 24 to the mandrel 12.
The spring 30 consists, in this embodiment, of about 6 turns of 1.1 centimeter diameter spring wire having an unstretched inside diameter of about 1.8 centimeters. The spring 30 is wound such that the tangs 32 extend about 0.6 centimeter from the outside diameter of the spring 30 and are arcuately spaced apart, for example, by about 0.3 centimeters.
In the preferred embodiment, the member 36 is an aluminum lever about 2.3 centimeters long of rectangular cross-section. The shaft 42 and the rod 48 are spaced apart by about 1.3 centimeters and extend away from the faces, 38 and 40 respectively. Preferably, the axes of the shaft 42 and the rod 48 are parallel openings to accept the shaft 42 and the rod 48 may be formed using known machining techniques.
Alternatively, the member 36 can be a plate formed from an aluminum disk and can either include the shaft 42 as an integral part thereof or be adapted to accept such a separate shaft therein. In this embodiment, the disk is about 3.2 centimeters in diameter and the integral shaft 42 is machined to about 0.6 centimeter in diameter and cut to a length of about 1 centimeter. An eccentrically positioned opening 56 of about 0.3 centimeter diameter is formed to accept the rod 48 therein. The opening 56 is axially offset by a radial length of about 1.3 centimeters and the rod 48 inserted therein. The rod 48 is of a length such that about 1 centimeter thereof protrudes from the face 40 of the member 36. The diameter of the rod 48, in this example, about 0.3 centimeter, is chosen so that it longitudinally extends through the tangs 32 of the spring 30.
In one mode of operation the assembly 10 is mounted such that the driven shaft 42 extends through a baseplate 58 of an analytical instrument and connects to a beam-directing mirror 44 on the other side. The extent of rotation of the mirror 44 is controlled by stops 60, only one of which is shown. The stops 60 are positioned such that when the mirror 44 is driven against them a light beam is directed to two different paths.
In operation, the motor 26 is activated whereupon the mandrel 12 is rotationally driven by the motor shaft 24. Since the spring 30 is unextended, and tight about the mandrel 12, rotational force is transferred to the rod 48. Consequently, the inertia and friction of the member 36 and mirror 44 is overcome and the mirror 44 is rotated from a first position to a second position. When the mirror 44 reaches the second position the mechanical stops 60 is encountered. Although the motor control 28 is designed to shut the motor 26 off after, or about, this amount of rotation occurs, the motor 26 nevertheless continues to rotate under its own inertia. Consequently, even if the motor 26 is not shut off, for whatever reason, the mechanism is undamaged.
Once the stop 60 is encountered by the mirror 44 however, the rod 48 becomes fixed with respect to the spring 30. Thus, any further motor rotation causes the spring 30 to begin to unwind about the mandrel 12. The spring 30 will continue to unwind against the rod 48 until its inside diameter becomes larger than the outside diameter of the first portion 14 of the mandrel 12. At that point, the mandrel 12 rotates freely within the spring 30 until the motor 26 completely stops. Nevertheless, the spring 30 continues to exert a torque on the rod 48 and, by continuously trying to rewind, thus securely positions the mirror 44 against the stops 60, i.e., in its precise optical position.
The slip clutch assembly 10 described above is reversible. That is, the shaft 42 could be connected to the motor 26 and the shaft 24 connected to the driven optical element 44.
An additional advantage of the slip clutch assembly 10 is that it provides a flexible coupling between the motor 26 and the element 44 and thereby accommodates alignment tolerance therebetween.
Although the present invention has been described herein with respect to a specific embodiment, other arrangements and configurations will become apparent to those skilled in the art upon reading this specification. This description is considered exemplary in nature and not as limiting, hence the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof. | A slip clutch assembly includes a mandrel having a spring wound on a portion thereof. The spring effects torque transfer and, when further rotation is impaired, unwinds about the mandrel to prevent excessive torque transfer. Even after torque transfer is removed the driven element is securely positioned by the spring force. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates, in general, to equipment utilized in conjunction with operations performed in subterranean wells and, in particular, to an apparatus and method for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations.
BACKGROUND OF THE INVENTION
[0002] Without limiting the scope of the present invention, its background is described with reference to safety joints, as an example.
[0003] It is common practice in the wellbore drilling and completion arts to include a safety joint in a downhole tubular string to provide a point of separation in the tubular string such that the portion of the tubular string uphole of the safety joint can be retrieved to the surface while leaving the portion of the tubular string downhole of the safety joint in the wellbore. Safety joints are useful in a variety of circumstances. For example, safety joints are commonly used during the installation of certain tools, such as packers, in a wellbore. Similarly, safety joints are useful in allowing the recovery of a majority of the tubular string when an element of the tubular string below the safety joint become stuck or during fishing operations to recover a downhole element that was previously stuck in the wellbore, without the risk of sticking the entire recovery tubular string during the fishing operation.
[0004] Conventional safety joints have been operated using a variety of complicated or risky techniques. For example, certain safety joints have been operated by reciprocating the tubular string up and down while maintaining right-hand torque on the tubular string. In this design, the tubular string reciprocation and right-hand torque backs off a left-hand exterior threaded nut within the housing, which nut prevents the mandrel of the safety joint from coming free from the housing during normal tubular string movement. It has been found, however, that while this type of safety joint may be acceptable in some circumstances, there are occasions when the amount of right-hand torque which can be applied to a tubular string while reciprocating the string is limited by the ability of tools in the tubular string to withstand the required torque.
[0005] In another design, the safety joint is operated by neutralizing the weight of the tubular string at the location of the safety joint and rotating the tubular string to the right, which rotation backs off a left-hand exterior threaded nut within the housing. It has been found, however, that in certain wellbore configurations such as deep or deviated wellbores, torque does not transmit well along the tubular string such that the tubular string itself can be put under large amounts of force which can damage the tubular string.
[0006] In still other designs, the safety joint includes a release sleeve coupled to a mandrel with one or more shearable elements which must be parted by the application of a predetermined tensile or compressive force on the tubular string to enable the desired separation. It has been found, however, that the application of the required tensile or compression force on the tubular string elongates or compresses the tubular string prior to parting the shearable elements. Upon parting of the shearable elements, the tubular string violently recoils within the wellbore, which may cause damage to components in the wellbore or within the tubular string. In addition, it has been found, that during the recoil of the tubular string, the maximum allowable flowrate through certain components of the tubular string may be exceeded.
[0007] Accordingly, a need has arisen for an improved apparatus and method for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations. A need has also arisen for such an apparatus and method that enable separating the tubular string into two parts without the use of complicated or risky techniques. In addition, a need has arisen for such an apparatus and method that enable separating the tubular string into two parts without the need to perform rotations of the tubular string. Further, a need has arisen for such an apparatus and method that enable separating the tubular string into two parts without causing the tubular string to recoil due to tensile elongation.
SUMMARY OF THE INVENTION
[0008] The present invention disclosed herein is directed to an improved apparatus and method for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations. The apparatus and method of the present invention enable separating the tubular string into two parts without the use of complicated or risky techniques. Also, the apparatus and method of the present invention enable separating the tubular string into two parts without the need to perform rotations of the tubular string. In addition, the apparatus and method of the present invention enable separating the tubular string into two parts without causing the tubular string to recoil due to tensile elongation.
[0009] In one aspect, the present invention is directed to an apparatus for separating a downhole tubular string into two parts. The apparatus includes a receptacle having a profiled surface that is operably associated with a first part of the downhole tubular string. A mandrel is operably associated with a second part of the downhole tubular string. The mandrel is slidably positioned relative to the receptacle. A first sleeve having a profile is slidably positioned between the receptacle and the mandrel. The first sleeve is operable to be securably coupled to the mandrel in first and second positions relative to the mandrel. A second sleeve having a profile is also positioned between the receptacle and the mandrel. A first ring is slidably positioned between the profile of the first sleeve and the profiled surface of the receptacle. A second ring is slidably positioned between the profile of the second sleeve and the profiled surface of the receptacle. The first and second rings initially limit longitudinal movement of the receptacle relative to the mandrel in first and second directions.
[0010] Upon application of a predetermined longitudinal force between the mandrel and the receptacle, the receptacle engages the second ring such that the second ring engages the first ring which shifts the first sleeve from the first position to the second position and allows the second ring to slide off the profile of the second sleeve such that the receptacle engages the first ring, thereby limiting longitudinal movement of the receptacle in the first direction. Upon subsequent movement of the receptacle in the second direction relative to the mandrel, the receptacle engages the first ring such that the first ring slides off the profile of the first sleeve, thereby allowing longitudinal movement of the receptacle relative to the mandrel in both the first and second directions.
[0011] In one embodiment, the profiled surface of the receptacle may be formed in a radially increased portion of an inner surface of the receptacle. In another embodiment, the mandrel may include a radially reduced portion that is operable to receive the first and second sleeves. In yet another embodiment, the receptacle may be positioned to the exterior of the mandrel. In this and other embodiments, at least one seal may be positioned between the receptacle and the mandrel. In one embodiment, the first sleeve may be securably coupled to the mandrel in the first position with at least one shear pin and may be securably coupled to the mandrel in the second position with a retaining ring. In this and other embodiments, the first and second rings may be split rings that are radially outwardly biased when positioned respectively on the profiles of the first and second sleeves.
[0012] In another aspect, the present invention is directed to an apparatus for separating a downhole tubular string into two parts. The apparatus includes a receptacle having a profiled surface that is operably associated with a first part of the downhole tubular string. A mandrel is operably associated with a second part of the downhole tubular string. The mandrel is slidably positioned relative to the receptacle. First and second sleeves are slidably positioned between the receptacle and the mandrel and are operable to be securably coupled to the mandrel in first and second positions relative to the mandrel. The first and second sleeves each have a profile. First and second rings are slidably positioned respectively between the profiles of the first and second sleeves and the profiled surface of the receptacle. The first and second rings initially limit longitudinal movement of the receptacle relative to the mandrel in first and second directions.
[0013] Upon application of a predetermined longitudinal force between the mandrel and the receptacle, the receptacle engages the second ring such that the second ring engages the first ring which shifts the first sleeve from the first position to the second position and allows the second ring to slide off the profile of the second sleeve such that the receptacle engages the first ring, thereby limiting longitudinal movement of the receptacle in the first direction. Upon subsequent movement of the receptacle in the second direction relative to the mandrel, the receptacle engages the first ring such that the first ring slides off the profile of the first sleeve, thereby allowing longitudinal movement of the receptacle relative to the mandrel in both the first and second directions.
[0014] In a further aspect, the present invention is direct to a method for separating a downhole tubular string into two parts. The method includes operably associating a receptacle with a first part of the tubular string and a mandrel with a second part of the tubular string; initially limiting movement in first and second longitudinal directions of the receptacle relative to the mandrel within a range between first and second positions; applying a predetermined longitudinal force between the mandrel and the receptacle; shifting the receptacle in the first direction relative to the mandrel to a third position that is outside of the range; limiting further movement of the receptacle relative to the mandrel in the first direction beyond the third position; releasing the predetermined longitudinal force between the mandrel and the receptacle; and shifting the receptacle in the second direction relative to the mandrel to a fourth position that is within the range to enable longitudinal movement of the receptacle in both the first and second directions.
[0015] The operation of applying a predetermined longitudinal force between the mandrel and the receptacle may also include parting at least one shearable element, applying a tensile force between the mandrel and the receptacle or applying a compressive force between the mandrel and the receptacle.
[0016] In an additional aspect, the present invention is direct to a method for separating a downhole tubular string into two parts. The method includes operably associating a receptacle with a first part of the tubular string and a mandrel with a second part of the tubular string, the receptacle and the mandrel having first and second sleeves disposed therebetween; initially limiting longitudinal movement of the receptacle relative to the mandrel in first and second directions with first and second rings respectively positioned between profiles of the first and second sleeves and a profiled surface of the receptacle; applying a predetermined longitudinal force between the mandrel and the receptacle such as a tensile force or a compressive force; engaging the second ring with the receptacle to shift the first sleeve from a first position to a second position relative to the mandrel and to slide the second ring off the profile of the second sleeve such that the receptacle engages the first ring which limits longitudinal movement of the receptacle in the first direction; and moving the receptacle in the second direction relative to the mandrel to slide the first ring off the profile of the first sleeve, thereby allowing longitudinal movement of the receptacle in both the first and second directions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
[0018] FIG. 1 is a schematic illustration of an offshore oil and gas platform operating an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations according to an embodiment of the present invention;
[0019] FIG. 2 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a first configuration according to an embodiment of the present invention;
[0020] FIG. 3 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a second configuration according to an embodiment of the present invention;
[0021] FIG. 4 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a third configuration according to an embodiment of the present invention;
[0022] FIG. 5 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a fourth configuration according to an embodiment of the present invention;
[0023] FIG. 6 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a fifth configuration according to an embodiment of the present invention;
[0024] FIG. 7 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a sixth configuration according to an embodiment of the present invention; and
[0025] FIG. 8 is a cross sectional view of an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string during downhole operations in a seventh configuration according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
[0027] Referring initially to FIG. 1 , an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string being deployed from an offshore platform is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over submerged oil and gas formation 14 located below sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 , including blowout preventers 24 . Platform 12 has a hoisting apparatus 26 , a derrick 28 , a travel block 30 , a hook 32 and a swivel 34 for raising and lowering pipe strings, such as a tubular string 36 .
[0028] A wellbore 38 extends through the various earth strata including formation 14 . Wellbore 38 includes casing that is cemented within wellbore 38 by cement 42 . Disposed within the lower portion of wellbore 38 as part of tubular string 36 is a tool string 44 including a variety of tools such as safety devices, flow control devices, sand control screens, packers and the like that are used to complete the well. In addition, tubular string 36 includes a safety joint 46 that provides a point of separation in tubular string 36 such that an upper portion 48 of the tubular string 36 can be retrieved to the surface while leaving a lower portion 50 of tubular string 36 downhole. Safety joint 46 may be used to disconnect upper portion 48 from lower portion 50 after the installation of tool string 44 or in the event a tool within tool string 44 become stuck in wellbore 38 prior proper installation. In either case, safety joint 46 may be operated using a combination of compressive and tensile forces to disconnect upper portion from lower portion 50 as described in greater detail below.
[0029] Even though FIG. 1 depicts a deviated wellbore, it should be understood by those skilled in the art that the apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string of the present invention is equally well suited for use in wellbores having other directional orientations including vertical wellbores, horizontal wellbores, multilateral wellbores or the like. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward, uphole, downhole and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the uphole direction being toward the top or the left of the corresponding figure and the downhole direction being toward the bottom or the right of the corresponding figure. Also, even though FIG. 1 depicts an offshore operation, it should be understood by those skilled in the art that the apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string of the present invention is equally well suited for use in onshore operations.
[0030] Referring next to FIG. 2 , therein is depicted an apparatus for disconnecting an upper part of a tubular string from a lower part of a tubular string or safety joint 100 according to the present invention. Safety joint 100 includes a longitudinally extending, generally tubular receptacle 102 . Receptacle 102 includes a profiled surface 104 that is depicted as a radially increased annular portion 106 of the inner surface of receptacle 102 that defines an upper shoulder 108 and a lower shoulder 110 . Preferably, receptacle 102 is operably associated with the lower portion of the downhole tubular string in which safety joint 100 is a part. Even though FIG. 2 depicts receptacle 102 as a single tubular member, those skilled in the art will recognize that receptacle 102 could alternatively be formed from a plurality of tubular sections that are threadably or otherwise secured together.
[0031] Safety joint 100 includes a longitudinally extending, generally tubular mandrel 112 . Mandrel 112 includes a radially reduced annular portion 114 that defines an upper shoulder 116 and a lower shoulder 118 . Mandrel 112 includes an upper shear pin receiving groove 120 and a lower shear pin receiving groove 122 . Alternatively, mandrel 112 may have discrete shear pin receiving openings that may be individually threaded to receive shear screws therein. Mandrel 112 also includes an upper retainer ring receiving groove 124 and a lower retainer ring receiving groove 126 . Preferably, mandrel 112 is operably associated with the upper portion of the downhole tubular string in which safety joint 100 is a part. Even though FIG. 2 depicts mandrel 112 as a single tubular member, those skilled in the art will recognize that mandrel 112 could alternatively be formed from a plurality of tubular sections that are threadably or otherwise secured together.
[0032] Mandrel 112 includes a gland groove 128 that is operable to receive a sealing array 130 therein that provides a seal between mandrel 112 and receptacle 102 . In the illustrated embodiment, sealing array 130 includes a pair of oppositely disposed adaptor members 132 , 134 , a pair of upper back up rings depicted as V-rings 136 , 138 , a pair of lower back up rings depicted as V-rings 140 , 142 , and an energizing element depicted as O-ring seal 144 . It should be understood by those skilled in the art that the material or materials selected for the V-rings and O-ring is based upon factors such as chemical compatibility, application temperature, sealing pressure and the like. In addition, even though a particular sealing array has been depicted and described, those skilled in the art will understand that other sealing systems having a greater number of seal elements or a lesser number of seal elements could alternatively be used in conjunction with the present invention. Further, in certain embodiments of the present invention, no sealing array or seal is required.
[0033] Safety joint 100 includes a longitudinally extending, generally tubular upper sleeve 146 and a longitudinally extending, generally tubular lower sleeve 148 . Upper and lower sleeves 146 , 148 are slidably received around radially reduced annular portion 114 of mandrel 112 . As illustrated, upper sleeve 146 is secured to mandrel 112 via a plurality of shearable elements depicted as shear pins 150 that may be threadably received within a like number of openings that extend through the wall of upper sleeve 146 . Likewise, lower sleeve 148 is secured to mandrel 112 via a plurality of shearable elements depicted as shear pins 152 that may be threadably received within a like number of openings that extend through the wall of lower sleeve 148 . Upper sleeve 146 includes a retainer ring groove 154 that houses a retainer ring 156 . Lower sleeve 148 includes a retainer ring groove 158 that houses a retainer ring 160 . Upper sleeve 146 includes an annular profile 162 that defines an annular shoulder 164 . Lower sleeve 148 includes an annular profile 166 that defines an annular shoulder 168 .
[0034] Safety joint 100 includes an upper ring 170 and a lower ring 172 . Upper ring 170 is positioned on profile 162 of upper sleeve 146 . Lower ring 172 is positioned on profile 166 of lower sleeve 148 . Preferably, upper ring 170 and lower ring 172 are in the form of C-rings or split rings and are biased outwardly when positioned on profile 162 and profile 166 , respectively and have a free configuration that is sized to be tight around mandrel 112 for the reasons discussed below. As illustrated in FIG. 2 , upper ring 170 and lower ring 172 are also received within profiled surface 104 of receptacle 102 . In this configuration, upper ring 170 and lower ring 172 limit the longitudinal travel of receptacle 102 relative to mandrel 112 within a predetermined range. Specifically, receptacle 102 can travel between the point at which shoulder 108 contacts upper ring 170 and the point at which shoulder 110 contacts lower ring 172 . In the illustrated embodiment, further downward travel of receptacle 102 relative to mandrel 112 is prevented by shear pins 152 due to contact between upper ring 170 and lower ring 172 . Likewise, further upward travel of receptacle 102 relative to mandrel 112 is prevented by shear pins 150 due to contact between lower ring 172 and upper ring 170 .
[0035] A first operating mode of safety joint 100 will now be described with reference to FIGS. 3-5 . As illustrated in FIG. 3 , weight is being applied from the surface which has caused mandrel 112 to move downhole relative to receptacle 102 such that lower ring 172 has come in contact with or been engaged by shoulder 110 of receptacle 102 . In this configuration, application of a predetermined compressive longitudinal force between mandrel 112 and receptacle 102 causes shear pins 150 to part due to the force of lower ring 172 on upper ring 170 . When shear pins 150 part, upper sleeve 146 is shifted in the uphole direction until upper sleeve 146 contacts shoulder 116 , as best seen in FIG. 4 . In this position, retainer ring 156 snaps into retainer ring receiving groove 124 which prevents subsequent longitudinal movement of upper sleeve 146 .
[0036] During the initial movement of upper sleeve 146 , lower ring 172 slides along profile 166 until support thereunder is lost. Lower ring 172 then snaps into contact with mandrel 112 . In this configuration, lower ring 172 no longer limits longitudinal travel of receptacle 102 relative to mandrel 112 . The longitudinal travel of receptacle 102 relative to mandrel 112 in the uphole direction outside of the initial range is allowed but the extent of the travel is now limited by upper ring 170 due to the engagement of shoulder 110 of receptacle 102 with upper ring 170 . In this manner, any compression in the tubular string during the operation of safety joint 100 will not result in recoil of the tubular string as the distance receptacle 102 can travel relative to mandrel 112 is limited.
[0037] Once safety joint 100 is in the configuration depicted in FIG. 4 , the weight from the surface can be reduced in a controlled fashion to allow decompression of the tubular string. Continued movement of mandrel 112 in the uphole direction now causes shoulder 108 of receptacle 102 to come in contact with or engage upper ring 170 once receptacle 102 returns to a position within its initial longitudinal range relative to mandrel 112 . This contact causes upper ring 170 to slide along profile 162 until support thereunder is lost. Upper ring 170 then snaps into contact with mandrel 112 , as best seen in FIG. 5 . In this configuration, neither upper ring 170 nor lower ring 172 limits longitudinal travel of receptacle 102 relative to mandrel 112 . As such, mandrel 112 and the upper portion of the tubular string can be retrieved uphole or to the surface while leaving receptacle 102 and the lower portion of the tubular string in position in the wellbore.
[0038] A second operating mode of safety joint 100 will now be described with reference to FIGS. 6-8 . As illustrated in FIG. 6 , the upper portion of tubular string is being raised from the surface which has caused mandrel 112 to move uphole relative to receptacle 102 such that upper ring 170 has come in contact with or been engaged by shoulder 108 of receptacle 102 . In this configuration, application of a predetermined tensile longitudinal force between mandrel 112 and receptacle 102 causes shear pins 152 to part due to the force of upper ring 170 on lower ring 172 . When shear pins 152 part, lower sleeve 148 is shifted in the downhole direction until lower sleeve 148 contacts shoulder 118 , as best seen in FIG. 7 . In this position, retainer ring 160 snaps into retainer ring receiving groove 126 which prevents subsequent longitudinal movement of lower sleeve 148 .
[0039] During the initial movement of lower sleeve 148 , upper ring 170 slides along profile 162 until support thereunder is lost. Upper ring 170 then snaps into contact with mandrel 112 . In this configuration, upper ring 170 no longer limits longitudinal travel of receptacle 102 relative to mandrel 112 . The longitudinal travel of receptacle 102 relative to mandrel 112 in the downhole direction outside of the initial range is allowed but the extent of the travel is now limited by lower ring 172 due to the engagement of shoulder 108 of receptacle 102 with lower ring 172 . In this manner, any tensile elongation of receptacle 102 and the portion of the tubular string therebelow during the operation of safety joint 100 will not result in recoil of the tubular string as the distance receptacle 102 can travel relative to mandrel 112 is limited.
[0040] Once safety joint 100 is in the configuration depicted in FIG. 7 , the tensile force from the surface can be reduced in a controlled fashion to allow the tubular string to return to its unstressed state. Continued movement of mandrel 112 in the downhole direction now causes shoulder 110 of receptacle 102 to come in contact with or engage lower ring 172 once receptacle 102 returns to a position within its initial longitudinal range relative to mandrel 112 . This contact causes lower ring 172 to slide along profile 166 until support thereunder is lost. Lower ring 172 then snaps into contact with mandrel 112 , as best seen in FIG. 8 . In this configuration, neither upper ring 170 nor lower ring 172 limits longitudinal travel of receptacle 102 relative to mandrel 112 . As such, mandrel 112 and the upper portion of the tubular string can be retrieved uphole or to the surface while leaving receptacle 102 and the lower portion of the tubular string in position in the wellbore.
[0041] While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments. | An apparatus for separating a downhole tubular string into two parts. The apparatus includes a receptacle operably associated with a first part of the downhole tubular string and a mandrel operably associated with a second part of the downhole tubular string. First and second sleeves each having a profile are slidably positioned between the receptacle and the mandrel and are operable to be securably coupled to the mandrel in first and second positions relative to the mandrel. First and second rings are respectively positioned between the profiles of the first and second sleeves and the profiled surface of the receptacle. The first and second rings are operable to initially limit longitudinal movement of the receptacle relative to the mandrel, to prevent tubular string recoil during operation and to allow longitudinal movement of the receptacle relative to the mandrel after operation. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to apparatus for monitoring the feeding of a sliver or band of fiber in a spinning machine.
2. Description of the Prior Art
In the event of a break of a fiber sliver or band in an open-ended (OE) spinning frame, or if the sliver should run out, several meters of yarn, or thread, of very different relative count or number may be spun, because the oncoming remaining sliver does not have the normal number or count. In most cases, the fiber sliver is narrower at the location of the break therein. The operator or servicing personnel would then have to pull off several meters of spun yarn or thread from the take-up coil or bobbin, in order to ensure that the section of yarn or thread with the wrong count is removed.
Generally, in open-ended or OE spinning frames having a device which automatically corrects or repairs yarn or thread breaks, a suction nozzle is used to search for the end of the yarn or thread on the take-up bobbin, and approximately one meter of yarn is withdrawn therefrom. In the case of a break in the spun yarn caused by a break in the fiber sliver, in order to ensure that the entire length of incorrect count is withdrawn, the device for correcting or repairing the yarn break usually removes a very long length of yarn. This would be unnecessary, in most cases, however.
SUMMARY OF THE INVENTION
It is therefore an object of the invention of the instant application to provide such a device which avoids the difficulties that occur as a result of a break in the fiber sliver or band and to shorten the time lost due to a failure in the feeding operation.
With the foregoing and other objects in view, there is provided in accordance with the invention, a device for monitoring the feeding of a fiber sliver in a spinning machine having means for feeding the fiber sliver thereto and means for loosening the fibers of the sliver prior to spinning the fibers into a thread, comprising means for detecting the presence and absence of the fiber sliver at a location forward of the fiber-loosening means along a path of travel of the fiber sliver from the means for feeding the fiber sliver to the means for loosening the fibers of the sliver.
In accordance with another feature of the invention, the fiber-loosening means have an inlet for the fiber sliver being fed thereto, and the sliver detecting means are located a distance at least equal to a staple length of the fibers of the sliver from the inlet of the fiber-loosening means.
In accordance with a further feature of the invention, the device includes means for stopping the feeding of the fiber sliver upon detection of the absence of the fiber sliver by the sliver detecting means.
In accordance with an added feature of the invention where the spinning machine is located at a winding station, the fiber-feed stopping means is a shut-off device for the winding station.
In accordance with an alternate feature of the invention, the fiber-feed stopping means is a shut-off device for the fiber loosening means.
As soon as the detecting means has ascertained or sensed that the fiber sliver is no longer present, the feeding of the fibers is immediately interrupted or the spinning station is stopped.
As mentioned hereinbefore, spinning frames or machines are known which contain a device for automatically correcting or repairing a break in the spun yarn or thread. A yarn or thread break can also be caused by a preceding break in the incoming fiber band or sliver. In such a case, an attempt by the automatic device to repair the yarn or thread break could not, therefore, be successful. In order to prevent beforehand the making of such an unsuccessful attempt, there are provided in accordance with a further feature of the invention, means operatively connected to the sliver detecting means for indicating the detection of the absence of the fiber sliver by the sliver detecting means.
As an alternate feature of the invention, the spinning machine further includes means for spinning the loosened fibers of the sliver into a thread, means for detecting the presence and absence of the thread being spun by the spinning means, and means for automatically repairing a break in the thread, and the device includes means operatively connected to the sliver detecting means for preventing operation of the automatic repairing means upon the detection of the absence of the fiber sliver by the sliver detecting means.
In accordance with yet another feature of the invention, both the means for preventing operation of the automatic repairing means, as well as the means for indicating the detection of the absence of the fiber sliver by the sliver detecting means are operatively connected to the sliver detecting means.
The indicating device thus immediately signals a break in the incoming fiber sliver, so that it can be corrected or repaired optionally either manually or automatically.
After the fiber sliver break has been corrected or repaired, the thread is joined again as fast as possible and the thread or yarn break is thereby eliminated.
In accordance with yet a further feature of the invention, the device includes means for manually initiating operation of the means for automatically repairing a break in the thread, and means for repetitively operating the automatic repairing means.
In accordance with a concomitant feature of the invention, the device includes means for actuating the means for preventing operation of said automatic repairing means after recurrence of a predetermined number of repetitive unsuccessful operations of the automatic repairing means.
Repetition of the joining attempts accelerates the resumption of the normal operation of the spinning station. Experience has found that the thread or yarn joining operation is not always successful on the first attempt. If the joining of the thread is not successful after five attempts at most, it must be assumed that a fault probably exists which can only be determined and corrected after thorough inspection. The joining attempts are therefore then again interrupted and a trouble indicator is energized.
Special advantages that are obtainable with the invention are that the production of yarn of incorrect number or count is prevented by the device of the invention if there should be a failure in the feeding of the fiber sliver or band. Unsuccessful joining attempts of an automatic thread joining device are also avoided, and the interruption of the operation of the spinning machine due to the failure of the fiber sliver feed is kept as short as possible.
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 an apparatus for monitoring sliver feed in a spinning machine, 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.
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, in which:
FIG. 1 is a diagrammatic sectional view of a spinning station of an open-ended (OE) spinning machine or frame equipped with a device for monitoring sliver feed in accordance with the invention;
FIG. 2 is a diagrammatic side elevational view of an open-ended (OE) spinning machine and winding unit with a traveling carriage for a joining device for automatically correcting or repairing breaks in the thread or yarn spun by the spinning machine and showing the spinning station of FIG. 1 in reduced scale; and
FIG. 3 is an electric circuit diagram of the system for operating the device of the invention in cooperation with the spinning and winding units and the joining carriage.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing and first, particularly to FIG. 1 thereof, there is shown a spinning station wherein a fiber band or sliver of relatively fine loosely packed fibers or filaments 1 is transported between a claimping table 2 and the drawing-in or feed roller 3 to an opening or loosening-up cylinder 4 and is loosened or broken up by the latter. The individual fibers enter a rotor 6 through a fiber guide channel 5. A thread is then formed in the rotor 6 and is withdrawn through a withdrawal tube 7, so that it can be wound on a non-illustrated take-up device. The sliver 1 is pulled out of a supply container, now shown in FIG. 1 but shown at the bottom of FIG. 2, and is led between a pair of rollers 8 and 9. The roller 8 is firmly connected to the spinning machine and can be driven with the same peripheral velocity as that of the feed roller 3. The roller 9 is articulatingly mounted or hinged by a lever 10. The lever 10 has a projection or extension arm 11 which acts upon a switch 12. If no sliver or fiber band passes any longer between the rollers 8 and 9, the roller 9 pivots into engagement with the roller 8, and the switch 12 is accordingly closed due to the depression of a push button by the arm 11. The switch 12 forms part of the system shown schematically in detail in FIG. 3, which controls the loosening-up device 3, 4, 5.
The sliver or roving 1, for example, has a thickness or diameter of about 3 to 5 cm. The distance between the rollers 8, 9 on the one hand, and the feed roller 3, on the other hand is advantageously at least equal to the staple length of the fibers of the sliver 1, for example substantially 3.8 to 15.2 cm. Although not specifically shown in the figures, the distance between the sensing roller 9 and the feed roller 3 may be readily adjustable by any conventional means to accommodate slivers having fibers of varying staple lengths.
It is furthermore noted, that if a break were to occur in the sliver 1, it would usually not be a "clean" break but one wherein part of the trailing length of the sliver 1 remaining secured by the roller 3 would have a reduced fiber count. Consequently if the distance between the rollers 8, 9, on the one hand, and the feed roller 3, on the other hand, were less than the staple length, part of the trailing length of reduced fiber count would travel beyond the roller 3 and into the region of the loosening-up cylinder 4 before shut-down of the sliver feed would occur. However, by providing a length at least equal to the staple length of the fiber of the sliver, the portion having a reduced count would remain accessible for removal upstream of the feed roller 3 in travel direction of the sliver 1.
FIG. 2 is a diagrammatic simplified side view of an open-ended (OE) spinning frame with a traveling device 51 for automatically repairing thread breaks. This traveling device 51 is hereinafter referred to as the piecing or joining carriage. Also shown in FIG. 2 is a spinning device 13, from which a thread 14 is drawn by a withdrawal cylinder 15 in cooperation with a pressure roller 16. The thread 14 runs over a deflecting wire 17 and a thread guide 18 onto a cross-wound coil or cheese 19. The cross-wound coil 19 is driven by a winding cylinder or roller 20. The joining carriage 51 travels back and forth in front of the individual spinning and winding stations of a textile machine. The essential operating elements of the joining carriage 51 are a suction nozzle 21, which, upon the occurrence of a break in the thread, withdraws the thread from the cross-wound coil or bobbin 19; a reversing or return motion roller 22, which drives the cross-wound bobbin 19 in unwinding direction during the thread-seeking operation; and a conventional thread feeder arm 23, which brings the thread from the suction nozzle 21 to the thread delivery tube 7. A thread monitor 24 has a feeler which engages or rests against the running thread just above the opening of the thread delivery tube 7, as viewed in FIG. 2. When a thread break occurs, the feeler of the monitor 24 swings downwardly about its pivot to shut off a switch suitably connected to the drive mechanism for the feed roller 8 and thereby shuts off the feeding of the fibers. If a thread break is registered, voltage is applied to an electromagnetic actuator 25, so that a plunger or tappet 26, which is connected with the magnetic actuator 25, is moved to the left so as to be able to act upon a switch 27. A signal is thereby given to the joining carriage 51 that a thread break must be corrected at this spindle. An electromagnetic actuator 28 is carried by the joining carriage 51. Voltage is applied to this magnetic actuator 28 if the joining carriage 51 has made several unsuccessful joining attempts at the respective spindle, and further attempts at joining at this spindle are to be blocked. The electromagnetic actuator 28 moves a push rod 29 to the right-hand side as viewed in FIG. 2 so as to act upon a switch 30. By actuating this switch 30 so that the contact 55 engages the contact 56 (FIG. 3), the electromagnetic actuator 25 is deenergized and the signal light 31 is switched on. By pressing the button 32, the operator can cancel the trouble signal 31.
The interaction or cooperation between the joining carriage 51 and the spinning and winding unit is explained in greater detail with reference to the electrical circuit diagram as shown in FIG. 3.
That part of the circuit diagram of FIG. 3 shown above the dot-dash dividing line 52 belongs to the joining carriage 51 and that part of the circuit diagram located below the dividing line 52 to the spinning and winding unit. FIG. 3 shows further switching and operating elements in addition to those shown in FIGS. 1 and 2 and described in connection therewith.
When the switch 12 is closed by the arm 11 of the fiber sliver sensing device formed of the lever 10 and the roller 9 (FIG. 1), voltage to ground M is applied through a diode 34 to the electromagnetic coupling or control device 33, such as a solenoid. The feed roller 3 of the fiber loosening or break-up device 3, 4, 5 (FIG. 1) is thereby disengaged from the drive 50 thereof, so that the supply of the fiber sliver is halted. Simultaneously, voltage is applied also to the indicator lamp 31, which lights up to indicate the existence of trouble. No call-up of the joining carriage 51 is made in this case, since the switch 30 is connected through its contact 55 to the contact 56 by an operative connection or mechanical coupling represented by the broken line 59. Furthermore, a subsequent thread break signal cannot then switch on the electromagnetic actuator 25 through the switch 24.
In the event of a normal thread break without disturbance or disruption of the fiber sliver feed, the switch 12 remains open. The thread break signal is then applied through the thread monitor switch 24. As soon as the switch 24 is closed, the electromagnetic actuator 25 is energized through the closed switch 30 i.e. in the position thereof shown in FIG. 3, and the plunger 26 of the stationary spinning station is pushed forward. When the joining carriage 51 travels past the spinning station, the plunger 26 actuates the switch 27 of the joining carriage 51, as indicated by a broken line 57 which represents operative engagement therebetween. As soon as the switch 27 is closed, voltage is applied to the coil of a relay 37 through a diode 36, so that contacts 38 and 39 are closed. An electromagnetic actuator 42, such as a solenoid, is energized through the contact 39, and a bolt 53 of the actuator 42 is then moved into a detent 54 provided on the stationary spinning station, as shown in FIG. 2, and thereby locks the joining carriage 51 to the spinning station.
Simultaneously, a motor 41 forming part of the automatic mechanism of the joining carriage 51 is energized through the contact 38, the carriage 51 closing the automatic latching contact 40 through an operative connection or mechanical coupling 60, after a brief delay, so that the relay 37 remains energized even when the thread monitor or switch 24 is opened again. Opening of the switch 24 occurs when the thread feeder arm 23 has introduced the thread into the delivery tube 7, and fibers are being fed-in to be joined.
If the full program or cycle for a joining attempt has run its course in the joining carriage 51, the switch 40 then opens and when the joining attempt has been successful, the relay 37 releases. The contacts 38 and 39 are opened and the joining carriage 51 can travel farther along its travel path. If the joining attempt has not been successful, the mgnetic actuator 25 is then re-energized and the switch 27 is closed before the switch 40 is opened. This occurs because the switch 24 closes again after the thread feeder arm 23 has swung away from the delivery tube 7 and no thread is present to hold the feeler of the thread monitor or switch 24 in place. In that case, the automatic joining mechanism of the joining carriage 51 runs through another joining program or cycle. Each time the switch 27 is closed, a counting pulse is fed to a counter 43, and each time the line to the motor 41 is opened i.e. currentless, the counter 43 is reset.
As soon as the storage locations set in the counter 43 are cancelled i.e. after two to five joining attempts, the counter 43 transmits an output signal to the electromagnetic actuator 28 which causes the switch 30 to switch over from the contact 55, as shown in FIG. 3, to the contact 56 through the mechanical or operative connection represented by the broken line 58. Voltage is thereby applied to the signal light 31 through the switches 24 and 30. Illumination of the signal light 31 signals trouble.
As soon as the operator or servicing personnel has corrected the trouble, he depresses the button 32 to set the switch 30 manually back to engagement with the contact 55 so to reactivate the joining carriage 51 for the next joining operation.
In the event of a disturbance in the feeding of the fiber sliver, the joining carriage 51 is not summoned, since the switch 24 is not yet closed initially and the switch 30 is opened when the switch 12 is closed.
After the fiber sliver break is corrected or eliminated, the joining carriage 51 is summoned by the operator by pressing the button 32 of the switch 30, so that the electromagnetic actuator 25 is energized through the closed switches 24 and 30. Conversely, in the event of a thread break without any disruption of the fiber sliver feed, the feed roller or cylinder and, thus, the fiber sliver feed are stopped, because voltage is applied to the electromagnetic clutch 33 through the closed switch 24 and the diode 35.
The operation of all of the important components has been described in detail in connection with the invention because of the importance of the cooperation of the spinning station, the fiber sliver monitor system, the thread monitor system and the automatic joining device.
As noted hereinbefore, the invention is not limited to the described and illustrated embodiment, but rather, other embodiments are conceivable within the scope of the claims and other information furnished in the specification. | Device for monitoring the feeding of a fiber sliver in a spinning machine having a device for feeding the fiber sliver thereto and a device for loosening the fibers of the sliver prior to spinning the fibers into a thread includes a device for detecting the presence and absence of the fiber sliver at a location forward of the fiber-loosening device along a path of travel of the fiber sliver from the device for feeding the fiber sliver to the device for loosening the fibers of the sliver, the fiber-loosening device having an inlet for the fiber sliver being fed thereto, and the sliver detecting device being located a distance at least equal to a staple length of the fibers of the sliver from the inlet of the fiber-loosening device. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/678,830 filed May 5, 2005 and which is incorporated herein by reference.
BACKGROUND
[0002] 1 Field of the Invention
[0003] The invention relates to novel methods and instruments for evaluating the strength of human and animal bones.
[0004] 2. Related Art
[0005] Recent measurements of materials properties of bone have demonstrated that there is substantial deterioration of these properties with aging. For example, Nalla, Kruzic, Kinney, & Ritchie, have shown that the stress necessary to initiate cracks in the bone, the initiation toughness, decreases by 40% over 6 decades from 40 to 100 years in human bone even without diagnosed bone disease. Even more dramatically, the crack-growth toughness is effectively eliminated over the same age range [1] This recent research extends and supports earlier research that showed a significant deterioration in another materials property, fracture toughness, with age [2-11]. These measurements suggest that deteriorating materials properties of bone due to aging or disease may play a role in bone fracture risk in addition to the well known factors of decrease in bone mineral density and deterioration of micro architecture.
[0006] Fracture risk is now commonly assessed by measuring bone mineral density (BMD) through various techniques including dual energy x-ray absorptiometry, quantitative ultrasound and others. These techniques all measure properties of bone without inducing fracture at any length scale. They are generally believed to be incomplete measures of fracture resistance. This is especially true for young, healthy people, such as Army recruits, for whom these conventional measures of bone fracture risk have been found to be ineffective in assessing fracture risk during basic training [12]. Further, it is known that these measurements, though valuable, do not fully characterize fracture risk in elderly patients or in patients with osteoarthritis, osteoporosis or other bone disease.
[0007] Osteoporosis is a major public health concern according to the World Health Organization (WHO) [13]. While 50 million women worldwide suffer from the disease, osteoporosis and osteopenia (low bone mass) are frequently associated with increased age, but both diseases affect people in every stage of life, having a huge impact on people in the workforce. The economic burden of osteoporosis is expected to reach $131.5 billion by 2050 [14]. Healthcare costs in the United States currently exceed $15 billion annually for osteoporosis related treatment [15].
[0008] Osteopenia and osteoporosis are frequently asymptomatic and diagnosis is often not ascertained until a fracture has occurred or until a low bone mineral density (BMD) has been determined. The most significant complication of osteoporosis is fracture, often induced by trauma of a very low magnitude [16]. For many, a fracture may mean loss of mobility along with life quality and increased risk of mortality. Numerous interventions have been shown to reduce the risk of fracture in this population; however, despite the overwhelming number of patients falling into the fracture risk categories, facilities for evaluations are inadequate and only those evaluated as the highest risk are adequately tested and treated. The vast majority of those at risk are unevaluated, due to costs considerations [17].
[0009] Initially, most patients are subjected to assessment instruments that strive to identify those at risk of low bone mineral density OST (Osteoporosis Self Assessment Tool), SCORE (Simple Calculated Osteoporosis Risk Estimation), SOFSURF (Study of Osteoporotic Fractures) and OSIRIS (Osteoporosis Index of Risk) are representative of these and often are used by practitioners to determine those cases most in need of BMD measurements while simultaneously improving patient awareness of risk factors. Tests are based on body weight, age and several additional factors. While these tests have a high sensitivity (up to 90%) there are many limitations in accuracy specific to each individual [18].
[0010] A plethora of diagnostic Instruments are currently in use for assessing fracture risk in patients, focusing on decrease in bone mineral density and deterioration of micro architecture. Dual-energy x-ray absorptiometry (DEXA) has been used to clinically measure these factors. Bone mineral density currently remains the most widely accepted indicator of fracture risk and is also used for true diagnosis of osteoporosis. DEXA is most commonly accepted as the instrument of choice and is used as the main determinant in evaluating risk, but numerous drawbacks and limitations have been observed. Discrepancies between instruments may have a serious effect on the diagnosis and treatment of patients [19]. Additionally, patients with normal BMD may experience fractures while those with low BMD may be at low risk [18]. Criteria are based on World Health Organizations recommendations and T-Scores exhibit discrepancies depending on the assessment sites. While proposals recommended DEXA evaluations of the hip, a higher incidence of greater bone loss in the spine than in the hip 10 years prior to and shortly after menopause has been reported [20]. Improved functions used to evaluate BMD have been recommended to encompass the distinct periodicity of bone development: adolescence, adult stability and reduction with age [21]. BMD results often fail to adequately diagnose children with high fracture risk.
[0011] Quantitative Ultrasound (QUS) has been investigated to determine its usefulness as a diagnostic tool for BMD. The equipment is less expensive than DEXA and is radiation free. An osteoporosis and ultrasound study recruited women between the age of 55 and 79. A comparison was done between DEXA and QUS. Results showed good correlation in predicting future incidence of low trauma fractures [22]. While this instrument may be useful for healthy children and postmenopausal women, the high rate of precision errors and large discrepancies in results ascribed to the diametric variations in calcaneus regions bring its usefulness into question [23]. In another study, osteoporotic patients had a lower QUS than controls but there was a large overlap of values [24]. Calcaneus ultrasound may provide a method of assessment for children with osteopenia and with fragility fractures. K. T. Fielding's research indicates results in Z scores similar to those achieved with DEXA but with only a modest correlation [25].
[0012] Peripheral quantitative computed tomography (pQCT) has also been studied in hopes of finding a useful tool for establishing bone fracture risk and was found to be less sensitive than DEXA and determined as a poor assessment tool for discriminating those with fractures [26]. In another investigation, pQCT does seem to be a reliable tool for calculating bone Calcium concentrations [27].
[0013] Development of morphometric X-ray Absorptiometry was investigated for determining vertebral deformities. High variability in analysis was determined with inter-operator assessment and the precision of analysis declined relative to complexity of the vertebral shape [28].
[0014] X-Ray radiogrammetry used routinely in management of patients with distal forearm fractures has been tested as a means of determining BMD and found to be useful in these instances as an alternative to DEXA without requiring further irradiation [29] but is not considered as an alternative to DEXA for alternate diagnoses.
[0015] With the exception of pOCT and DEXA, which quantify calcium content as well as BMD, each of these instruments strives to quantify only bone mineral density. While this is a valuable tool in bone strength indication, it overlooks many other aspects of bone that may well be equally important in determining fracture resistance. Tissue quality along with the size, shape and architecture of bone all influence strength and fragility factors [30,31].
[0016] Blood tests are sometimes prescribed to evaluate other conditions that influence bone strength. These cover a wide range of activities from alkaline phosphatase and thyroid stimulating hormone to vitamin D and calcium levels. Many of these tests may be beneficial in diagnostics and in determining treatment protocols [32].
[0017] In recent years, the value of indentation techniques in the investigation of the mechanical properties of biological materials including bone, dentin and cartilage has been realized [5, 16, 33-42]. Intrinsic toughness characterizes the resistance of mineralized tissues to cracking and fracture. Indentation protocols offer a means to quantify both the toughness and hardness of the biomaterials [1]. Examinations of the dentin-enamel junction of teeth further confirm the value of indentation protocols for understanding crack propagation and fracture mechanics. Using a Vickers indentation instrument, Imbeni et al. were able to characterize how cracks propagate and where crack-arrest barriers appear. Toughness and hardness factors for the enamel, dentin and the interface between the two were quantified [43]. Vickers indentation testing would, however, be difficult on a living patient because of the need to image, at high resolution, the indentations and the cracks that propagate from the corners of the indentations.
[0018] Indentation instruments also currently exist that are designed for use under surgical conditions. One such instrument has been designed to measure the stiffness of cartilage through arthroscopic surgical control [44, 45]. Biomechanical property changes in articular cartilage are early indicators of degeneration in the tissues. A reduction in compressive stiffness of articular cartilage is related primarily to the reduction of proteoglycan content and early detection offers possibilities for treatment to arrest the conditions leading to the degenerative process [44]. A similarly designed instrument was used for measurement of structural properties of the cartilage present near the metacarpal bones in Equine species and the results correlated positively with glycosaminoglycan levels in the tissues [46]. An arthroscopic cartilage indenter has been recently used to detect cartilage softening as the early mechanical sign of degradation not yet visible to the eye [47].
[0019] Another instrument, the Osteopenetrometer, was designed for in vivo testing of trabecular bone during surgical procedures. This instrument was developed to characterize the mechanical properties of trabecular bone to obtain information relevant to reducing the problem of implant loosening following total knee arthroplasty [48]. The Osteopenetrometer involved penetrations of lengths of order 8 millimeters and widths of order millimeters in diameter at implant sites during surgery. The goal was to have large enough penetrations to average over many trabeculae inside the trabecular bone.
[0020] While each of these advances in technology and diagnostic instrumentation produce significant and valuable data toward accurate diagnosis of bone fragility and osteoporosis, they each require skilled technicians. The limitations of available equipment to assess the growing, aging population, and the high expense incurred when diagnostics are available make these tools prohibitive to many patients that are at high risk for fracture. There exists, to our knowledge, no instrument that can clinically measure the material properties of bone relevant to fracture risk in living subjects without surgical exposure of the bone, including removal of the periosteum. The need for an inexpensive diagnostic tool to assess fracture risk within the clinical environment seems clear. While many researchers are still trying to set standards for evaluations of BMD, many also acknowledge its limitations; such as, the uncertainty of applicability to those who have not yet reached their peak bone mass, and the need for adjustments to results based on anatomical location, bone geometry and ethnic background. There is a strong need for a diagnostic instrument with low cost and low labor requirements that can directly determine indications of fracture risk through microcrack inducement, to enable multitudes of “at risk” patients to receive preventative therapy before suffering a fracture.
SUMMARY OF THE INVENTION
[0021] The present invention overcomes the foregoing disadvantages by evaluating material properties of the bone through contact with a test probe. In particular embodiments, one can thereby measure the actual resistance of bone to fracture. A novel instrument is provided that assesses macroscopic bone fracture risk by measuring how resistant the bone is to microscopic fractures caused by a test probe inserted through the skin or other soft tissue and periosteum down to the bone. The microscopic fractures are so small that they pose negligible health risks: the volume of damaged bone can be on the order 0.01 cubic millimeter or smaller in current embodiments. The resistance of the bone to these microscopic fractures is a good indication of the resistance of the bone to macroscopic fracture. Thus, bone fracture risk is assessed by creating microscopic fractures in bone. The advantage of such an instrument is that it gives, with a very quick and inexpensive test, information about bone fracture risk that is not available from any existing instrumentation. This new diagnostic information can be used alone or to supplement the results from conventional diagnostics, such as bone mineral density.
[0022] Conceptually, the invention provides methods and instrumentation to assess bone fracture risk in a subject, comprising inserting a test probe through the periosteum and/or soft tissue of the subject so that the test probe contacts the subject's bone, and determining the resistance of the test bone to microscopic fracture by the test probe. The subject can be a living person or animal in a clinical setting where the test probe is inserted through overlying skin, or directly through the periosteum during an operation where the periosteum is exposed, or into a cadaver bone through both skin and periosteum or through soft tissue or only the periosteum, depending on the nature of the experiment. Similarly, the instrument could penetrate the endosteum if an interior surface of bone were surgically exposed. The instrument can also measure directly on bone surfaces that have been surgically exposed. The instrument can also measure directly on bone pieces that have been cut out of subjects, whether or not they are still covered with periosteum or endosteum. The test probe is inserted a microscopic distance into the bone to create one or more microscopic fractures in the bone. Bone fracture risk can be assessed by determining the extent of penetration, or it can be assessed by determining the resistance of the bone to penetration of the test probe.
[0023] In a preferred embodiment, the method further includes similarly inserting a reference probe so as to contact the subject's bone without the reference probe significantly penetrating the bone, to serve as a reference for determining the extent of insertion of the tip of the test probe. The test probe can be formed as a rod and the reference probe can be in the form of a sheath in which the test probe is disposed, the end of the sheath proximal the test probe tip serving as the reference. The test probe and reference probe can be sharpened asymmetrically to minimize lateral offset between the tip of the test probe and the tip of the reference probe.
[0024] In other embodiments, the test probe is sufficiently sturdy to resist deformation when penetrating the bone, while in still other embodiments, the test probe resists deformation when penetrating weak bone but is deformed by healthy bone. High deformation indicates bone that is fracture resistant, low deformation indicating bone that is at risk for fracture. The test probe can contain a stop surface to prevent penetration into the bone beyond a predetermined distance, facilitating quantification of the deformation.
[0025] The test probe can be a single use test probe that can be discarded after use by a patient, or by a physician, as can the reference probe. The test probe can be sterilized as can the reference probe. A manufacturer could supply single use combinations consisting of sterilized test probes with sterilized reference probes in a sterile package.
[0026] In still other embodiments, rearward motion of the test probe is resisted as the test probe is pulled out of the bone and the extent of resisting force is determined as a measure of resistance of the bone to fracture. Alternatively, or additionally, bone fracture risk is assessed by determining the force needed to insert the test probe into the bone, and a force versus distance parameter can be generated and correlated with fracture risk.
[0027] In particular embodiments, a diagnostic instrument for assessing bone fracture risk in a subject is provided, comprising a housing supporting a test probe constructed for insertion through the periosteum on a bone of a subject, whether or not through soft tissue or other overlying skin, for contacting the subject's bone, and means for evaluating a material property of the bone through contact with the test probe. The material property evaluated by the diagnostic instrument is one or more of:
[0028] (a) a mechanical property of the bone;
[0029] (b) the resistance of the bone to microscopic fracture by the test probe;
[0030] (c) a curve of the indentation depth into the bone versus force needed;
[0031] (d) indentation of the bone at a fixed force;
[0032] (e) indentation of the bone at a fixed impact energy;
[0033] (f) hardness of the bone;
[0034] (g) the elastic modulus of the bone;
[0035] (h) the resistance of the bone to fatigue fracture;
[0036] (i) the resistance to penetration of a screw into the bone;
[0037] (j) the rotary friction on the bone;
[0038] (k) a curve of the indentation depth vs. time after an impact;
[0039] (I) a curve of the force vs. time after impact to set distance;
[0040] (m) curves of the indentation depth vs. time for repetitive impacts;
[0041] (n) curves of the force vs. time for repetitive impacts; or
[0042] (o) the response of the bone to a series or combination of the above measurements.
[0043] The test probe is inserted a microscopic distance into the bone to create one or more microscopic fractures in the bone to enable the determination of one or more of:
[0044] (a) the extent of insertion of the penetrating end of the test probe into the bone;
[0045] (b) the resistance of the bone to penetration of the test probe; or
[0046] (c) the resistance of the bone to removal of the test probe after it penetrates the bone.
[0047] The diagnostic instrument can include a reference probe constructed for insertion through the periosteum, and any overlying skin or other soft tissue, to contact the bone without the reference probe significantly penetrating the bone, to serve as a reference for determining the extent of insertion of the tip of the test probe. The reference probe can be in the form of a sheath in which the test probe is disposed, the end of the reference probe being proximal the test probe tip serving as a reference. The test probe can be formed as a rod with its tip disposed to extend a maximum predetermined distance beyond the end of the reference probe. The test probe, which can be formed of tool steel or stainless steel (with the tip of the test probe formed of the same material as the shaft of the test probe, or of another material such as diamond, silicon carbide, or hardened steel), and the reference probe, which can be formed from a hypodermic needle, can each be tapered asymmetrically whereby to minimize lateral offset between the test probe tip and the reference probe tip, and are sufficiently sharp to penetrate the periosteum of the bone and any overlying skin or other soft tissue.
[0048] The diagnostic instrument can apply a fixed force of a first magnitude to the test probe to determine a starting position of the test probe relative to the reference probe, apply a fixed force of a second magnitude to the test probe, measure a change in position of the test probe relative to the reference probe, reduce the fixed force to the first magnitude, and record the change in the position of the test probe relative to the reference probe. The diagnostic instrument can further determine a force versus distance parameter for the inserted test probe by determining the force needed to insert the test probe a predetermined distance into the bone, and/or the distance the test probe inserts into the bone under predetermined force.
[0049] For example, the diagnostic instrument can include a load cell connected to the test probe for determining the force needed to insert the test probe said predetermined distance. To generate the force needed to insert the test probe a predetermined distance into the bone, a solenoid can be electromagnetically connected to a mounting pin, with the test probe connected to an end of the mounting pin, for generating the force. One or more springs can be disposed to oppose action of the solenoid.
[0050] The diagnostic instrument can include a linear variable inductance transducer having a core connected to the test probe for determining the distance the test probe inserts into the bone under a predetermined force. Other distance sensors can also be used. For current embodiments it is desirable for the distance sensor to have: 1) sensitivity down to roughly 1 micron, 2) range up to about 1 mm and 3) response time preferably a few milliseconds or faster. Distance sensors with these characteristics include optical distance sensors and capacitance sensors.
[0051] To insert the test probe, a rotating cam and a follower pin can be included, the cam having a surface operating on the follower pin, one end of the follower pin being in sliding contact with the cam surface, the other end of the follower pin being connected to the test probe. Other mechanisms to insert the test probe with a rotary motor include a motor-driven, ball screw or Acme screw to convert the rotary motion of the motor to linear motion. The Acme screw has the advantage that it can hold a load in a power off situation enabling measurements of force relaxation vs. time after an indentation to fixed depth. For repetitive cycling without reversing the motor direction, rotary to linear motion mechanisms such as piston mechanisms can be used. Other linear motion generators may also be used. For current test probe geometries the linear motion generator should supply forces up to 10 Newtons with a range of motion up to 1 mm. Sharper or smaller diameter test probes could use less force. Measurements of some pre-yield mechanical parameters such as elastic modulus could use much less, force, down to the milliNewton range. A disadvantage, however, of going to much smaller forces and indentation depths is that the properties of a smaller volume of bone is probed. Our tests to date have shown that it is desirable to have enough Volume to average over at least several osteons, which have typical diameters of order 0.2 mm, to reduce scatter in the measured data.
[0052] A guide for the test probe and reference probe can be mounted at the lower end of the housing, the guide and the reference probe being formed to removably connect to each other with aligned passageways through which the test probe extends. The reference probe itself can be removably mounted to the guide. For example, the guide can be formed with an externally threaded neck extending from its lower end, the reference probe being formed with an internally threaded opening about its passageway for threadably mounting to the neck of the guide. In a particular embodiment, the test probe is a single use, replaceable probe. In another particular embodiment, the test probe and reference probe are both single use, replaceable probes
[0053] The combination of test probe and reference probe can be provided as disposable, replaceable and, optionally, sterile, parts, as can the probe guide.
[0054] The diagnostic instrument of the present invention is distinct from previous instruments. It is designed to be used without the need to surgically expose the bone surface. The small diameter probe assembly is inserted through the periosteum and any overlying skin or other soft tissue, down to the bone. It is not necessary to expose or visualize the bone surface. It is also distinct from the OsteoSonic™, developed by Liebschner at Rice University, which uses acoustic waves to measure the structural integrity of bone without penetrating the skin with any sort of probe. The diagnostic instrument of the present invention is designed to probe not only pre-yield parameters like elastic modulus, but also post-yield parameters like toughness by actually creating yield in a small probed volume of the bone.
[0055] The diagnostic instrument of the present invention can also be operated with an oscillating force in addition to a slowly varying or static force. This can be accomplished, for example, by feeding a solenoid, a moveable coil in a permanent magnetic field such as used for loudspeakers or other devices for converting electrical current to mechanical force with an oscillating current plus a slowly varying current or static current. The resultant oscillating force can be read from a force sensor such as a load cell. The oscillating distance can be read from a distance sensor such as an LVDT. For higher frequency response, a faster distance sensor such as an optical sensor like the MTI-2000 Fotonic sensor can be used. The optical fiber probe of the sensor can be attached to the body of the instrument and can read the distance to a tab which is connected to the test probe. The amplitude or phase of the oscillating distance as a function of frequency and as a function of slowly varying or static force can be explored to increase diagnostic differentiation.
[0056] With a solenoid plus spring system for supplying the force there is nonlinearity and hysteresis in the force as a function of current because the force is a function not only of the current, but also of the position of the core in the solenoid. The nonlinearity and hysteresis cause an abrupt increase in force (rise time of order 1 millisecond) just after the force from the current in the solenoid becomes greater than the spring force. This abrupt increase in force creates an impact on the bone. Alternately an impact can be created with a moving coil, attached to the test probe, in permanent magnetic field such as used for loudspeakers. A plot of the distance into the bone that the test probe moves as a result of this impact vs. time is diagnostic. For example, if the current consists of a static current plus a triangle wave of current at frequencies of order 1 Hz and amplitude sufficient to create impacts at the 1 Hz frequency, then the slope of the distance vs. time plot just after the impact has distinguished baked from unbaked bone in some tests. The slope of the distance vs. time plot in the 10s of milliseconds after the impact was significantly less for the unbaked bone: by more than a factor of 5. This indicates that the unbaked bone impeded the repetitive insertion of the probe better than the baked bone in these tests. For this type of measurement it is necessary to use a distance sensor with faster time resolution than a typical LVDT. Hence we used an optical sensor, the MTI-2000 Fotonic sensor, in our tests. Any other fast distance sensors with the required 1) sensitivity, down to roughly 1 micron, 2) range, up to about 1 mm and 3) response time, preferably a few milliseconds or faster, could be used. Other examples of such sensors include optical lever sensors and capacitance sensors.
[0057] Finally, we note that the instrument that we describe here could be used to characterize materials other than bone. It could be used to characterize other tissues such as cartilage and skin. It could be used to measure materials properties of metals such as aluminarn alloys and copper alloys, plastics such as polymethylmethaicrylate and Teflon, wood, and ceramics. It has the advantage that it can be used as a hand held instrument to measure materials properties outside of testing labs. For example, it could be used to measure materials properties of aircraft wings to check for fatigue or welds on pipelines to check for embrittlement. Its narrow combination of test probe and reference probe would allow it to measure on surfaces inaccessible to other testing instruments such as durometers. Further, with a sharpened test probe and reference probe it could penetrate soft coatings such as rust or dirt or polymer coatings or corrosion layers or marine organic deposits to measure the properties of the underlying material. It could test pipes buried underground.
BRIEF DESCRIPTION OF DRAWINGS
[0058] FIGS. 1 a, b and c depict an assembly of test probe and reference probe as it is used in three stages of an embodiment of the invention;
[0059] FIG. 2 schematically depicts a generalized diagnostic instrument for a preferred embodiment of the invention;
[0060] FIGS. 3 a, b and c depict respectively front, side and rear views of a specific embodiment of the generalized diagnostic instrument of FIG. 2 ;
[0061] FIGS. 4 a - e depict (a and b) force versus distance curves obtained respectively on samples of unbaked and baked bovine bone, (c and d) distance versus time curves respectively on samples of unbaked and baked bovine bone, and (e) distance versus number of cycles on samples of unbaked and baked bovine bone, all using the diagnostic instrument of FIG. 3 ;
[0062] FIGS. 5 a and b depict (a and b) force versus distance curves obtained respectively on samples of age 19 human bone and age 59 human bone, using the diagnostic instrument of FIG. 3 ;
[0063] FIGS. 6 a - d depict (a and b) multiple force versus distance curves obtained respectively on samples of baked bovine bone and unbaked bovine bone through soft tissue, and (c and d) force versus number of cycles to a fixed distance obtained again respectively on samples of baked bovine bone and unbaked bovine bone through soft tissue, using the diagnostic instrument of FIG. 3 ;
[0064] FIG. 7 is a cross-sectional view of a combination of a test probe and a reference probe of this invention in accordance with another embodiment;
[0065] FIG. 8 is a cross-sectional view of a diagnostic instrument used in an embodiment of FIG. 2 ;
[0066] FIGS. 9 a - 9 g depict the penetrating ends of a variety of test probes that can be used in the invention;
[0067] FIGS. 10 a and b depict the penetrating ends of other test probes that can be used in the invention;
[0068] FIG. 11 depicts the penetrating end of still another test probe that can be used in the invention;
[0069] FIGS. 12 a - d depict various supports for diagnostic instrument embodiments that can be used in the invention;
[0070] FIGS. 13 a - d depict embodiments of the force generator that can be used in diagnostic instruments of this invention;
[0071] FIG. 14 depicts another embodiment of the invention;
[0072] FIG. 15 depicts top views of the slide rail and interconnecting flange used in the embodiment of FIG. 14 ;
[0073] FIG. 16 is a plan view of the test probe vice used in the embodiment of FIG. 14 ; and
[0074] FIG. 17 shows electronics used for operation of some diagnostic instruments of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0075] The following will first describe a preferred embodiment, followed by a number of alternative embodiments, all using the underlying principles of the invention.
Preferred Embodiment
[0076] The essential feature of the invention is a test probe, which is inserted through the periosteum and through any overlying skin or other soft tissue to contact a bone surface. Referring to FIGS. 1 a - c, the design concept for the diagnostic Instrument of this invention is that a probe assembly, consisting of a test probe 100 and a reference probe 102 is inserted through the periosteum of a bone and any overlying skin or other soft tissue of a living person, animal or cadaver so that it comes to rest on the surface of the bone. Three stages for an exemplary assembly of test probe 100 and reference probe 102 are shown in FIGS. 1 a - c. The test probe is inserted into the bone to measure material properties. With a sharpened test probe (for example, sharpened to half angles of order 11 degrees) it is possible to measure post-yield properties and detect irreversible changes in force vs. distance curves. The force vs. distance curves can be processed to give parameters such as: 1) maximum insertion distance, 2) maximum force reached and 3) change of these values after multiple cycles of insertion.
[0077] The test probe and reference probe can optionally be sharpened asymmetrically, as shown in FIGS. 1 a - c, to minimize the lateral offset between the tip of the test probe 100 and the tip of the reference probe 102 . This minimizes the zero offsets in force vs. distance curves that result from bone surfaces that are not completely perpendicular to the axis of the probe assembly. One can alternatively routinely use symmetrically sharpened probes when zero offsets in distance are unimportant, for example, when cycling under a fixed maximum force rather than to a fixed maximum distance, or when sensing the distance at a fixed threshold force and then inserting to a constant distance beyond the distance corresponding to the fixed threshold force. In that case, the test probe 100 can be formed from a rod of tool steel that is 0.5 mm in diameter tipped with a 5 degree to 90 degree cone. It slips inside a #21 syringe, with a specially sharpened end, that acts as the reference probe 102 .
[0078] An exemplary assembly consists of a sharpened high speed steel rod as the test probe 100 and a sharpened hypodermic needle, 22 gauge as the reference probe 102 . FIG. 1 a shows the probe assembly on the surface of the bone just before test probe insertion. Note that the tip of the reference probe 102 has been ground to have its tip close to the tip of the test probe 100 .
[0079] The distance the test probe 100 is inserted into the bone is measured relative to the position of the reference probe 102 on the surface of the bone. The force to insert and withdraw the test probe 100 is also measured. If the test probe is cycled deeply enough into the bone, typically over a few microns, there will be post-yield damage that can be sampled in subsequent cycles, which is shown in FIG. 1 c as a hole 104 remaining in the bone after the test probe is withdrawn.
[0080] FIG. 2 shows a generalized diagnostic instrument for the currently preferred embodiment. The test probe 200 is connected through a shaft 206 to an optional torque and angular displacement sensor 208 then to an optional torque generator 210 , then to an optional linear displacement sensor 212 , then to an optional force sensor 214 , and finally to an optional force generator 216 . The optional reference probe 202 is connected to the housing 218 that holds the sensors and generators. The housing 218 could be supported and positioned on the sample under test by a support. This does not exhaust the possibilities for measurement or actuation. For example, it is also possible to include an optional linear displacement generator such as shown, by example, in FIG. 3 and used to collect the data in FIG. 6 . As another example, a solenoid plus a fixed stop could be used to insert the test probe 200 to a fixed distance. The force vs. time after the insertion would have information about how the bone relaxed after the insertion. In this case the solenoid would generate a force, but as long as the force was larger than needed to insert the test probe 200 to the fixed distance, then it would act like a displacement generator: generating a fixed displacement. This functionality also exists in FIG. 3 . Thus the separation between force generator and distance generator is not always clear. Other additions could include a heater to heat the probe that could be wound around the shaft 206 .
[0081] FIG. 3 shows an enhanced example of the generalized diagnostic instrument shown in FIG. 2 . In addition to the components mentioned in FIG. 2 , an optional displacement generator 320 consisting of a motor 322 , a rotating horizontal cam 324 and a follower pin 326 held in contact with the cam 324 with two springs 328 . The motor can be translated laterally with a screw 344 and locked down with screws 346 to adjust the range of motion: the closer the axis of the motor 322 is to the axis of the follower pin 326 , the smaller the range of motion. Other embodiments can be constructed without the use of springs. For example, a ball screw or Acme screw can be used to convert the rotary motion of a motor to linear motion. The Acme screw has the advantage that it can hold a load in a power off situation enabling measurements of force relaxation vs. time after an indentation to fixed depth. For repetitive cycling without reversing the motor direction, rotary to linear motion mechanisms such as piston mechanisms can be used. One can sense force with a load cell, Futek model LSB200, acting as the optional force sensor 330 , and distance with a linear variable inductance transformer (LVDT), Macro Sensors model CD 375, acting as an optional distance sensor 332 . The diagnostic Instrument also has an optional force generator that cycles the test probe 300 into and out of the bone with forces generated by a solenoid 334 in combination with the two springs 328 . This combination provides positive forces for insertion, when the force from the solenoid 334 exceeds the force from the two springs 328 and it provides negative forces to pull the test probe out of the bone when the force from the solenoid is less than the force from the two springs. The two adjustable stops 348 , which are screws, prevent the solenoid from inserting the test probe too far into the bone. If it is desired to study the response of the bone to forces, then these screws 348 act only as safety devices—they are adjusted to stop the test probe 300 only well beyond the range that is actually probed. Alternately, 1) these screws can be adjusted to give a fixed indentation depth and 2) the current to the solenoid adjusted to be sufficient to insert the test probe 300 all the way until the stops 348 stop the indentation for all samples being tested. Then the response of all the samples to the same indentation can be monitored. In particular embodiments, one can eliminate either the force drive or the distance drive, the instrument operating with just one actuation system. The optional displacement generator 320 consisting of a motor 322 , a rotating horizontal cam 324 and a follower pin 326 held in contact with the cam 324 with two springs 328 can also serve another purpose. It can be used to adjust the initial position of the test probe 300 relative to the reference probe 302 for subsequent measurements with a force generator 216 such as the solenoid 334 . This adjustment can be made more precise if the motor 322 is a stepping motor, which makes it easier to rotate the cam 324 to a precise position that moves the follower pin 326 and the connected test probe 300 to precisely the desired position relative to the reference probe 302 . Alternately, in a diagnostic instrument that will have only an electromagnetic actuation system, the adjustment of the position of the test probe 300 relative to the reference probe 302 can be made with a screw or micrometer that pushes the follower pin 326 . This screw or micrometer can be mounted where the motor 322 would have been mounted; it replaces the motor 322 and cam 324 .
[0082] The force sensor 330 can be any appropriate commercial force sensor, such as an s-beam load cell connected to the follower pin 326 at its top end and to a connector 335 at its bottom end, which in turn is connected to the test probe 300 . the LVDT 332 is connected at its top end to the bottom end of the follower pin 326 . the bottom end of the LVDT 332 is connected to test probe by a connecting pin 336 .
[0083] For the embodiment of FIGS. 3 a - c, in which the force to pull sharpened test probes 300 out of the bone exceeds 1 Newton, one can clamp the test probe 300 to the connecting pin 336 with a collet 338 . The test probe 300 then passes through a guide 340 that can be screwed into and out of the body of the instrument to adjust the projection of the test probe 300 relative to the reference probe 302 . The reference probe 302 mounts on a mating neck 342 machined on the end of the guide 340 .
[0084] The diagnostic Instrument shown in FIG. 3 can be used in two different measurement modes: (1) force controlled or (2) distance controlled. In the first, the test probe gets inserted into the bone until a set force is reached and the measured parameter is the resulting insertion distance. In the second mode, the insertion force is increased until the test probe inserts a set distance. Corresponding to these two modes, the diagnostic Instrument can cycle the test probe into and out of the bone with two different actuation systems. One system, based on a solenoid, is most convenient for cycling to a fixed force. For this a current is supplied to the solenoid by a 0-2 A voltage controlled current source. For operation to a fixed force the current source supplies a current that increases to a fixed maximum. The other system, based on a motor and cam, is most convenient for cycling to fixed distance. As will be shown in the following examples, FIGS. 4 and 5 demonstrate the use of the solenoid system. FIG. 6 demonstrates the use of the motor and cam system.
[0085] It is-also possible to operate the diagnostic instrument shown in FIG. 3 with an oscillating force in addition to a slowly varying or static force. This can be accomplished, for example, by feeding the solenoid 334 with an oscillating current plus a slowly varying current or static current. The resultant oscillating force can be read from a force sensor 330 such as a load cell 330 . The oscillating distance can be read from a distance sensor, 332 , such as an LVDT. For higher frequency response, a faster distance sensor such as an optical sensor like the MTI-2000 Fotonic sensor can be used. The optical fiber probe of the sensor 350 can be attached to the body of the instrument and can read the distance to a tab 352 which is connected to the test probe 300 . The amplitude or phase of the oscillating distance as a function of frequency and as a function of slowly varying or static force can be explored to increase diagnostic differentiation.
[0086] With a solenoid, 1351 , plus spring, 1352 , system for supplying the force, such as in the embodiment in FIG. 13 , there is nonlinearity and hysteresis in the force as a function of current because the force is a function not only of the current, but also of the position of the core in the solenoid. The nonlinearity and hysteresis cause an abrupt increase in force (rise time of order 1 millisecond) just after the force from the current in the solenoid becomes greater than the spring force. This abrupt increase in force creates an impact on the bone. A plot of the distance into the bone that the probe moves as a result of this impact vs. time is diagnostic. For example, if the current consists of a static current plus a triangle wave of current at frequencies of order 1 Hz and amplitude sufficient to create impacts at the 1 Hz frequency, then the slope of the distance vs. time plot just after the impact can easily distinguish baked from unbaked bone. The slope of the distance vs. time plot in the 10s of milliseconds after the impact is significantly less for the unbaked bone: by more than a factor of 5. This indicates that the unbaked bone impedes the repetitive insertion of the probe better than the baked bone. For this type of measurement it is necessary to use a distance sensor with faster time resolution than a typical LVDT. Hence we used an optical sensor, the MTI-2000 Fotonic sensor, in our tests. Any other fast distance sensors with the required 1) sensitivity, down to roughly 1 micron, 2) range, up to about 1 mm and 3) response time, preferably a few milliseconds or faster, could be used. Examples of such sensors include optical lever sensors and capacitance sensors.
EXAMPLE 1
[0087] FIGS. 4 a - e show that the diagnostic instrument of this invention can discriminate between baked bovine bone and unbaked, control, bovine bone. This model system of baked vs. unbaked bone is very useful because baking is an easy way to degrade its fracture resistance. Differences in fracture properties become dramatic for bone baked at 250 degrees C. for 2.5 hours [4,49]. The bones are held in a small machinist's vices in a glass bowl that is resting on a simple spring scale on a lab jack. The lab jack is used to raise the scale, bowl, vice and bone until the bone contacts the probe assembly of the diagnostic instrument. The applied preloading force with which the reference probe contacts the bone can be set by continued raising of the lab jack until the desired force is read on the scale. This applied force will set the maximum force that can be used during the testing cycles. If the applied force is exceeded, the reference probe will lift off the bone.
[0088] The unbaked, control, bone resists penetration of the test probe better: the distance that the test probe penetrates at fixed force is smaller. The unbaked, control, bone also survives cycling better, i.e. repetitive loading to a fixed force. The maximum penetration that results from each cycle reaches a limit for the unbaked, control bone, while the maximum penetration continues to increase for the baked bone. Note that the maximum force for each cycle increases slightly, especially for the baked bone. This is because we are using open loop electronics that just cycles the current to a fixed maximum. The force from the solenoid is, however, dependent on not only the current, but also on the position of the ferromagnetic core in the solenoid coil. As the distance of penetration increases, the position of the core changes to positions that give slightly more force for the same current. Feedback on the measured force in a closed loop system that controls the current can stabilize the force.
EXAMPLE 2
[0089] FIGS. 5 a and b demonstrate that the diagnostic instrument can discriminate between the bone material properties of two individual humans that could be expected, based on previous investigations [1,4,50,51] to have different fracture properties because one is young, 19 years old, and one is elderly, 59 years old. The bone of the younger individual shows increased recovery upon retraction of the probe and requires more force to penetrate repeatedly to the same depth. Further, the maximum penetration distance that results from each cycle reaches a limit for the bone from the younger individual, while the maximum penetration distance continues to increase for the bone from the older individual even though the bone from the younger individual is cycled to a larger fixed force (7 vs. 5.5 Newton). This suggests that the bone from the older individual is less able to resist damage accumulation. Damage accumulation in the form of microcracks has been associated with increased fracture risk [52-55]. Because of the small number of samples, we cannot, however, statistically conclude that that a significant difference has been demonstrated between the bone material properties of bone from younger vs. older individuals.
EXAMPLE 3
[0090] FIGS. 6 a - d demonstrate the use of the diagnostic instrument with the alternate actuation system involving a motor and cam rather than the solenoid used in the experiments of FIGS. 4 and 5 . In this case the disfance of penetration is controlled with the motor and the force is measured with the load cell. The force necessary to insert the test probe to a fixed distance decreases as the bone is damaged. For unbaked bovine bone, FIGS. 6 a - d also demonstrate the ability of the diagnostic instrument to penetrate soft tissue, even the tough periosteum that covers the bone surface, and still make measurements on the bone. Note that the curves of FIG. 6 b , measured with the unbaked bone covered with soft tissue, including the periosteum, are very similar to the unbaked bovine curves of FIG. 4 , for which all soft tissue, including the periosteum, had been removed from the bone surface.
Alternative Embodiments
[0091] In one class of alternative embodiments, small indentations are made into the bone with a sharpened test probe that is sturdy enough to not be deformed by penetrating bone. Examples of this type of test probe include test probes with diamond, silicon carbide, or hardened stainless steel tips. The resistance of the bone to the penetration of this sharpened test probe and/or its response, i.e., resistance, as the sharpened test probe is removed, are indicators of the fracture risk of the bone on the microscopic scale, which are in turn related to the fracture risk of bone on the macroscopic scale.
[0092] In different embodiments of the invention, different parameters are measured. For example, in a fully instrumented version, a force vs. distance curve comparable to those taken with existing macro-mechanical testing, nanoindentation, microindentation or AFM indentation equipment is measured, with the sharpened test probe inserted through the skin to contact the bone. In such a version hardness and elastic modulus could be evaluated using the well established protocols and standards that have been established for materials testing with the existing macro-mechanical testing, nanoindentation, microindentation or AFM indentation equipment. Test probe tips for this purpose have been shown in FIG. 9 . In some embodiments a sheath over the sharpened test probe comes into contact with the bone surface and serves to define a reference position. The penetration of the sharpened test probe into the bone is then measured relative to the sheath. From measurements of force vs. penetration distance, parameters can be extracted as for conventional indentation testing of materials. In particular, this method can be used to measure recovery properties of bone to repeated indents. This supplies information pertinent to the fatigue resistance of bone, an aspect currently not measured by other devices. A valuable feature of this invention is that it can be done on a living patient with minimal impact and negligible health risks. For pain-sensitive patients, local anesthesia could be injected at the site to be tested.
[0093] In other embodiments of the invention, disposable single-use test probes can include good vs. bad indicators and can be available for use by individuals outside a doctor's office to assess their own bone fracture risk. For example, in a specific embodiment of the invention the test probe tip extends a fixed distance beyond a sheath that stops at the bone surface. A spring or elastomer resists the motion of the test probe shaft back into the sheath and an indicator measures the motion of the test probe shaft back into the sheath. As the sheath is pushed until it contacts the bone surface the test probe tip must enter the bone or the test probe shaft must be pushed back into the sheath. The amount that the test probe shaft is pushed back into the sheath is a measure of the resistance of the bone to penetration and fracture; more fracture resistant bone will be indicated by more motion of the test probe shaft back into the sheath rather than penetration of the test probe tip into the bone.
[0094] Another embodiment of the instrument uses a special material for a test probe tip that is hard enough to indent weak bone, but not healthy bone. For examples ceramics with controlled porosity or metal alloys or polymers could be used. If such a test probe is inserted to a controlled force—such as in the range of 10 to 1000 milliNewton—then, after it is withdrawn, the deformation of the special material can be quantified: high deformation indicates bone that is fracture resistant; low deformation indicates bone that is at risk for fracture.
[0095] Alternatively, the test probe can be inserted up to a stop, for example a broad shoulder on the test probe a fixed distance behind the tip, with the deformation of the special material quantified.
[0096] Referring to FIG. 7 , a test probe 700 is shown, which passes inside a reference probe 702 and is attached to a mounting pin 704 , which passes through an alignment plate 705 , and adheres to a magnet 706 mounted in a holder 707 that is screwed into a shaft 708 connected to the diagnostic instrument ( FIGS. 8 and 2 ). The reference probe 702 is mounted in a reference probe holder 710 , for example a Luer lock as used in hypodermic needles. The reference probe holder 710 locked onto a mating receptacle 712 connected to the diagnostic instrument.
[0097] The probe assembly 714 consisting of the test probe 700 , its mounting pin 704 , the reference probe 702 and its reference probe holder 710 can be disposable and sterilizable. The probe assembly 714 can be quickly mounted and dismounted from the diagnostic instrument. During mounting, the mounting pin snaps into contact with the magnet 706 as the reference probe holder 710 is mounted onto the mating receptacle 712 . An optional test probe stop 716 in combination with a retaining stop 718 can simplify dismounting by pulling the mounting pin 704 off the magnet 706 as the reference probe holder is dismounted. The entire probe assembly 714 then comes off at once, eliminating the need to remove the test probe 700 and its mounting pin 704 separately after the reference probe 702 and the reference probe holder 710 are removed. In this figure, for clarity in this specific example, subcomponents of the probe assembly have been identified with individual numbers. More generally we will use the phrase “combination of test probe and reference probe” to refer to the complete probe assembly ready for mounting on the diagnostic instrument. This combination of the test probe and the reference probe could be supplied sterilized and disposable for single use.
[0098] FIG. 8 shows the diagnostic instrument in a preferred embodiment. The test probe 800 is connected via the mounting pin 804 , the alignment plate 805 , the magnet 806 and the holder 807 to the shaft 808 of a distance sensor 813 . In this embodiment, the distance sensor comprises a commercial electronic digital indicator with a range of 0-125 mm and a readout down to 0.001 mm. The position of the test probe is measured relative to the reference probe 802 , which is connected via components 803 and 809 to the distance sensor 813 .
[0099] A force or impact is transmitted through the distance sensor 813 by the shaft 808 , which projects above the sensor. In a currently preferred embodiment, an impact plate 814 screwed to the top of the shaft 808 is impacted by a mass 815 that accelerates due to gravitational and/or optional spring 816 forces. The impacts are made reproducible by an indexing shaft 817 which is connected to the mass 815 with an indexing pin 818 that runs through the top cap 819 . This top cap is screwed onto the body of the impact device 820 which is, in turn, screwed onto the distance sensor 813 . The indexing shaft 817 is kept centered by a linear bearing 821 .
[0100] The diagnostic instrument in FIG. 8 is a specific example of the more general diagnostic instrument shown in FIG. 2 . For the diagnostic instrument in FIG. 8 , the optional torque and angular displacement sensor 208 and the optional torque generator 210 are omitted. The optional linear displacement sensor 212 is a digital dial gauge 813 . The optional force sensor 214 is omitted. The optional force generator 216 is an assembly of parts 814 - 820 .
[0101] Referring to FIG. 9 , the test probe 900 and reference probe 902 previously shown in FIG. 7 as 700 and 702 respectively, in FIG. 2 as 200 and 202 respectively and in FIG. 1 as 100 and 102 respectively can have various shapes, and be made of various materials. FIG. 9 shows different possibilities for each. Test probe 900 a, designed for testing the fracture resistance of bone, has a cone at its end. In a preferred embodiment θ=90 and the test probe is tool steel. Test probe 900 d/c is patterned after the indenters used in some Rockwell and Brinell hardness testing, and has a half sphere of tungsten carbide 900 b bonded to a steel shank 900 c. Test probe 900 d/e is patterned on the diamond indenter used in Knoop hardness testing. It has a pyramid-shaped diamond 900 d with apical angles of 130° and about 170°, mounted on a tungsten carbide shank 900 e. Test probe 900 f/g, has a diamond 900 f in the shape of a square-based pyramid whose opposite sides meet at the apex at an angle of 136° as used in Vickers hardness testing of metals and ceramics, mounted on a ceramic shaft 900 g. Test probe 900 h is a tube that can be rotated for measuring friction on the surface of bone. Test probe 900 i is a disk that can be rotated for measuring friction, Φ=0, or viscosity of tissue near a bone surface, at Φ=0 or Ø>0 as in conventional viscosity measurements. Test probe 900 j is a screw that can test bone by measuring the torque necessary to screw it into the bone from inside the reference probe 902 a.
[0102] Reference probe 902 a is designed to penetrate skin and soft tissue before coming to rest on the surface of a bone. Reference probes 902 b and 902 c are designed for use with an optional outer syringe ( FIG. 11 ) so that they do not need to be sharp for tissue penetration. Reference probe 902 d/e is designed for penetrating soft tissue including tough soft tissue on bone surfaces, with the sharpened end 902 d that is made of a material such as a soft aluminum alloy or plastic that can penetrate the soft tissue, but flattens when striking the bone and is mounted on a tube of more rigid material such as stainless steel 902 e. Other pairings of test probes 900 and reference probes 902 are possible, such as test probe 900 b with reference probe 902 e/d.
[0103] As shown in FIG. 10 , reference probes need not be cylindrically symmetric tubes. The reference probe can be a tube with slits 1002 f to allow soft tissue to flow out from between the test probe and reference probe. It can be a rod 1002 h terminated with ends 1002 g. It can also be a hypodermic syringe with optional reground tip as shown in FIG. 1 .
[0104] As shown in FIG. 11 , an optional outer syringe 1122 can be reversibly locked to the reference probe 1102 with an adhesive 1123 such as wax or soft plastic that is designed to stay intact through soft tissue, but break when the outer syringe 1122 hits the bone, thus allowing the test probe 1100 and the reference probe 1102 to contact the bone. Alternately, the outer syringe 1122 can be attached to the reference probe 1102 during insertion by a removable pin 1124 . After the removable pin 1124 is removed the reference probe 1102 and test probe 1100 can be slid into contact with the bone to be tested. The outer syringe 1122 can optionally be slid back out of the soft tissue before the bone is tested.
[0105] FIGS. 12 a - 12 d show various supports for the diagnostic instrument. In FIG. 12 a , the diagnostic instrument slides through a guide 1225 that rests on the skin 1226 . The test probe 1201 and reference probe 1202 penetrate the skin 1226 and soft tissue 1227 down to the bone 1228 . The guide 1225 keeps the test probe approximately normal to the skin and underlying bone.
[0106] In FIG. 12 b , the diagnostic instrument is hand-held. The indexing pin 1218 is pulled out with a thumb ring 1229 to initiate an impact during a test. The bone being tested 1231 is held in a vice 1232 under fluid 1233 contained in a vessel 1234 . The diagnostic instrument can also be hand-held used for testing bone in regions of the body when the guide 1225 is not used.
[0107] In FIG. 12 c , the diagnostic instrument is held in a clamp 1235 that is attached via a rod 1236 to a support plate 1237 —as shown rotated 90°—that rests on a lab jack 1238 which can be raised or lowered to adjust for different height samples such as the bone 1239 inside an arm 1240 that rests in a “V” block support 1241 . The support plate 1237 moves freely on top of the lab jack 1238 to adjust the lateral position of the test probe. The bubble level 1242 on the rod 1236 guides adjustment of the lab jack 1238 to keep the test probe 1200 vertical.
[0108] In FIG. 12 d , the diagnostic instrument is attached through an x, y, z force sensor 1242 to an x, y, z translator 1243 . The translator 1243 controls the lateral positioning of the test probe to directly above the region to be tested and then lowers the test probe at controlled speed. The x, y, z force sensor 1242 can be used to monitor the vertical, z, force during insertion of the test probe and stop the lowering of the test probe by the x, y, z translator 1243 when a given set force is reached. Further, the x, y, z force sensor 1242 can be used in a feedback system to keep the lateral, x and y, forces below set tolerances by positioning the diagnostic instrument with the x and y axes of the x, y, z translator 1243 during insertion of the test probe.
[0109] FIGS. 13 a - d show various embodiments of the force generator 216 of FIG. 2 . FIG. 13 a is a schematic version of the force generator shown in FIG. 8 without the optional spring 816 or the indexing pin 818 . In operation, the weight 1315 is lifted by shaft 1317 which is graduated so it can be lifted a precise amount. It is dropped, accelerates under gravity, and hits the impact plate 1314 on the shaft 1308 .
[0110] In FIG. 13 b , a magnetic core 1350 is pulled down by a coil 1351 to apply a force to shaft 1308 . There is an optional gap 1352 between the bottom of the core 1350 and the top of the shaft 1308 : for an impact, the gap 1352 is nonzero, allowing the core 1350 to accelerate before impacting the shaft 1308 . For a more gradually increasing, steady force, the gap 1352 is zero from the start: the current through the coil 1351 determines the force. A spring 1353 controls the starting position of the core 1350 and returns it to the starting position after an impact or slower varying force is applied by passing current through the coil 1351 . This force generator is especially well suited to measurements of the resistance of the bone to fatigue fracture because it is easy to use an electronic pulse generator or other repetitive waveform generator to apply a series of impacts or force cycles to measure the indentation depth as a function of the number of impacts or force cycles.
[0111] We have also used this type of force generator for applying a fixed force of a first magnitude to the test probe to determine a starting position of the test probe relative to the reference probe; optionally applying an impact to the test probe; applying a fixed force of a second magnitude to the test probe; measuring the change in position of the test probe relative to the reference probe; reducing the fixed force to the first magnitude; and recording the change in the position of the test probe relative to the reference probe. In this case the force of a first magnitude is applied by a spring that is included inside the distance sensor 813 ( FIG. 8 ) that we used, a Grizzly Digital Indicator, supplemented by an optional external spring (not shown) that surrounds the shaft 807 and, by pushes on a washer (not shown) between the holder 807 and the shaft 808 . We have used forces of a first magnitude ranging from 0.1 to 0.8 lbs. We have used forces of a second magnitude ranging from 1 to 3 lbs by applying currents of 0.42 to 1.25 amps to the coil 1351 . We used a gap, 1352 , of approximately ¼ inch, to supply the impact.
[0112] In this case a typical procedure would be:
[0113] (1) To zero the instrument by allowing the full weight of the instrument, approximately 4 lbs, to rest on a hard surface so the tip of the test probe 800 is pushed in flush with the end of the reference probe 802 and then zeroing the distance sensor 813 .
[0114] (2) To insert the test probe 800 and reference probe 802 through the soft tissue down to the bone with the test probe 800 extended approximately 0.02 inches beyond the reference probe 802 and held there by the springs. When the bone is contacted, the test probe 800 is forced back into the reference probe 802 by allowing the full weight of the instrument, approximately 4 lbs. to rest on the bone surface, until the test probe 800 is flush with the end of the reference probe 802 as shown by a reading on the distance sensor 813 of within an acceptable margin of zero (one can generally used an acceptable margin of less than 10 microns). At this time the test probe is applying a force of first magnitude to the bone: we have used 0.8 lbs.
[0115] (3) To energize the coil 1351 with a current by using a power supply and a foot switch, we have used a current of 1.25 amps. The reading on the distance sensor is recorded with the current still flowing to the coil 1351 .
[0116] (4) To stop the current to the coil by releasing the foot switch and taking a second reading. The first reading is a measure of the resistance to penetration by the test probe: 100 microns is typical with smaller values indicating stronger bone. The difference between the first and second reading is a measure of the elastic recovery of the bone: 15 microns is typical with larger values indicating stronger bone.
[0117] In FIG. 13 c , multilayer piezoelectric actuators 1354 , such as the Tokin model AE1010D44H40, produce the force. They are shown in a push-pull configuration. To push down on the shaft 1308 the center two are expanded, and the outer four are contracted. They are joined at the top by a coupling plate 1355 which can be glued on with epoxy. In this way, forces up to over 2,000N can be generated with displacements up to 160 μm. These are sufficient for bone indentation experiments with the probe assembly shown in FIG. 7 .
[0118] In FIG. 13 d , a motor 1356 such as a digital stepper motor, derives a threaded nut 1358 with a rotating screw 1357 . This screw can optionally be a ball screw or Acme screw. The Acme screw has the advantage that it can hold a load in a power off situation enabling measurements of force relaxation vs. time after an indentation to fixed depth. This compresses the spring 1359 which is constrained not to rotate. The spring 1359 applies a force to the plate 1360 at the top of the shaft 1308 .
[0119] An alternate embodiment of the invention is shown in FIG. 14 . The frame of the device 1410 is connected to a support stand 1407 for immobilizing the limb of a patient on a firm foam cushion 1408 using Velcro straps 1409 .
[0120] A slide rail 1412 is attached to the frame. A sliding flange 1414 holds the diagncistic instrument, which in this FIG. 14 consists of a test probe 1400 connected with a test probe vice 1406 via a shaft 1416 to a force and tension gauge 1403 . Other examples of diagnostic instruments such as shown in FIGS. 2 , 3 and 8 can alternately be mounted on the sliding flange 1414 This assembly of sliding flange 1414 and diagnostic instrument can either: 1) be dropped from a fixed height to deliver an fixed impact or 2) gradually lowered to apply a force approximately equal to the weight of the assembly of sliding flange and diagnostic instrument.
[0121] If the assembly of sliding flange 1414 and diagnostic instrument is dropped to deliver an impact then a force and tension gauge 1403 records the force administered at indentation and the tension required to free the test probe 1400 from the bone can both be measured.
[0122] If the assembly of sliding flange 1414 and diagnostic instrument is gradually lowered to apply a force approximately equal to the weight of the assembly of sliding flange and diagnostic instrument, then the diagnostic instrument can be operated as discussed above with reference to FIGS. 2 , 3 and 8 .
[0123] In either case, dropping or gradual lowering, the diagnostic instrument can be attached to the sliding flange via a y, 1404 , x, 1405 translator that can be used to move the diagnostic instrument laterally to be correctly positioned over the limb of a patient held on a firm foam cushion 1408 using Velcro straps 1409 .
[0124] FIG. 15 shows a the top view of slide rail 1510 and interconnecting flange 1512 .
[0125] Referring to FIG. 16 , the test probe vice 1616 attaches to directly to the force and tension gauge such as shown in FIG. 14 and has a tightening collar to tighten the jaws that hold the disposable test probe 1600 .
[0126] FIG. 17 shows the electronics necessary for operation of some diagnostic instruments ( FIG. 2 ). Measurement and control electronics 1710 are needed to read the signals from the optional torque and angular displacement sensor 208 , the optional linear displacement sensor 212 and the optional force sensor 214 , and to supply signals to drive the optional torque generator 210 and optional force generator 216 , as well as the optional x, y, z force sensor 1742 and the optional x, y, z translator 1743 . An optional Computer 1711 is needed for implementing complex and/or automated test sequences using programs such as Labview or custom software.
[0127] For example, an automated test sequence can include the following steps:
[0128] the x, y, z translator 1743 is used under computer 1711 control, to position the test probe 200 above a sample 1739 , 1740 ;
[0129] then the diagnostic instrument is lowered until the reference probe 202 penetrates tissue down to the bone 1739 as sensed by an increased z force on the x, y, z force sensor 1742 , as measured by the measurement and control electronics 1710 ;
[0130] when a preset value of z force is reached, the computer 1711 stops the x, y, z translator 1743 ;
[0131] then the computer 1711 sends a signal via the measurement and control electronics 1710 to generate a specified force sequence with the force generator 216 ;
[0132] the resultant displacement of the test probe 200 relative to the reference probe 202 is sensed by the linear displacement sensor 212 measured by the measurement and control electronics 1710 and recorded by the computer 1711 ; and
[0133] the computer 1711 then sends a signal through the measurement and control electronics 1710 to the x, y, z translator to raise the test probe 200 out of the sample.
[0134] As a final example, for a diagnostic instrument to measure the mechanical properties of bone relevant to accepting and holding a screw as used in orthopedic repair, the test probe 200 has a screw shape such as 900 j in FIG. 9 . The optional reference probe is omitted. A torque sensor 208 such as the National Instruments RTS series or the S. Himmelstein MCRT series is used together with a torque generator 210 such as a motor. The displacement sensor 212 is a linear variable differential transducer (LVDT) such as the P3 America model EDCL, or a linear motion potentiometer such as a P3 America model MM10. The force sensor 214 is a load cell such as the National Instruments SLB series or the Sentran ZA series. The force generator 216 is a digital stepper motor driving a spring-screw arrangement as shown in FIG. 13 d . The entire diagnostic instrument is supported as shown in FIG. 17 . The torque needed to screw the test probe 900 j into the bone is measured by torque and angular displacement sensor 208 for fixed kirce supplied by the force generator 216 as the screw screws into the bone. After the screw is screwed into the bone, the force to pull the screw out is, optionally, measured with the force sensor 216 . This same diagnostic instrument could be used with test probe 200 and an optional reference probe 202 to measure the rotary friction of test probe 200 with shape 900 i, 900 b, 900 h or other shapes on the surface of the bone. We have observed that some osteoporotic bone has decreased friction due to fatty deposits on the surface. Thus this rotary friction could be diagnostic for some types of osteoporosis.
REFERENCES
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EFFECT OF AGING ON THE TOUGHNESS OF HUMAN CORTICAL BONE. Orthopedic Research Society Proceedings (2005). 51. Currey, J. D., Brear, K. & Zioupos, P. The effects of aging and changes in mineral content in degrading the toughness of human femora. Journal of Biomechanics 29, 257-260 (1996). 52. Vashishth, D., Kim, D. & Rho, J. The influence of tensile and compressive damage on bending fatigue of human cortical bone. in Second Joint EMBS-BMES Conference 2002 24 th Annual International Conference of the Engineering in Medicine and Biology Society. Annual Fall Meeting of the Biomedical Engineering Society Vol. 1 417-418 (IEEE, Houston, Tex., 2002). 53. Taylor, D. & Lee, T. C. Microdamage and mechanical behaviour: predicting failure and remodelling in compact bone. Journal of Anatomy 203, 203-211 (2003). 54. Zioupos, P. Accumulation of in-vivo fatigue microdamage and its relation to biomechanical properties in ageing human cortical bone. Journal of Microscopy-Oxford 201, 270-278 (2001). 55. Schaffler, M. B., Choi, K. & Milgrom, C. Aging and matrix microdamage accumulation in human compact bone. Bone 17, 521-525 (1995). | Methods and instruments for assessing bone, for example fracture risk, in a subject in which a test probe is inserted through the skin of the subject so that the test probe contacts the subject's bone and the resistance of the test bone to microscopic fracture by the test probe is determined. Macroscopic bone fracture risk is assessed by measuring the resistance of the bone to microscopic fractures caused by the test probe. The microscopic fractures are so small that they pose negligible health risks. The instrument may also be useful in characterizing other materials, especially if it is necessary to penetrate a layer to get to the material to be characterized. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/600,289, filed Feb. 17, 2012 and entitled “Asphalt Sealer for Surface Crack Repair”, the disclosure of which is hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to an asphalt sealer for filling cracks in paved surfaces. More specifically, the present invention relates to an improved asphalt sealer for filling cracks in asphalt surfaces that provides significantly improved performance and durability, particularly in areas of high temperature.
BACKGROUND OF THE INVENTION
[0003] It is well known that paved surfaces, such as roadways, sidewalks, driveways, tennis courts and the like, can develop cracks, which necessitate repair. These cracks often develop over time, but can also appear in new paved surfaces. Asphalt surfaces in particular are susceptible to developing cracks in regions that have extreme weather conditions or that have large temperature fluctuations. It is desirable to repair these cracks to preserve the longevity of the entire asphalt surface as well as to prevent damage or injury to those using the surface.
[0004] One way to eliminate cracks from paved surfaces is to tear it up and replace the entire surface. This process is extremely expensive. It is also not practical to replace the entire surface, which has many more years of useful life, because cracks have formed in a small portion of the surface.
[0005] Instead of ripping up an entire paved surface, various less expensive methods have been employed to repair cracks that may develop in these surfaces. One known process is to fill the cracks with an asphalt sealer. While this often serves to fill the cracks at least temporarily, the utilization of current asphalt sealers to repair cracks suffers from some significant disadvantages. Initially, current asphalt sealers are susceptible to melting when subjected to high temperatures, which results in the sealer flowing away from a crack filling position. For example, when the asphalt sealer heats up, it becomes softer and can be squeezed, such as by a vehicle passing thereover, so that it no longer properly fills the crack. Additionally, because of their composition, current sealers can be slippery, which is undesirable. As existing asphalt sealers have very limited durability when serving to fill cracks, if the sealer no longer serves to fill the crack, additional crack repair services are required. Accordingly, existing crack repair methods and systems are costly, both in terms of material and labor.
[0006] In some instances where the crack is deep enough, a grout material, such as a mortar or cement, is used to assist in filling these cracks. In these instances, the grout material is placed in the crack and allowed to harden. Thereafter, the asphalt sealer is placed in the crack over top of the grout material to completely fill the crack and level out the paved surface. This can also create durability issues in that existing grout fillers that are used in crack repair applications often have significant shrinkage issues. Thus, while an asphalt sealer used to help fill a crack may initially be level with the surface being repaired, when the grout material shrinks, the asphalt sealer will drop into the crack as the level of the grout material recedes. The asphalt sealer thus is no longer flush with the upper paved surface and often falls into the crack itself.
[0007] In an effort to address some of these deficiencies, aggregates such as sand or limestone, were added to the asphalt sealer to provide it with more substance. However, these efforts were unsuccessful as these aggregates would release from the sealer, such as when contacted, and they would therefore eventually fail. Thus, while they provided some increased durability, they ultimately suffer from the same disadvantages as asphalt sealers without an aggregate.
[0008] It would therefore be advantageous to provide an improved asphalt sealer for paved surfaces that overcomes these disadvantages. It would also be advantageous to provide an improved crack repair system that overcomes the failings with current systems.
SUMMARY OF THE PRESENT INVENTION
[0009] It is therefore an aspect of the present invention to provide an improved asphalt sealer for paved surfaces that provides increased durability over existing systems.
[0010] It is another aspect of the present invention to provide an improved asphalt sealer for paved surfaces that decreases the cost associated with repairing cracks.
[0011] It is still another aspect of the present invention to provide an asphalt sealer crack repair system that can withstand extreme weather conditions and large temperature fluctuations.
[0012] It is yet another aspect of the present invention to provide an improved asphalt sealer, which has increased structural integrity and bonding.
[0013] It is a further aspect of the present invention to provide an improved asphalt sealer having no-skid characteristics.
[0014] It is yet a further aspect of the present invention to provide an improved asphalt sealer that utilizes an aggregate material.
[0015] It is still a further aspect of the present invention to provide an improved crack repair system that employs an asphalt sealer over top of a grout material, which provides increased durability and decreased cost.
[0016] In accordance with the above and the other aspects of the present invention, an improved asphalt sealer for repairing cracks in a paved surface is provided. The asphalt sealer includes slag sand that is mixed therein in an amount of approximately 40-55% by weight of slag sand. The addition of the slag sand yields a sealer that has improved structural integrity and increased durability. To repair one or more cracks in the paved surface, the improved asphalt sealer with slag sand is placed into the crack to fill it and allowed to harden.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic illustration of a crack repair system in accordance with a preferred embodiment of the present invention; and
[0018] FIG. 2 is a schematic illustration of a crack repair system in accordance with another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The present invention relates to an improved asphalt sealer for use in repairing cracks in a paved surface, such as an asphalt surface. The paved surface can be any type of surface, including a roadway, a parking lot, a driveway, a sidewalk, a tennis court, a basketball court, a track or the like. While the present invention is preferably for use with asphalt surfaces, it will be understood that it may also be used in connection with any other type of paved surface, such as concrete surfaces. It may also be used in connection with non-paved surfaces.
[0020] It is known that over time whether due to extreme weather, large temperature fluctuations or other factors, cracks can form in paved surfaces, such as asphalt surfaces. In accordance with a preferred embodiment, a crack 10 in a paved surface 12 is identified as needing repair. It will be understood that the cracks often extend into the ground 20 for some distance as well. To fill and repair the crack, an asphalt sealer 14 is placed therein such that it fills the crack and substantially levels out the paved surface on either side of the crack. It will be appreciated that the crack can be filled to varying degrees and heights, as desired. For example, the asphalt sealer could fill the crack to a level above or below the adjacent paved surface. In accordance with a preferred embodiment, the asphalt sealer 14 used to fill the crack may consist of a conventional asphalt sealer mixed with slag sand 16 in an amount of approximately 40-55% by weight of slag sand. More preferably, slag sand 16 is utilized in an amount of approximately 48% by weight. In another composition, 30 lbs of sealer are mixed with 25 lbs of slag sand. To mix the slag sand, the asphalt sealer 14 is melted and then the slag sand 16 is added such that when the asphalt sealer 14 hardens, the slag sand 16 is firmly bonded thereto. Alternatively, the asphalt sealer 14 could be delivered to the site where needed premixed such that the sealer and the slag sand are already combined.
[0021] An asphalt sealer 14 having the following specific chemical identity may be employed (CA5 8052-42-4). However, other asphalt sealer compositions may also be utilized. The slag sand may be of the air cooled blast furnace type (ACBF) and is preferably 316 in size. It will be understood that other types of slag sand 16 may also be employed as well as slag sand of other sizes. In accordance with a preferred embodiment, the disclosed asphalt sealer has a specific gravity of 1.0-1.3 and a melting point of 160-220° F. It will also be appreciated that other types of aggregates that exhibit similar characteristics, as desired herein, may also be employed.
[0022] The disclosed asphalt sealer 14 has been tested and provides significantly increased durability particularly in areas, such as the Southwest United States where high temperatures and large temperature changes can cause existing asphalt sealers to fail. For example, the temperature changes in Las Vegas, New Mexico, Arizona, or Southern California can be between 60-95° F. These large temperature changes are known to cause existing asphalt sealers to fail. The inclusion of the slag sand provides structural integrity and a mechanical bond to the asphalt sealer. Additionally, the inclusion of the slag sand 16 minimizes softening and flowing of the sealant when the ground temperature is hot as the improved sealer has a higher melting point. Further, the slag sand provides an abrasive characteristic that minimizes slipperiness. Moreover, the asphalt sealer has been tested through observation and manipulation and once the slag sand has been mixed in the asphalt sealer, it does not readily separate, which provides significantly increased durability.
[0023] Turning to FIG. 2 , which illustrates another preferred embodiment of the present invention. As shown, a crack 10 has formed in a paved surface 12 , which has been identified as needing repair. It is not critical how the creaks are formed, as they could be created intentionally to install utilities underground. In this embodiment, the crack is relatively large and therefore a grout material 18 is placed into the crack 10 to fill a part thereof. The grout material 18 preferably includes class F fly ash in a range of approximately 0 to 30% by weight of the grout material and cement kiln dust in a range of approximately 50 to 90% by weight of the grout material, such as is disclosed in Applicant's co-pending U.S. patent application Ser. No. 12/885,101, entitled “Grout for Filling a Micro-Trench”, and filed on Sep. 17, 2010, the disclosure of which is hereby incorporated by reference. According to a preferred aspect, the Class F fly ash has the composition of that produced by the Lafarge facility in Alpena, Mich. This preferred grout material 18 resists shrinkage and therefore will keep the crack filled after it hardens. In other words, the grout material 18 remains in contact with the sides of the crack to keep it substantially filled. It will be understood that other grout materials may also be employed. It will also be understood that the disclosed asphalt sealer may be used to fill the entire crack.
[0024] After the grout material 18 has been placed in the crack 10 , the asphalt sealer 14 with slag sand 16 can then be placed over the grout material 18 to fill the remaining part of the crack 10 and also level off the surface being repaired. The disclosed asphalt sealer 14 provides an additional benefit when utilized with the preferred grout material 18 as the asphalt sealer 14 bonds strongly to the grout material 18 as a result of their compositions, as disclosed herein. It will also be appreciated that the asphalt sealer 14 may be utilized to fill the entirety of the crack 10 . Thus, a crack repair system consisting of the preferred grout material 18 and the preferred asphalt sealer 14 provided significantly enhanced durability.
[0025] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described. These antecedent recitations should be interpreted to cover any combination in which the inventive novelty exercises its utility. | A method of repairing cracks in a paved surface includes identifying at least one crack in the surface that needs to be repaired. The crack is then filled with an asphalt sealer including approximately 40-55% by weight of slag sand. | 4 |
CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese application serial No. 2007-21512, filed on Jan. 31, 2007, the content of which is hereby incorporated by reference into this application.
TECHNICAL FIELD
[0002] The present invention relates to a sheet-form, ribbon-form or tape-form adhesive-free aramid-polyester laminate, a method of manufacturing the same and an apparatus for manufacturing the laminate. The laminate is particularly useful for insulting material for electric apparatuses.
BACKGROUND OF THE INVENTION
[0003] Aramid fiber is aromatic polyamide fiber known as NOMEX trade name of du Pont), which is excellent in electric insulation, heat resistance, anti-chemicals, etc. Accordingly, it has been widely used as an insulating material.
[0004] Aramid-polyester laminates wherein aramid papers prepared by mixed-paper making forces of aramid fiber and aramid pulp are laminated and bonded with an adhesive as disclosed in patent documents Nos. 1 to 5.
[0005] In patent document No. 1, a prepreg sheet is disclosed wherein plasma-treated aramid films, aramid non-woven cloth and semi-cured adhesive are united. In patent document No. 2, adhesive-free aramid laminate which is prepared by heat bonding aramid paper composed of m-aramid fibrid and heat resistive short fiber and polyethylene terephthalate film at 220 to 250 degrees Celsius under a pressure of line pressure of 50 kg/cm or higher.
[0006] In patent document No. 3, there is disclosed a method of manufacturing aramid-polyester laminate wherein molten polyester is impregnated into aramid paper. In patent document No. 4, there is disclosed a method of manufacturing a laminate sheet by calendar treatment of m-aramid paper and polyester film.
[0007] The technology disclosed in patent document No. 1 has such problems that coating of adhesive or adhesive tape is necessary, and treatment of volatile solvent in the adhesive is necessary. In the technology disclosed in patent document No. 5 the prepreg is prepared by impregnating thermosetting resin into aramid fiber, wherein the thermosetting resin is a kind of adhesive.
[0008] On the other hand, technologies disclosed in patent document Nos. 2, 3 and 4 do not use adhesive, but polyester film or sheet and aramid fiber or aramid paper are laminated, then the polyester is melted and impregnated into the aramid fiber or aramid paper. In order to melt the polyester, the polyester must be heated at a temperature higher than a glass transition temperature. Accordingly, the cooled polyester re-crystallizes to decrease its elasticity.
[0009] (Patent document 1) Japanese patent laid-open 2003-246018
[0010] (Patent document 2) Japanese patent laid-open 07-032549
[0011] (Patent document 3) Japanese patent laid-open 07-299891
[0012] (Patent document 4) Japanese patent laid-open 08-099389
[0013] (Patent document 5) Japanese patent laid-open 11-209484
SUMMARY OF THE INVENTION
[0014] Accordingly, it is an object of the present invention to provide an aramid-polyester laminate without using an adhesive, which is featured by maintaining characteristics of polyester, flexibility of polyester and making ecological treatment of the production easy.
[0015] The present invention provides an adhesive-free aramid-polyester laminate comprising a plasma surface-treated aramid paper formed from aramid fiber and aramid pulp and plasma surface-treated polyester film wherein the aramid paper and the polyester are laminated and bonded using a pressure roll device preferably at room temperature to 200 degrees Celsius. The present invention is featured by that the plasma-treated aramid paper and plasma treated polyester film are directly laminated and bonded without using any adhesive (in the absence of an adhesive). The plasma treated aramid paper and plasma treated polyester film have some chemically active groups which assist the direct bonding therebetween.
[0016] The present invention also provides a method of manufacturing an adhesive-free aramid-polyester laminate which comprises plasma surface-treated aramid paper and a plasma surface-treated polyester film are directly laminated and bonded at a temperature of room temperature to 200 degrees Celsius under a line pressure of 200 kgf/cm or more.
[0017] The present invention further provides an apparatus for manufacturing the adhesive-free (adhesive-less) aramid-polyester laminate, which comprises means for re-winding a plasma-surface treated aramid paper; means for re-winding plasma surface-treated polyester film; means for laminating and bonding aramid paper and polyester film by imparting pressure the laminated aramid paper and polyester film; means for detecting and controlling the pressure of the laminating and bonding means; means for winding the laminated and bonded body; and means for detecting and controlling the re-winding speed and/or the winding speed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a diagrammatic view of a laminating-bonding apparatus according to an embodiment of the present invention.
[0019] FIG. 2 shows a diagrammatic view of a laminating-bonding apparatus according to another embodiment of the present invention.
[0020] FIG. 3 is a diagrammatic view for explaining a roll-bending compensation of the embodiments of the present invention.
[0021] FIG. 4 is a drawing for explaining a roll flexure.
REFERENCE NUMERALS IN THE DRAWINGS ARE
[0022] 1,2; pressing rolls, 3 , 4 ; aramid paper reel, 5 ; aramid paper, 6 ; polyester film reel, 7 ; polyester film, 8 ; laminate, 9 ; pressing down device, 10 ; speed detector, 11 ; winding reel, 12 ; pre-heating-slow cooling zone, 13 ; flexure compensating apparatus of roll bending type, 14 , 15 ; roll shafts, 18 ; temperature controlling device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] According to the preferred embodiments of present invention, it is possible to realize an aramid laminate, a method of manufacturing the same and an apparatus for manufacturing the same, without using an adhesive and without losing flexibility of polyester, and to provide an ecology compliance type aramid laminate.
Preferred Embodiment of the Present Invention
[0024] In bonding faces of the aramid paper-polyester laminate the aramid paper and polyester film are directly in contact with each other. According to observation with a microscope, a very thin interface of several nm thick is found at the contact faces. That is, it is thought that a surface layer formed of porous aramid paper and the surface layer of polyester film are directly and continuously bonded in the absence of an adhesive. The word “continuously” is used to means that there may not be a clear bonding line (interface) between the aramid paper and polyester film, which is found in case of adhesive bonding. Although it has not been sufficiently elucidated that the interface layer has what structure and has what function, this can be one of features of the aramid paper-polyester laminate of the present invention.
[0025] Though thicknesses of the aramid paper and polyester film are not limited particularly, when the aramid paper is used as sheet, tape or ribbon form insulating material, the aramid paper should have a thickness of 30 to 150 μm and the polyester film should have a thickness of 100 to 200 μm are practical. A total thickness of three layers is preferably 130 to 350 μm.
[0026] In the aramid paper-polyester laminate, the temperature for pressing the laminate should preferably be a temperature lower than a glass transition temperature of the polyester film. If the heating temperature is higher than the glass transition temperature, polyester in the laminate re-crystallizes when the polyester is cooled down to loose flexibility and become fragile. As a result, the handling of the laminate becomes worse and properties thereof become worse, too.
[0027] A laminate of a three-layered structure comprising aramid paper, polyester film and aramid paper is preferable. Further, the polyester film should be polyethylene terephthalate (PET) or polyethylene naphthalate (PEN) in view of mechanical strength, flexibility, cost, electrical insulation, etc.
[0028] The temperature for pressing the laminate should be a temperature lower than a glass transition temperature of polyester film. If the temperature is higher than the glass transition temperature of polyester, flexibility of the laminate will be lost by re-crystallization at the time of cooling thereof. As example of PEN, there is TEONEX, which is a trade name of Teijin Du Pont Corp. This is a two axes extension polyethylene naphthalate. The glass transition temperature of PET is about 78 degrees Celsius and that of PEN is about 121 degrees Celsius.
[0029] Aramid paper secures electrical insulating properties, chemical stability and heat resistance, and polyester secures flexibility and impermeability to gas and liquid. Aramid papers are arranged on both faces and polyester is used as a core material. As mentioned earlier, preferable materials for the polyester core are polyethylene terephthalate and polyethylene naphthalate.
[0030] The rolls for pressing the laminate should be made of rigid (high rigidity) material. In the conventional methods a combination of a rubber roll and a metal roll has been used, but the rubber roll is deformed in its pressing face so that a sufficient pressing force is not exerted on the laminate. When a pair of metal rolls that are more rigid than the rubber rolls are used, a sufficient pressing force can be exerted on the laminate.
[0031] In the method of manufacturing the adhesive-free aramid-polyester laminate, the rolls are equipped with a flexure compensating device of a roll bending type, whereby an amount of flexure of the rolls can be adjusted.
[0032] Even if the metal rolls are rigid, the rolls may be slightly deformed in their pressing faces that sandwich the laminate. As a result, there are problems such as insufficient pressurizing force or a partially biased pressure to the laminate. In order to compensate or correct the flexure and to apply a sufficient pressurizing force, it is desirable to install the roll bending type flexure compensating mechanism.
[0033] It is preferable that at least the rolls are disposed in an atmosphere where the temperature is controllable. In order to keep a desired temperature of at least a means for pressure-laminating the laminate, a temperature control device equipped with a pre-heating zone and a slow cooling zone. Although the lamination and bonding may be done at room temperature, it is preferable to keep the polyester film at a temperature higher than room temperature but lower than the glass transition temperature of the polyester so as to increase a bonding speed and sufficiently lower the pressurizing force.
[0034] In the manufacturing apparatus for the adhesive-free aramid-polyester laminate, the laminating-bonding means should preferably be a pair of rolls. The rolls are provided with the roll flexure compensating device of roll bending type thereby to compensate or correct the flexure of the rolls. Further, the lamination bonding means should preferably be within a means wherein the temperature is controllable. In addition, the flexure compensating mechanism of the roll bending type should preferably be constituted to impart independent or different compensation amounts to right shaft and/or left shaft of the rolls.
[0035] In the present invention the plasma treatment is a chemical plasma treatment using direct current or alternating current high frequency carried out in vacuum or various atmospheres, that include corona discharge (approximately in atmospheric pressure) and glow discharge (vacuum under reduced pressure). According to the plasma treatment, aramid paper or polyester film or sheet is subjected to surface modification to thereby form some types of functional groups such as COOH or OH groups in the surface of the aramid paper and polyester film. As a result of the surface modification it is possible to strongly bond the aramid paper and polyester film at a temperature of 200 degrees Celsius or lower. This phenomenon is a very peculiar one and cannot be presumed from the description of the above-mentioned patent documents. Since the plasma treatment itself is has been well known as a method of increasing bonding property of different resins, the detailed explanation on this technology is omitted.
[0036] In the following the present invention will be explained based on embodiments by reference to drawings. FIG. 1 shows a diagrammatic view of a bonding apparatus for a laminate. In the apparatus shown in the drawing aramid paper 5 rewound from reels 3 , 4 for aramid paper and polyester film 7 rewound from reel 6 for polyester film are laminated in three layers (sandwich structure). The laminate is pressurized and bonded by the rolls without an adhesive. The surfaces of the aramid paper and the polyester films were surface treated by plasma treatment in advance.
[0037] In order to detect and to compensate or control a pressure of the rolls there is disposed a pressure device 9 with a control device. It is preferable to set a pressure of 200 kgf/cm as a line pressure or more, particularly 300 kgf/cm or more. A rotating speed of the rolls is set by controlling the rotating speeds of the winding-out shaft and winding shaft so as to give a constant tension force to the film and paper at positions of back and forth of the film and paper.
[0038] For a more accurate speed control, a transfer speed of the laminate by the rolls is detected with a detector and the detected speed may be feed-backed to the roll rotating speed. A transfer speed optimum for production of the laminate may change depending on the pressure force and temperature. The higher the pressure force and higher the temperature, the higher the transfer speed will become. Depending on the transfer speed, the pre-heating temperature or the roll temperature may be set to 50 to 100 degrees Celsius higher than the glass transition temperature. However, the temperature of the polyester film should be controlled not to be heated up to the glass transition temperature. The laminate 8 wound by the winding reel 11 is a product.
[0039] Conditions for the roll type laminating-bonding apparatus are a homogeneous load over the width of the laminate and constant temperature in the surface of the rolls (directions in width and circumference). In order to achieve the conditions, it is preferable to utilize rolls with high precision (high cylindricity, high circularity, small deflection, etc), the roll flexure compensation mechanism, and a surface temperature control mechanism (for example, the use of heating medium circulating roll).
[0040] FIG. 2 shows a laminating-bonding apparatus according to another embodiment, wherein the same reference numerals as in FIG. 1 designate the same elements. FIG. 2 differs from FIG. 1 in disposition of rolls that are arranged in a pre-heating slow cooling zone 12 . According to this apparatus, the films and paper are pre-heated and slowly cooled so that quick heating and rapid cooling of the films and paper can be avoided to thereby prevent wrinkles, etc due to quick heating and rapid cooling of the films and paper.
[0041] In addition to that, there may be a case where the films and paper cannot be heated sufficiently to heat them to a desired temperature by contacting them with the rolls because the contact time is short. The pre-heating and slow-cooling zones carry pre-heating them to compensate necessary heat to thereby increase productivity. A control device 18 for detecting temperature of the pre-heating and slow-cooling 12 is disposed. In FIGS. 1 and 2 , the roll pressing down device 9 is shown above the rolls for illustration, but the roll pressuring down device 9 is actually fixed to the supporting member of the roll shaft.
[0042] In the present embodiment a pair of rolls should preferably be made of more rigid (high rigidity) iron base materials, but an intermediate portion of the rolls may be bent at the time of lamination and bonding so that a sufficient pressure force cannot be given to the laminate or biased pressure force may be given to the laminate. In order to solve this problem, a roll bending compensation mechanism 13 is provided in addition to the roll pressure device 9 to change or correct a roll profile within a short time. An example of this method is shown in FIG. 3 .
[0043] In FIG. 3 a pressure force F is imparted to shafts 14 , 15 of the rolls 1 , 2 . On the other hand, in order to prevent such a case where a constant and sufficient pressure force is not imparted to the laminate 8 because the shafts 14 , 15 of the rolls 1 , 2 sandwich the laminate 8 to bend to be curved as shown in FIG. 4 , a pressure P is imparted to the shafts from an opposite direction of the pressure force F. This method is called a roll bending compensation. The roll bending compensation should preferably be done independently with respect to the right and left pressure down devices.
[0044] Table 1 and Table 2 show different conditions in the embodiments according to the present invention and characteristics of laminates produced under the above conditions. Aramid papers having thicknesses of 50 μm and 130 μm that have been subjected to the low temperature plasma Surface treatment and PEN having a thickness of 125 μm were laminated and bonded with the apparatus shown in FIG. 2 to produce laminates of a three-layered sandwich structure of aramid-PEN-aramid under the conditions shown in Table 1 and Table 2.
[0045] The produced laminates of adhesive-less aramid-polyester exhibited characteristics shown in the evaluation columns. According to evaluation of peeling-off, when PEN is used as polyester film, the roll temperature of 121 degrees Celsius or lower, which is lower than the glass transition temperature of polyester, particularly 110 to 40 degrees Celsius is preferable. A roll line pressure for the laminates of 300 kgf/cm or more, particularly 400 kgf/cm or more is preferable. If the pressure is too high, the process is not economical. Thus, the line pressure should be 1000 kgf/cm or less.
[0046] The roll rewinding speed (a withdrawing speed of paper or film from a reel) may vary on the roll temperature and line pressure. The speed may be determined according to the productivity and cost of the laminates. IN the examples shown in Tables, the speed of 0.5 m/min or more, particularly 1 to 20 m/min is preferable.
[0047] According to the evaluation of sticking property of laminates, laminates of examples 3, 6-10 and 13-16 showed particularly good sticking property. These laminates are laminated and bonded under proper transfer speeds and proper line pressures at proper temperatures.
[0048] In the following, marks are defined as follows.
[0049] 1; aramid paper-PEN-aramid paper (aramid paper: type 411 , which is subjected to calendar treatment)
[0050] 2; aramid paper-PEN-aramid paper (aramid paper: type 410 , which is not subjected to calendar treatment)
[0000] D; the paper of film is easily peeled-off
C; the paper or film is peeled-off.
B; good sticking
A; excellent sticking
[0000]
TABLE 1
Comp.
Comp.
Ex. 1
Ex. 1
Ex. 2
Ex. 3
Ex. 2
Ex. 4
Ex. 5
Ex. 6
Ex. 7
Ex. 8
Materials
*1
*1
*1
*1
*2
*2
*2
*2
*2
*2
Thickness
50
50
50
50
130
130
130
130
130
130
of aramid
paper (μm)
Roll
110
110
110
110
100
100
100
100
100
100.0
temp.
(degrees
Celsius)
Transfer
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
speed of
laminate
(m/min)
Roll line
100
210
300
400
100
210
250
300
500
750
pressure
(kgf/cm)
Sticking
D
C
B
A
D
C
B
A
A
A
property
[0000]
TABLE 2
Comp.
Ex.
Ex.
Ex.
Ex.
Ex.
Ex. 9
Ex. 10
Ex. 3
11
12
13
14
15
Ex. 16
Material
*2
*2
*2
*2
*2
*2
*2
*2
*2
Thickness
130
130
130
130
130
130
130
130
130
of aramid
paper (μm)
Roll
100
100
100
100
100
100
100
100
100
temp.
(degrees
Celsius)
Transfer
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
speed of
laminate
(m/min)
Roll line
1000
500
100
210
250
300
500
750
1000
pressure
(kgf/cm)
Sticking
A
A
D
C
B
A
A
A
A
property
[0051] In Table 1 and Table 2, though the roll temperatures of the pressing rolls are set forth 50 to 110 degrees Celsius, which is lower than the glass transition temperature of polyester film (PEN), polyester film does not cause glass transition (particularly, changes such as melting or flowing of the film). The fact that aramid paper and polyester film are strongly bonded under these conditions would not have been expected. In this point, the present invention principally differs from the technologies disclosed in Patent documents No. 2 to 4.
[0052] As having been described, the present invention provides a laminate of aramid paper-polyester film having excellent sticking property without using an adhesive. | A laminate comprising aramid paper containing aramid fiber and aramid pulp and polyester film, the aramid paper and polyester film having been subjected to plasma surface treatment before laminating, wherein the aramid paper and polyester film are continuously bonded to each other. The disclosure is concerned with a process for manufacturing the laminate and an apparatus for manufacturing the laminate. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to phase-lock loop systems and more particularly to phase-lock loop systems for frequency stabilizers.
2. Description of the Related Art
Phase-lock loops (PLLs) find applications in a wide variety of devices including wireless communication systems, disk drive electronics, high speed digital circuits and instrumentation. A PLL is simply a servo system that controls the phase of an output signal so that the phase error between the output signal and a reference input signal are reduced to a minimum. PLL circuits include at a minimum a phase/frequency detector (PFD) and a voltage control oscillator (VCO). It is also common for these circuits to contain a charge pump which is used to convert the logic states of the PFD into analog signals suitable for controlling the VCO. Such circuits are known as charge-pump phase-lock loops.
Charge-pump PPL's are commonly used to lock a local oscillating signal to a carrier frequency so that the carrier frequency can be removed, leaving an information signal of interest. Many of the devices which utilize charge-pump phase-lock loop systems operate in the microwave (900 MHZ-30 GHz) or millimeter wave (30-300 GHz) portion of the electromagnetic spectrum.
As shown in FIG. 1, a prior art charge-pump PPL circuit 20 includes a VCO 22, which may be implemented as an LC tank circuit and which develops a local oscillating signal that is locked to a remotely received carrier signal. Both the local signal (whose frequency may be divided by a factor N) and the remote signal are applied to a PFD 24 which compares their phases and frequencies. The phase/frequency difference between the two signals results in a voltage output which is received by a charge pump 26. The charge pump, otherwise known as a transresistance amplifier, converts the voltage signal into a current signal which is provided to a fixed capacitor 28. The capacitor integrates the current, producing an output voltage which is supplied to the VCO to adjust the local signal. A low pass filter 30 is often utilized to remove unwanted harmonics generated by charge pump 26. The filter is commonly placed in the circuit prior to the VCO. The circuit may additionally contain a divider 32 between the VCO and the PFD to reduce the frequency of the local signal generated by the VCO.
As the capacitance of capacitor 28 is fixed, the designer must make an initial decision as to its size. If a large capacitor is selected, integration is slow but the system finds the carrier signal much faster then it would with a small capacitor. This is primarily due to limited over- and under-shoot. However, the larger capacitor may lack sensitivity to accurately lock onto the carrier signal. A smaller capacitor, on the other hand, results in a more accurate lock onto the carrier signal but the process is much slower. This is primarily due to the large number of over- and under-shoots. However, a small capacitor permits a more accurate lock onto the carrier signal. Alternately, a conventional variable capacitor can be utilized. However, conventional variable capacitors only slightly improve the situation in that their tunability is only on the order of 2:1. These capacitors are also quite large in size and their tuning quite slow. Other smaller variable capacitors have been used, but they too had limited tunability range. See Darrin J. Young and Bernhard E. Boser, "A Micromachined Variable Capacitor for Monolithic Low-Noise VCOS," Technical Digest of the 1996 Solid-State Sensor and Actuator Workshop, Hilton Head, S.C., pp. 86-89.
SUMMARY OF THE INVENTION
In view of the above problems, the present invention provides a charge-pump phase-lock loop circuit that more rapidly and with greater precision determines the phase and frequency of a carrier signal so that it can be extracted, to obtain an information signal of interest. This is achieved by the use of a Micro Electro-Mechanical Systems (MEMS) adjustable capacitance device. The MEMS capacitance device could be a single tunable MEMS capacitor, a series of tunable MEMS capacitors, or a MEMS switched capacitor bank. Such MEMS devices have the added advantage of providing low insertion losses, higher isolation, high reliability, and linear capacitance. They run on low power and permit the entire circuit to be fabricated on a common substrate. Using the large tunability range of the MEMS device, an initial large capacitance is preferably set. The capacitance is reduced to rapidly converge the local signal to the carrier signal. This permits rapid and accurate lock of the local signal to the carrier signal. The use of MEMS tunable capacitance devices prevents large over- and under-shoots of the local signal in locking onto the carrier signal, thereby reducing unwanted harmonics generated by the charge pump and allowing the filtering requirements of the low pass filter to be relaxed and perhaps eliminated.
Further features and advantages of the invention will be apparent to those skilled in the art from the following detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a prior art charge-pump PPL circuit using a conventional fixed or variable capacitor;
FIG. 2 is a block diagram of a new circuit in accordance with the invention utilizing a MEMS variable capacitance device;
FIG. 3 is perspective view of a master-slave configuration for a tunable MEMS capacitor used in one embodiment;
FIGS. 4a and 5a are plan views showing sequential steps in the integration of a MEMS tunable capacitor into a charge-pump PPL circuit;
FIGS. 4b and 5b are sectional views taken along sectional lines 4b-4b and 5b-5b of FIGS. 4a and 4b, respectively; and
FIG. 5c is a sectional view taken along section line 5c-5c of FIG. 5a depicting the raised bridge structure of the tunable MEMS capacitor.
DETAILED DESCRIPTION OF THE INVENTION
The invention uses a MEMS capacitance device, preferably a tunable MEMS capacitor or a MEMS capacitor bank, to implement a frequency synthesizer which not only has a better capacitance range then that provided by conventional fixed or adjustable capacitors, but can be monolithically integrated. The MEMS capacitor provides linear capacitance with low insertion losses, higher isolation, higher reliability, and requires less power since the device is operated by electrostatic force.
FIG. 2 shows a block diagram of one implementation of the circuit. The objective is to match a locally generated signal to the carrier portion of a remotely generated signal at an input terminal 36 to remove the carrier signal and obtain its modulated information signal. The preferred embodiment shown in FIG. 2 is similar to the charge-pump PPL circuit 20 of FIG. 1, but a MEMS variable capacitor 38 is used. The frequency of the MEMS capacitor is preset to establish an initial input to the phase detector 24 with a frequency equal to the carrier signal to be received at input terminal 36. The MEMS tunable capacitor 38 integrates the current output from the charge pump 26 to determine how far off in frequency and in phase the VCO generated signal is from the carrier signal. The capacitance of capacitor 38 can be controlled either remotely or preferably by an output from charge pump 26. This can be handled in one of several fashions, with either the charge pump suppling a voltage signal to the master side of the MEMS capacitor, as described below, or by the use of a look up table that would provide a feedback signal to MEMS capacitor based on an initial signal received from charge pump 26. The MEMS capacitor is tunable over a range of approximately 10 to 1, or more. This allows for a large capacitance to be initially set, followed by a rapid reduction in capacitance to accurately match and remove the carrier signal. This approach not only provides for a rapid determination of the carrier signal, but also permits the signal to be accurately defined. In conventional circuits, the capacitance is normally fixed at a relatively large value in order to help assure that the locally generated signal approximates the carrier signal. This results in charge pump 26 producing a relatively large ΔI with an accompanying high level of detrimental harmonics, requiring the presence of a low pass filter 30 to remove them. The use of a MEMS capacitor 38 provides the unexpected advantage of allowing low pass filter 30 to be removed or at least be a less sophisticated, lower cost filter than is conventionally used. This is due to the fact that, for most of the circuit's operation, capacitor 38 has a small capacitance as the carrier signal is being honed in on. This results in a small ΔV being produced by phase detector 24, and likewise a small ΔI being produced by charge pump 26. As the current produced by charge pump 26 is quite small the unwanted harmonics generated by pump 26 also lessen. The filter 30 can therefore either be a less sophisticated filter, or preferably removed.
FIG. 3 is a perspective view of the MEMS tunable capacitor 38 shown in FIG. 2. The capacitor 38 comprises a master-slave capacitor structure fabricated on a common substrate 40, preferably silicon. A master (control) capacitor 42 responds to a control voltage to set the capacitance of the slave (signal) capacitor 44. The capacitors 42 and 44 have respective contact 46M and 46S mounted to substrate 60, with respective sets of flat parallel fingers 48M and 48S extending from contact 46M and 46S parallel to and elevated above the substrate surface, with the flat fingers surfaces vertical. Capacitors 42 and 44 include respective second pairs of contacts 50aM, 50bM, and 50aS, 50bS with bridge structures 52M and 52S respectively connecting the two contact pairs. Bridges 52M and 52S carry respective second sets of flat fingers 54M and 54S which are substantially parallel and interdigitated with fingers 48m and 48S. Bridges 52M and 52S and their associated fingers 54M and 54S form a series of movable capacitor plates 56M and 56S and are connected to each other by a mechanical coupler 58.
In the master-slave configuration, a signal voltage V sig (typically an RF signal in the MHZ to Ghz frequency range) is applied via contacts 46S and 50aS, 50bS across fingers 48s and 54s. A low frequency control voltage V c is applied across fingers 48M and 54M to produce an electrostatic force that attracts its movable capacitor plate 56M toward contact 46M causing a change in the capacitance of capacitor 44. The interdigitated configuration is preferred because it can be designed so that the force is independent of the displacement in the x direction. This is achieved by spacing the fingers evenly so that the force between them cancel and the fringing forces at the ends of the fingers in the z-direction dominate.
The master and slave capacitors 42 and 44 respectively, are oriented so that the electrostatic force produced by the signal voltage is orthogonal to the motion of movable plate 56M of master capacitor 42 in the Z direction. In order to make the direction of force on the slave capacitor 44 perpendicular to the direction of motion so that the spring constant can be low in the direction of motion and high in the direction of force, the interdigitated fingers 48M, 48S and 54M, 54S are offset so that they are a symmetric. The force between the fingers dominates the much smaller fringing force such that the lateral spring constant can be relatively small thereby providing a large range of motion and a correspondingly large tuning ratio, presumably on the order of 10:1 or more.
The invention can be implemented with a variety of substrate materials requiring several active device types. A monolithic microwave integrated circuit (MMIC is an I.C. in which microwave frequency active devices are integrated with passive components to perform a specific circuit function). A key advantage presented by the invention is the ability to integrate a series of microwave frequency active devices and their associated passive components (referred to herein as "MMIC components"), with a MEMS tunable capacitor on a common substrate, using MMIC fabrication processes. MMIC fabrication techniques are well known, and are discussed, for example, in C. T. Wang, Introduction to Semiconductor Technology, John Willy and Sons (1990), pp. 187-195 (active devices) and pp. 422-433 (passive components).
When fabricating a conventional MMIC, the active devices are fabricated using MMIC fabrication processes, followed by the fabrication of the passive components and the concurrent deposition and patterning of metal interconnecting runs ("runs") which connect the circuit elements together. The invention utilizes the processing steps that create the runs to concurrently fabricate the preferred MEMS tunable capacitor and to interconnect the capacitor with the other circuitry. Plan views of a fabrication sequence showing the integration of an active device in a MEMS tunable capacitor are shown in FIGS. 4a and 5a and corresponding sectional views are shown in FIGS. 4b, 5b taken across section lines 4b--4b and 5b--5b respectively. FIG. 5c is a sectional view taken across section 5c--5c of FIG. 5a showing the free-standing capacitor structure. The steps described and shown are intended only to illustrate the process sequence, they're not intended to depict the implementation of a particular function or frequency synthesizer. However, the process of simultaneously building up both the MEMs tunable capacitor and the interconnecting runs shown in FIGS. 4a, 4b, 5a, 5b and 5c may be extended as necessary to produce functional circuits.
FIGS. 4a and 5a fit one implementation of a MEMS tunable capacitor 38 shown in FIG. 2, integrated into a charge-pump phase-lock loop circuit 20 fabricated on a single crystal silicone substrate 60. Voltage control oscillator 22, phase detector 24, charge pump 26, low pass filter 30 and divider 32 are shown schematically fabricated on substrate 60, by known methods. Phase detector 24 furthermore has a series of pads 62 and 64 which the circuit receives and provides signals respectively. There are many possible ways of fabricating the MEMS tunable capacitor 38. One way is to use a silicon on insulator (SOI) wafer structure where the top silicon will be used as the capacitors structural material. A photo resist is first patterned forming contacts 46M, 46S, 50aM, 50aS, 50bM, 50bS and fingers 48M, 48S, 54M, 54S and bridges 52M and 52S. The pattern is then transferred to the top silicon 60 using reactive ion etching with an anisotropic sidewall profile that stops at a silicon dioxide layer 66 pattern on substrate 60. Next, a layer of Si 3 N 4 , suitably 0.5 to 2.0 microns thick to provide sufficient rigidity in the x-direction is patterned on the wafer to form mechanical coupler 58 that rigidly couples bridges 52M and 52S. Lastly, the wafer is subjected to a hydrofluoric acid (wet) etch to partially remove the underlying silicon dioxide layer 66, leaving the large structures still in tact with substrate 60 while the small geometry structures are free standing, as shown in FIG. 5c. Because all of the structure are formed in the top silicon, the control and signal capacitors are not, at this point, electrically isolated. Therefore, a deposition layer 68, suitably aluminum, covers the structure, specifically the capacitors fingers, to increase the conductivity of the master and slave capacitors with respect to the mechanical coupler 58 so that they are electrically isolated. The discontinuity between coupler 58 and bridges 52M and 52S create a discontinuity in the deposition layer that provides isolation. Additional details on the fabrication and use of the preferred MEMS tunable capacitor described above can be found in co-pending U.S. application Ser. No. 08/848,116 to Bartlett, et al. assigned to the same assignee as the present application and hereby incorporated by reference.
For the reasons noted above, it is preferred that circuit be fabricated together on a common substrate. However it is not essential that the invention be implemented this way. For example, MEMS capacitor 38 could be fabricated on a separate substrate and interconnected to the remainder of the circuit via wire bonds. This approach permits the MEMS device and the remainder of the circuit to be fabricated using different substrate materials and processing steps.
Though the integration of a MEMS tunable capacitor 38 and the series of active and passive devices of circuit was illustrated with a silicon substrate 60, other combinations of substrates are similarly contemplated.
In an alternate embodiment of the charge-pump phase-lock loop circuit, the MEMS tunable capacitor 38 can be replaced by a series of MEMS tunable capacitors which can be individually controlled by the circuit itself or by an external device. In a second alternate embodiment, the MEMS tunable capacitor 38 can be replaced by a MEMS switched capacitor bank. Additional details on the fabrication and use of the MEMS switched capacitor bank can be found in co-pending U.S. application Ser. No. 08/848,116 to Bartlett, et al. assigned to the same assignee as the present application and hereby incorporated by reference.
While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations in alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims. | A frequency stabilizer circuit in the form of a charge-pump phase-lock loop utilizing a MEMS capacitance device, preferably a tunable MEMS capacitor or a MEMS capacitor bank, which more rapid and with a greater precision determine the phase and frequency of a carrier signal so that it can be extracted, providing an information signal of interest. Such MEMS devices have the added advantage of providing linear capacitance, low insertion losses, higher isolation and high reliability, they run on low power and permit the entire circuit to be fabricated on a common substrate. The use of the MEMS capacitance device reduces unwanted harmonics generated by the circuit's charge pump allowing the filtering requirements to be relaxed or perhaps eliminated. | 7 |
RELATED APPLICATIONS:
This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 60/606,253 filed Aug. 31, 2004, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
This invention relates to liquid crystal displays (LCDs) and, in particular, to methods of maximizing the field of view and elimination of leakage of LCDs while maintaining high contrast ratio and minimal variance in relative gray levels over a wide range of viewing angles.
BACKGROUND OF THE INVENTION
High quality information display such as high contrast ratio and gray-scale stability can be obtained only within a narrow range of viewing angles centered about the normal incidence in conventional LCDs. The angular dependence of the viewing is due to the fact that both the phase retardation and optical path in most LC cells are functions of viewing angles. The narrow viewing angle characteristics have been a significant problem in advanced applications such as avionics displays and wide-screen displays, which require LCDs whose contrast and gray scale must be as invariant as possible with respect to viewing angle.
Accordingly, there is a need of further development in LCDs for high performance applications. The present invention provides a solution to the prior art problem by providing retardation films to achieve high contrast ratios and gray-scale level stability in LCDs.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood by the following detail description and appended claims with reference to the drawings below, in which:
FIG. 1 shows a Poincaré sphere illustrating polarization states;
FIG. 2 a shows an (+a, −a) wave plate combination where the retardance of each plate is Δnd=λ/6 (=92 nm at λ=550 nm). The +a plate transforms the polarization state from P to Q. The −a plate then transforms the polarization state from Q to P′;
FIG. 2 b shows an equi-transmittance contours of unpolarized light of Case 1 using Extended Jones matrix method;
FIG. 3 shows an (−a, +a) wave plate combination where the retardance of each plate is Δnd=λ/6 (=92 nm at λ=550 nm). The −a plate transforms the polarization state from P to R. The +a plate then transforms the polarization state from R to P′;
FIG. 4 a shows an (+a, +c, +a) wave plate combination where the retardance of a plate is Δnd=λ/6 (=92 nm at λ=550 nm) and the retardance of c plate is Δnd=√{square root over (3)} λ/6 (=159 nm at λ=550 nm). The +a plate transforms the polarization state from P to Q. The +c plate then transforms the polarization state from Q to R. The last +a plate then transforms the polarization state from R to P′;
FIG. 4 b shows an equi-transmittance contours of unpolarized light for Case 3;
FIG. 5 shows an (−a, −c, −a) wave plate combination where the retardance of a plate is Δnd=λ/6 (=92 nm at λ=550 nm) and the retardance of c plate is Δnd=√{square root over (3)} λ/6 (=159 nm at λ=550 nm). The −a plate transforms the polarization state from P to R. The −c plate then transforms the polarization state from R to Q. The last −a plate then transforms the polarization state from Q to R.
FIGS. 6-9 show combinations of vertically aligned liquid crystal (VALC) cell and c-plate with the designs shown in FIGS. 2-5 ;
FIG. 10 demonstrates a principal dielectric tensor axes orientation in a general case of optically anisotropic media;
FIG. 11 demonstrates a principal dielectric tensor axes orientation in cases including a negative A-plate compensator;
FIG. 12 demonstrates a principal dielectric tensor axes orientation in cases including a positive A-plate compensator;
FIG. 13 demonstrates a principal dielectric tensor axes orientation in cases including a positive C-plate compensator;
FIG. 14 demonstrates a principal dielectric tensor axes orientation in cases including a negative C-plate compensator;
FIG. 15 is spectra of refraction indices of the retardation films in accordance with one embodiment of the present invention; and
FIG. 16 is a Poincaré sphere showing polarization states in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Various embodiments of the present invention are described hereinafter with reference to the figures. It should also be noted that the figures are only intended to facilitate the description of specific embodiments of the invention. They are not intended as an exhaustive description of the invention or as a limitation on the scope of the invention. In addition, an aspect described in conjunction with a particular embodiment of the present invention is not necessarily limited to that embodiment and can be practiced in any other embodiments of the present invention. For instance, in the drawings and the following detailed description, the present invention is described with embodiments of retardation films with vertically aligned liquid crystal (VALC) cells. It will be appreciated that the claimed invention can be used with any other liquid crystal cells such as twisted nematic liquid crystal (TN-LC) cells.
FIG. 1 shows a Poincaré sphere illustrating various polarization states. In FIG. 1 , O represents polarization of transmitted component of first O-type polarizers at normal incidence; P represents polarization of transmitted component of first O-type polarizers at oblique incidence (angular deviations from 0 up to 16 degrees on the equatorial plane, 8 degrees in physical space); and P′ represent polarization of absorbed component of 2nd O-type polarizers at oblique incidence. PQP′ is substantially an equilateral triangle on Poincaré sphere. This triangle shrinks to a point O at normal incidence.
A pair of crossed polarizers only eliminate light at normal incidence. For off-axis light, the transmission polarization state of the first polarizer is rotated by up to 8 degrees in physical space, while the absorption polarization state of the second polarizer is rotated by up to 8 degrees in the opposite direction. These polarization states are shown as P and P′ on the Poincaré sphere. The present invention provides phase retardation films or compensators to transform the polarization state from P to P′ for off-axis light without affecting the normally incident light.
In one embodiment, the present invention provides compensator for two polarizers in “dark-state” comprising at least two layers from birefringent materials, wherein one of the layers operates as a positive A-plate and another layer operates as a negative A-plate. In another embodiment, the compensator further includes a negative C-plate between the birefringent layers.
In one embodiment, the negative A-plate comprises at least one layer of a birefringent material which has a crystal structure formed by at least one polycyclic organic compound with conjugated π-system, and an intermolecular spacing of 3.4±0.3 Å is in the direction of at least one of optical axes.
In one embodiment, the negative C-plate comprises at least one layer of a birefringent material which has a crystal structure formed by at least one polycyclic organic compound with conjugated π-system, and an intermolecular spacing of 3.4±0.3 Å is in the direction of at least one of optical axes.
In some embodiments, the compensator of the present invention further includes a positive C-plate between the birefringent layers.
In some embodiments, the compensator further includes at least two polarizers, wherein the axes of transmission of the two polarizers are mutually perpendicular. The organic compound forming the birefringent material may include ionogenic functional groups such as —COOH, —SO 3 H, PO 3 H, NH 2 . In one embodiment, the organic compounds is acenaphtho[1,2-b]quinoxaline sulfoderivative of the general structural formula:
where n is an integer in the range of 1 to 4;
m is an integer in the range of 0 to 4;
z is an integer in the range of 0 to 6, and m+z+n≦10;
X and Y are individually selected from the group consisting of CH 3 , C 2 H 5 , OCH 3 , OC 2 H 5 , Cl, Br, OH, and NH 2 ;
M is a counterion; and
j is the number of counterions in the molecule.
Examples of the organic compounds having the above general formula include but are not limited to the following structures I-VIII:
where m is an integer in the range of 0 to 3, and z is an integer in the range of 0 to 6;
where m is an integer in the range of 0 to 4, and z is an integer in the range of 0 to 5;
where m is an integer in the range of 0 to 2, and z is an integer in the range of 0 to 6;
where m is an integer in the range of 0 to 4, and z is an integer in the range of 0 to 4;
where m is an integer in the range of 0 to 3, and z is an integer in the range of 0 to 5;
where m is an integer in the range of 0 to 3, and z is an integer in the range of 0 to 4;
where m is an integer in the range of 0 to 2, and z is an integer in the range of 0 to 5;
where m is an integer in the range of 0 to 2, and z is an integer in the range of 0 to 4;
and where X, Y are individually selected from the group consisting of CH 3 , C 2 H 5 , OCH 3 , OC 2 H 5 , Cl, Br, OH, and NH 2 , M is a counterion, and j is the number of counterions in the molecule.
FIGS. 2-5 show specific configurations for cross-polarizers leakage elimination.
Case 1 shown in FIGS. 2 a and 2 b includes a combination of a positive a-plate and then a negative a-plate. The retardance of each plate is Δnd=λ/6 (=92 nm at λ=550 nm). The +a plate transforms the polarization state from P to Q. The -a plate then transforms the polarization state from Q to P′.
Case 2 shown in FIG. 3 includes a combination of a negative a-plate and then a positive a-plate. The retardance of each plate is Δnd=λ/6 (=92 nm at λ=550 nm). The −a plate transforms the polarization state from P to R. The +a plate then transforms the polarization state from R to P′.
Case 3 shown in FIG. 4 includes an ACA combination: a positive a-plate, a positive c-plate and then a positive a-plate. the retardance of a plate is Δnd=λ/6 (=92 nm at λ=550 nm) and the retardance of c plate is: Δnd=√{square root over (3)} λ/6 (=159 nm at λ=550 nm). The +a plate transforms the polarization state from P to Q. The +c plate then transforms the polarization state from Q to R. The last +a plate then transforms the polarization state from R to P′.
Case 4 shown in FIG. 5 includes an ACA-combination, a negative a-plate, a negative c-plate and then a negative a-plate. The retardance of a plate is Δnd=λ/6 (=92 nm at λ=550 nm) and the retardance of c plate is Δnd=√{square root over (3)} λ/6 (=159 nm at λ=550 nm). The −a plate transforms the polarization state from P to R. The −c plate then transforms the polarization state from R to Q. The last −a plate then transforms the polarization state from Q to R.
The configurations in Cases 1-4 can be combined with LC cells such as vertically aligned LC (VA LC) cells or field-on state of a TN-LC cells in LCDs. FIG. 6 illustrates a (VALC, c-plate) combination placed after a polarizer or before an analyzer. FIG. 7 illustrates a (VALC, c-plate) combination placed after a polarizer or before an analyzer. FIG. 8 illustrates a (VALC, c-plate) combination placed after a polarizer or before an analyzer. FIG. 9 illustrates a (VALC, c-plate) combination placed after a polarizer or before an analyzer.
It should be pointed out that other configurations are possible and the present invention is not limited to the above specific exemplary configurations.
Optically anisotropic media is characterized by its second rank dielectric tensor. The classification of the compensator plates is tightly connected to the orientation of the principal axes of a particular dielectric tensor with respect to the natural coordinate frame of the plate. The natural xyz coordinate frame of the plate is chosen in a way when the z-axis is parallel to its normal direction.
The orientation of the principal axes can be characterized by three Euler angles φ, θ, ψ, which, together with the principal dielectric tensor components (∈ A , ∈ B , ∈ C ) uniquely define different types of the optical compensators ( FIG. 10 ). The case when all the principal components of the dielectric tensor are unequal corresponds to the biaxial compensator. In this case the plate has two optical axes. For instance, in case of ∈ A <∈ B <∈ C these optical axes are in the plane of C and A axes on both sides with respect to the C-axis. In a uniaxial limit when ∈ A =∈ B we have the degenerated case when these two axes coincide with the C-axis that is just a single optical axis.
The zenithal angle between the C-axis and the z-axis is important in definitions of different compensator types.
If a plate is defined by Euler angle θ=π/2 and ∈ A =∈ B ,≠∈ C then it is called “A-plate.” In this case the principal C-axis lies in the plane of the plate (xy-plane), while A-axis is normal to the plane surface (due to the uniaxial degeneration the orthogonal orientations of A and B-axes can be chosen arbitrary in the plane that is normal to the xy-surface). In a case of ∈ A =∈ B <∈ C the plate is called “positive A-plate” ( FIG. 11 ). Contrary, if ∈ A =∈ B >∈ C the plate is defined as the “negative A-plate” ( FIG. 12 ).
Uniaxial C-Plate is defined by value of Euler angle θ=0 and ∈ A =∈ B ,≠ C . Thus the principal C-axis is normal with respect to the plate surface (xy-plane). In a case of ∈ A =∈ B <∈ C the plate is called “positive C-plate” ( FIG. 13 ). Contrary, if ∈ A =∈ B >∈ C the plate is defined as the “negative C-plate” ( FIG. 14 ).
Similar to the A-plate case, the C-plates can be either positive (∈ A =∈ B <∈ C ) or negative (∈ A =∈ B >∈ C ).
The disclosed compensator for a liquid crystal display comprises at least one layer of negative biaxial birefringent material, which is thin crystal film (TCF) based on an aromatic polycyclic compound. This material usually possesses negative biaxial features n 1 o ≧n 2 2 o >n e . The extraordinary optical axes of the same materials coincide with direction of alignment. For practical applications the thin crystal films may be regard as uniaxial films: n 1 o ≈n 2 o .
Preferably a developed system of π-conjugated bonds between conjugated aromatic rings are present in the molecules and groups (such as amine, phenol, ketone, etc.) are lying in the plane of the molecule and involved into the aromatic system of bonds. The molecules and/or their molecular fragments possess a planar structure and are capable of forming supramolecules in solutions. Preferably there is the maximum overlap of π orbitals in the stacks of supramolecules. The selection of raw materials for manufacturing the compensator deals with spectral characteristics of these compounds.
Aromatic polycyclic compounds suitable for the obtaining of thin crystal films (TCFs) are characterized by the general formula {R} {F}n, where R is a polycyclic fragment featuring a π electron system, F is a modifying functional group ensuring solubility of a given compound in nonpolar or polar solvents (including aqueous media), and n is the number of functional groups.
The TCFs can be obtained by a method called Cascade Crystallization Process developed by Nitto Denko Corporation, Osaka, Japan. According to this method such an organic compound dissolved in an appropriate solvent forms a colloidal system (lyotropic liquid crystal solution) in which molecules are aggregated into supramolecules constituting kinetic units of the system. This liquid crystal phase is essentially a precursor of the ordered state of the system, from which a solid anisotropic crystal film is formed in the course of subsequent alignment of the supramolecules and removal of the solvent.
A method stipulated for the synthesis of thin crystal films from a colloidal system with supramolecules includes the following stages:
(i) application of the aforementioned colloidal system onto a substrate (or onto a device or a layer in a multilayer structure); the colloidal system must possess thixotropic properties, which are provided by maintaining a preset temperature and a certain concentration of the dispersed phase;
(ii) conversion of the applied colloidal system into a high flow (reduced viscosity) state by any external action (heating, shear straining, etc.) decreasing viscosity of the solution; this action can be either applied during the whole subsequent alignment stage or last for a minimum necessary time, so that the system would not relax into a state with increased viscosity during the alignment stage;
(iii) external alignment action upon the system, which can be produced using mechanical factors or by any other means; the degree of the external action must be sufficient for the kinetic units of the colloidal system to acquire the necessary orientation and form a structure that would serve as a base of the crystal lattice of the anisotropic thin crystal film;
(iv) conversion of the aligned region of the layer from the state of reduced viscosity, achieved due to the external action, into the state of the initial or higher viscosity; this transition is performed so as not to cause disorientation of the anisotropic thin crystal film structure and not to produce surface defects;
(v) final stage of solvent removal (drying), in the course of which the anisotropic thin crystal film structure is formed; this stage can also include an additional thermal treatment (annealing) characterized by the duration, character, and temperature, which are selected so as to ensure full or at least partial removal of water molecules from said crystal hydrate structure, while retaining the structure of supramolecules and crystalline structure of conjugated aromatic crystalline layer intact.
In the resulting anisotropic TCF, the molecular planes are parallel to each other and the molecules form a three-dimensional crystal structure, at least in a part of the layer. Optimization of the production technology may allow the formation of a single-crystal film. These films are disclosed in the present invention as base for manufacturing negative A-plate.
The TCF thickness usually does not exceed approximately 1 mkm. The film thickness can be controlled by changing the content of a solid substance in the applied solution and by varying the applied layer thickness. In order to obtain the films possessing desired optical characteristics, it is possible to use mixed colloidal systems (such mixtures can form joint supramolecules).
The mixing of said organic compounds in solutions results in the formation of mixed aggregates of variable composition. The analysis of X-ray diffraction patterns for dye mixtures allow us to judge about the molecular packing in supramolecules by the presence of a characteristic diffraction peak corresponding to interplanar spacing in the range from 3.1 to 3.7 Å. In general, this value is common for aromatic compounds in the form of crystals and aggregates. The peak intensity and sharpness increase in the course of drying, however, no changes in the peak position are observed. This diffraction peak corresponds to the intermolecular spacing within aggregates (stacks) and has been observed in the X-ray diffraction patterns of various materials. The mixing is favored by the planar structure of molecules (or their fragments) and by the coincidence of one molecular dimension in the organic compounds under consideration. In the applied aqueous layer, the organic molecules possess a long-range order in one direction, which is related to the alignment of supramolecules on the substrate surface. As the solvent is evaporated, it is energetically favorable for the molecules to form a three-dimensional crystal structure.
Preferably the chemical compound for compensators is non-absorbing in working ranges. The series of new chemical compounds, namely acenaphtho[1,2-b]quinoxaline sulfoderivatives, can be synthesized which are well suited for the construction of optical compensators. These compounds have a general structural formula:
where n is an integer in the range of 1 to 4; m is an integer in the range of 0 to 4; z is an integer in the range of 0 to 6, and m+z+n≦10; X and Y are individually selected from the group consisting of CH 3 , C 2 H 5 , OCH 3 , OC 2 H 5 , Cl, Br, OH, and NH 2 ; M is a counter ion; and j is the number of counter ions in the molecule.
The material formed from an acenaphtho[1,2-b]quinoxaline sulfoderivative is well suited for the construction of optical compensators for liquid crystal displays, although the present invention is not limited by using only this compound.
The present invention expands the assortment of compounds that are either not absorbing or only weakly absorbing in the visible spectral region and that are capable of forming a lyotropic liquid crystal (LLC) phase. High optical anisotropy (up to Δn=0.6 in the visible spectral range) and high transparency (extinction coefficients are on the order of 10 −3 ) of the films allow high-efficiency compensators for LCDs to be designed.
The following examples are provided to illustrate the invention and are not intended to limit the invention in any way.
EXAMPLE 1
A-plate compensator was produced according to the present invention and analyzed to determine the optical characteristics.
The liotropic liquid crystal contained 14% the mixture of sulfoderivatives of acenaphtho[1,2-b]quinoxaline and 0,1% PAV (Zonyl FS 300). The LLC was coated onto a glass substrate (Display Glass) with a Mayer rod #1.5 at a temperature of 20° C., and a relative humidity of 65%. The film was dried at the same humidity and temperature. The thickness of made film is 039 nm.
To determine optical characteristics of the film, sample transmission spectra were measured in polarized light in the wavelength range from 400 to 800 nm using Cary-500 spectrophotometer. The obtained data were used to calculate of the refraction indices tensor components (n X , n Y , n Z ) ( FIG. 7 ). Here Z-axis is perpendicular to the surface of the film and Y-axes is parallel to the alignment direction. The produced film is A-plate compensator and exhibits high retardation characteristic Δn=n X -n Y increasing from 0.24 up to 0.48 in the visible spectral range. The low values of absorption coefficients (k X,Y,Z <2*10 −3 ) confirm high transparency of the film.
EXAMPLE 2
A-plate compensator was produced according to the present invention and analyzed to determine the film's optical characteristics. 12 g of the mixture of sulfoderivatives of acenaphtho[1,2-b]quinoxaline were introduced with stirring at a temperature 20° C. into 65.0 g of deionized water. Then 5.3 ml of 25% aqueous ammonia solution were added and the mixture stirred to complete dissolution. The solution was concentrated on rotary evaporator to 30% and coated onto a polymer substrate (SONY-film, “Zeonor”) with a Mayer rod #2.5 at a linear rate of 15 mm s −1 , a temperature of 20° C., and a relative humidity of 65%. The film was dried at the same humidity and temperature. This film on the substrate is a negative A-plate compensator.
To determine optical characteristics of the film, sample transmission spectra were measured in polarized light in the wavelength range from 400 to 800 nm using Cary-500 spectrophotometer. The findings demonstrate a very low absorbance of the film in the visible spectral range at the wavelength above 430 nm.
The obtained data were used to calculate refraction indices (n e , n o ) and absorption coefficients (k e ,k o ) parallel and perpendicular to the alignment direction ( FIG. 8 ). The produced film is optically anisotropic and exhibits high retardation characteristic Δn=n o −n e increasing from 0.21 up to 0.38 in the visible spectral range. The low values of absorption coefficients ko and ke confirm high transparency of the film.
EXAMPLE 3
C-plate compensator was produced according to the present invention as multilayer structure. This compensator has been obtained in the following way. Initially, anisotropic layer TCF has been formed on the polymer substrate as it was described above. Then, the separating layer of SiO 2 with thickness of 100 nm was deposited, and another the same anisotropic layer was deposited such that the directions of the optical axes of the first and the second anisotropic layers would be perpendicular. Any suitable transparent material may be used as the separating layer, for example: lacquer, polymer and etc.
From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. | The compensator design, which comprises at least two layers of birefringent material, one of them is a positive A-plate and another one is a negative A-plate, makes possible a significant improvement in color rendering properties and contrast ratios of liquid crystal displays over a wide range of viewing angle. | 8 |
FIELD OF THE INVENTION
This invention relates to a mechanical lock for securing two flaps together to form a panel of a carton. More particularly, it relates to a mechanical lock adapted for use in a wrap-around carrier.
BACKGROUND OF THE INVENTION
Wrap-around carriers or cartons are commonly used to package beverage containers as well as other types of articles. To form a package the centrally located top panel section of a carrier blank is normally positioned on a group of articles to be packaged and the side panel sections are folded down. Bottom panel flaps at opposite ends of the blank are then folded into place, with one of the flaps partially overlapping the other. Although the bottom panel flaps in some carriers are glued to each other, integral mechanical locks are commonly employed to connect the flaps together. Typically, primary locking tabs on one of the flaps engage an edge of a primary locking opening in the other flap, and separately formed secondary locking tabs are secured in secondary locking openings to prevent the primary locks from separating.
A variety of locking mechanism designs have been used over the years. While many of the designs are capable of adequately locking bottom panel flaps together, it would nevertheless be desirable to provide an improved locking mechanism which not only locks the bottom panel flaps in place and prevents them from separating, but also reduces the cost of the carton by reducing the material usage of the carrier. In addition, the locking mechanism should be such that the bottom panels can be locked together by existing packaging machinery.
It is an object of the invention to provide a panel locking mechanism which meets these criteria.
BRIEF SUMMARY OF THE INVENTION
The invention is incorporated in a carton which includes a panel formed from a pair of partially overlapped mechanically connected flaps. The overlapping panel flap includes a male locking flap which is foldably connected to the panel flap. A primary locking tab is at one end of the male locking flap adjacent the locking flap fold line and a secondary locking tab is at the other end. The primary locking tab extends into a primary locking opening in the overlapped panel and a secondary locking tab extends into a secondary locking opening in the overlapped panel to lock the panels together.
In a preferred arrangement the male locking flap fold line is comprised of spaced segments, with the primary locking tab being located between the spaced segments. The male locking flap extends from the male locking flap fold line over the free edge of the first panel flap and into the secondary locking opening. The primary female locking opening is thus in the overlapped area of the panels and includes an edge substantially parallel to the male locking flap fold line, with the secondary female locking opening being spaced therefrom. Typically, the pair of flaps are the bottom panel flaps of a wrap-around carrier.
In addition to providing a strong secure lock to hold the bottom panel flaps together, the carrier is economical to produce, aided by the fact that the male locking flap is formed from an opening in the overlapping bottom panel flap and thus reduces the amount of carrier material in a blank. These and other aspects and benefits of the invention will readily be apparent from the more detailed description of the preferred embodiment of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a pictorial view of a wrap-around carrier incorporating the locking mechanism of the invention;
FIG. 2 is a plan view of a blank for forming the carrier of FIG. 1;
FIG. 3 is an end view of an initial stage of the formation of a carrier from the blank of FIG. 2;
FIG. 4 is a partial pictorial view of the bottom panel flaps of the carrier at an initial stage of formation of one of the bottom panel locks;
FIG. 5 is partial end view of the interim form of carrier lock shown in FIG. 4;
FIG. 6 is a partial pictorial view of the bottom panel flap similar to that of FIG. 4, but showing the locking tabs at a later stage of lock formation;
FIG. 7 is a partial plan view of the bottom panel of the finished carrier, showing the locking tabs in their final positions;
FIG. 8 is a partial plan view of the interior of the bottom panel of the finished carrier, with the packaged articles omitted; and
FIG. 9 is an enlarged transverse sectional view taken on line 9--9 of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the invention is incorporated in package 10, which is comprised of wrap-around carrier 12 containing four beverage cans C. The carrier is of basic wrap-around design, including a top panel 14 connected by fold lines 16 to side panels 18, which in turn are connected by fold lines 20 to bottom panel 22. Included in the side panels are sloped shoulder panel sections 24, defined by fold lines 16 and 26, and sloped heel panel sections 28, defined by fold lines 20 and 30. Can lid cutouts 32 are provided in the shoulder panel sections 24 and heel cutouts 34 are provided in the heel panel sections 28. A finger hole 36 covered by separable tab 38 is provided in the top panel for use as a grip for lifting the carrier. As described in more detail below, the bottom panel is formed from partially overlapping flaps 40 and 42 which are connected to each other by the mechanical locking means of the invention.
A blank 44 for forming the carrier is shown in FIG. 2 as comprising a generally rectangular sheet of flexible material possessing sufficient stiffness and strength to make it capable of withstanding the stresses to which the carrier is subjected during packaging and use. Paperboard of the type normally associated with the carrier industry is preferred. The top panel section 14 is substantially centrally located in the sheet between the shoulder panel portions 24 of side panel sections 18, and the bottom panel flaps 40 and 42 are connected to the heel panel portions 28 of the side panel sections. The heel cutouts extend throughout the major portion of the width of the associated heel panel section 28 and for a slight distance into the bottom panel flaps 40 and 42. Spaced slits 46 in the side panel sections 18 extend to the inner edge of the heel cutouts 34 to form tabs 48 which are arranged so as to contact the sides of packaged cans just above the heel cutouts.
Spaced from the outer end of the bottom panel flap 40 are two primary locking openings 50 which include an outer edge 52 parallel to the fold line 20. Inwardly spaced from each primary locking opening 50 is a secondary locking opening in the form of arcuate slit 54 and contiguous end slits 56 which together form tabs 58. The primary and secondary locking openings are located opposite the heel cutout areas.
Spaced from the outer edge of the bottom panel flap 42 are two primary locking tabs 60 formed by slits 62. Extending from the ends of each tab 60 are fold lines 64. Connecting the ends of the fold lines 64 are slits 66 which together with the fold lines 64 and tabs 60 form male locking flaps 68. Transverse fold lines 70 extending across the width of the locking flaps 68 separate the flaps into a portion containing the primary locking tab 60 and a portion consisting of secondary locking tab 72. Both the fold lines 70 and 64 are parallel to the fold line 20. The secondary locking tab 72 is generally in the shape of an arrow head, including ears 74.
To form a package, the articles are segregated into the desired final arrangement and the blank is positioned so that the top panel section rests on top of the cans. The side panel sections and the bottom panel flaps are then folded in the conventional manner. A typical point in this folding process is illustrated in FIG. 3. As the inward folding of the bottom panel flaps continues the male locking flaps 68 are folded outwardly, eventually pivoting about the fold lines 64 through an angle of substantially 180°. As the folding process of the male locking flaps and the bottom panels continues a point is reached at which the bottom panel flaps have reached their final relative positions in which the bottom panel flap 42 partially overlaps the bottom panel flap 40 and the male locking flaps 68 have been folded out from the bottom panel flap 42 through an angle of approximately 90°. At this point the primary male locking tabs 60 are directly aligned with the edges 52 of the primary female locking openings 50 and extend through the locking opening 50. The relative positions of the locking elements at this point in the package forming process are illustrated in FIGS. 4 and 5.
As the male locking flaps 68 continue to be pivoted about the fold lines 64 the secondary locking tab portions 72 are folded about the fold lines 70 to bring the ends of the secondary locking tabs to the slits 54 of the secondary locking openings. This intermediate point in the locking process is illustrated in FIG. 6. Pressure on the fold line 70 of the secondary locking tabs moves the secondary locking tabs into the interior of the carrier beneath the slit 54, pushing the secondary locking opening tabs 58 out of the plane of the bottom panel flap 40. The tabs 58 are biased against movement out of the plane of bottom panel flap 40, thus being urged against the secondary locking tabs 72 to help maintain them in place. The primary and secondary locks at this point are now fully activated. The final arrangement of the locks as they appear from the exterior of the carton is shown in FIG. 7. The final arrangement of the locks as they appear from the interior of the carton is shown in FIG. 8. The relationship of the locking elements in their final locked condition is illustrated in FIG. 9. Note that the primary and secondary locking tabs are firmly locked in place. The secondary locking tabs 72 are being urged by the tabs 58 against the interior face of the bottom panel flap 40, while the locked condition of the secondary locking tabs 72 causes the primary locking tabs 60 to also be held against the inner face of the bottom panel flap 40. In addition, the locking flaps 68 are looped over the ends of the bottom panel flap 42, forming a strap-like configuration which further supports and strengthens the bottom panel.
Although the various folding steps and the tightening step can be performed by hand, it is preferred to carry them out by conventional elements of a packaging machine, which are well known in the industry and need no further explanation or illustration. Although the panel locking process has been described in connection with the formation of an upright carton, it will be understood that the same principles would apply if the panel were formed with the carton inverted. Also, although described in connection with the packaging of beverage cans, the principles of the invention may be applied to carriers designed to package other types of articles.
It will be appreciated that the locking system of the invention provides the carrier with the structural integrity to support packaged articles without risk of failure of the locked panel flaps. Since the male locking flaps are fully formed from the overlapping bottom panel flap the length of the blank is reduced, thus reducing the cost of the carrier material.
It should be understood that the invention is not limited to all the specific details described in connection with the preferred embodiment and that changes to certain features of the preferred embodiment which do not alter the overall basic function and concept of the invention may be made without departing from the spirit and scope of the invention defined in the appended claims. | A wrap-around carrier having primary and secondary locks for connecting the bottom panel flaps together. One of the bottom panel flaps includes a foldably connected male locking flap having a primary locking tab adjacent the fold and a secondary locking flap at the other end. The other bottom panel flap contains primary and secondary female locking openings. The bottom panel flap containing the male locking flap partially overlaps the other bottom panel flap, with the male locking tabs being inserted into the female locking openings. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the biological treatment of ordnance or explosives to improve the environmental character thereof and, in particular, to the degradation of TNT (2,4,6-Trinitrotoluene) by using Phanerochaete chrysosporium or white-rot fungus to convert TNT to CO 2 .
2. Description of the Prior Art
The compound TNT (2,4,6-trinitrotoluene) is the predominant conventional explosive used by military forces. Unfortunately, past practices for the disposal of TNT generated during the production of TNT and of military ordnance which use TNT have led to soil, sediment, and water contamination. This is of concern because exposure to TNT can cause diseases such as pancytopenia, a disorder of the blood forming tissues characterized by a pronounced decrease in the number of leukocytes, erythrocytes and reticulocytes in the human body. In addition, TNT is known to be toxic to fish such as bluegills at concentrations of 2 to 3 micrograms per milliliter, certain green algae such as Microcystis aeruoinosa and oysters.
In the past TNT has been treated by methods such as the invention disclosed in U.S. Pat. No. 4,038,116 to Andrews et.al. U.S. Pat. No. 4,038,116 discloses a method for treating an aqueous solution of aromatic explosives whereby explosive molecules, such as TNT, are destroyed, and the resulting effluent is safe for disposal. An additive, such as acetone or hydrogen peroxide, is added to an aqueous solution of an aromatic explosive and this mixture is exposed to ultraviolet light. The light exposure of the additive provides a free radical which strips hydrogen molecules from the aromatic explosive to change the aromatic explosive to an unstable intermediate compound. Continued exposure of the unstable intermediate compound to ultraviolet light converts the unstable intermediate compound to carbon dioxide and ammonia. While satisfactory for its intended purpose, that of disposing of aromatic explosives such as TNT, the invention of U.S. Pat. No. 4,038,116 is not very efficient for large scale treatment of contaminated waste disposal sites, can require a considerable expenditure of funds to obtain the required materials and equipment and has obvious limitations, particularly when it is required to treat soil contaminated with TNT.
It is therefore an object of the present invention to provide a relatively inexpensive and efficient method for disposing of waste discharges containing the explosive TNT.
It is further an object of the present invention to provide an ecologically acceptable method of disposing of waste discharges containing TNT by biodegrading the TNT using white rot fungus to convert TNT to carbon dioxide (CO 2 ).
Other objects, advantages, and novel features of the present invention will become apparent from the following detailed description of the present invention.
SUMMARY OF THE INVENTION
The present invention comprises a process of biodegrading TNT contained in liquid or solid waste utilizing a white-rot fungus as the active ingredient in the TNT degrading process. The white-rot fungus is grown in a liquid medium in the presence of certain nutrients including nitrogen. The white-rot fungus is then caused to enter a secondary metabolic state by limiting the nutrient nitrogen and supplying a carbon source for hydrogen peroxide production. After the white-rot fungus enters a secondary metabolic state the white-rot fungus is capable of degrading TNT. The white-rot fungus may then be added to soil containing TNT resulting in degradation of the TNT within the soil. It has been determined that over a period of 90 days approximately 85% of TNT in water at 100 mg/liter and in soil at 10,000 mg/kg was degraded.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating the mineralization of [ 14 C] TNT in nutrient nitrogen-limited-liquid cultures of Phanerochaete chrysosporium with each culture containing 57.92 nmol of [ 14 C]TNT;
FIG. 2 is a graph illustrating the mineralization of [ 14 C]TNT in soil-corncob cultures of Phanerochaete chrysosporium with each culture consisting of 57.9 nmol of [ 14 C]TNT;
FIG. 3 is an HPLC elution profile of authentic [ 14 C] trinitrotoluene;
FIG. 4 is an HPLC elution profile of a methylene chloride extract of a nutrient nitrogen-limited culture of Phanerochaete chrysosporium incubated with [ 14 C]TNT for a time period of 18 days;
FIG. 5 is an HPLC elution profile of an acetonitrile extract of a soil-corncob culture incubated with Phanerochaete chrysosporium and [ 14 C]TNT for a time period of 30 days.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Though the process of the present invention can use any of many white-rot fungus, Phanerochaete chrysosporium strain VKM-F-1767 was used in the preferred embodiment of the present invention because of its vigorous growth and rapid degradation capabilities. The white-rot fungus, Phanerochaete chrysosporium strain VKM-F-1767 used to degrade TNT was acquired from the Forest Products Laboratory, U.S. Department of Agriculture, Madison, Wis. A culture of the white-rot fungus, Phanerochaete chrysosporium strain VKM F-1767, is deposited with the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852-1776. The accession number for the white-rot fungus, Phanerochaete chrysosporium strain VKM F-1767 is ATCC 20696. The white-rot fungus was maintained at room temperature on 2% (wt/vol) malt agar slants.
The first step in the method/process of the present invention is to culture the white-rot fungus to provide a readily available active ingredient capable of biodegrading TNT. Such development should take place under sterile or semisterile conditions in a stationary liquid medium containing nitrogen and sufficient nutrients for germination and rapid growth. Glucose, cellulose, and inexpensive, commercially available corn cobs or a source of cellulose work equally well as a source of nutritional requirements for fungal growth.
The white-rot fungus was incubated in a liquid culture media composed of 56 millimolers (mM) glucose, 1.2 mM ammonium tartrate (nitrogen-limited), trace metals and thiamine (1 milligram per Liter) in a 20 mM 2,2'-dimethylsuccinate buffer (Ph 4.2). The liquid culture media was first sterilized by filtration through a cellulose acetate membrane filter (pore size 0.22 μm). Culture bottles for the liquid culture media were sterilized by autoclaving at 121° C. and 15 psi for 20 minutes.
Nine milliliter aliquots of the liquid culture medium were next dispensed into each of a plurality of 250 milliliter Wheaton bottles equipped with a gas exchange manifold having a Teflon seal. To grow the fungus, a one milliliter (ml), 0.5 absorbance unit at 650 nanometers spore suspension of Phanerochaete chrysosporium was inoculated into the liquid culture medium and grown at 39° C. The spores which readily germinate were grown in the culture medium under ambient air for 6 days. After the white-rot fungus has entered a secondary metabolic state the white-rot fungus is capable of degrading TNT. Control cultures contained the culture media minus the Phanerochaete chrysosporium inoculum.
At this time it should be noted that there are other processes for growing white-rot fungus, Phanerochaete chrysosporium strain VKM F-1767, such as the process described in Chang et. al. U.S. Pat. No. 4,554,075.
In one experiment, 57.92 nano-moles (13μg) of [ 14 C]TNT, which is a radiolabeled or radioactive TNT having a specific activity of 21.58 Mci/nmol, was added to the nitrogen limited cultures after six days of the white-rot fungus growth under ambient atmosphere. At 3-day intervals thereafter, the headspaces of the culture bottles were flushed with oxygen (99.9% pure) and liberated CO 2 was passed through a volatile organic trap consisting of 10 ml of scintillation cocktail, tradename Safety Solve, manufactured by Research Products International Corp. of Mt. Prospect, Ill. prior to passage through a vial containing 10 ml of CO 2 trap. The CO 2 trap was a mixture of ethanolamine in methanol and scintillation cocktail (1:4:5; vol/vol/vol). The volatile organic trap was used to ensure that the radiolabeled material trapped in the CO 2 trap was not contaminated with volatile organics as a result of air stripping during flushing. The amount of radioactivity in each trap was then determined by liquid scintillation spectrometry and is best illustrated by FIG. 1. It should be noted that the radiolabeled TNT was manufactured by Chemsyn Science Laboratories of Lenexa, Kans.
The ability of white-rot fungus to degrade [ 14 C]TNT in soil was also examined in a second experiment. An agricultural silt loam soil consisting of 19% sand, 54% silt and 27% clay was used in this experiment. The organic matter content of the soil was 3.62% of which 2.10% was organic carbon. Total nitrogen was 0.19% and the soil Ph was 6.4. The cation exchange capacity was 23.6 milliequivalents per 100 grams. Ten grams of soil was placed in 250 ml Wheaton bottles. Then, 57.92 nmoles of [ 14 C]TNT dissolved in 160 μl acetone was added to the soil. The acetone was allowed to evaporate and the soil was then mixed with 6.7 grams of corn cob that had ten days earlier been inoculated with white-rot fungus. The moisture content of the soil was adjusted to the maximum water binding capacity of the mixture by adding 3.5 ml of water. Unlike the liquid culture experiment, sterile conditions were not used. Also, cultures were not supplemented with buffer, trace metals or other nutrients. Cultures were incubated at 39° C. for 30 days. Every 3 days the head spaces of the culture bottles were flushed with oxygen. The liberated 14 CO 2 was trapped in the manner described for the first experiment, and the amount of 14 CO 2 recovered was determined by liquid scintillation spectrometry. The results of the second experiment are, in turn, illustrated by FIG. 2.
To perform mass balance analyses on liquid cultures incubated with [ 14 C]TNT, the contents of each 250 ml Wheaton bottle were extracted three times with 30 ml of dichloromethane and 30 ml of water (1:1, vol/vol). The dichloromethane extracts were combined and concentrated by evaporation under a gentle stream of nitrogen. Following the extractions, particulate matter, that is fungal mat, was separated from the aqueous fraction by filtration through glass wool. The amount of 14 C which was bound to the fungal mat and not extractable by organic solvent was determined by combustion in a Harvey Biological Oxidizer manufactured by R. J. Harvey Instrument Corp. of Hillsdale, N.J. followed by measurement of trapped 14 CO 2 by liquid scintillation spectrometry. The aqueous portion was also assayed for radioactivity by liquid scintillation spectrometry.
High Performance Liquid Chromatography (HPLC) of [ 14 C]TNT metabolites was performed by using a system equipped with a Spectra-Physics model SP 8810 pump manufactured by Spectra Physics of San Jose, Calif.; a Rheodyne injector manufactured by Rheodyne Inc. of Cotati, Calif.; a 5 μm, 4.6 by 250 mm model Rsil C-18 reverse-phase column manufactured by Beckman Instrument Inc. of San Ramon, Calif. and a Spectra-Physics model SP 8450 variable wavelength absorbance detector. Isocratic elution was performed with methanol:water (50:50 vol/vol) at a flow rate of 1 ml/min. The wavelength of the absorbance detector was 254 nm. The retention time of [ 14 C]TNT was established by monitoring the elution of authentic TNT at 254 nm as is best illustrated by FIG. 3. For the mass balance studies, 20 μl samples of the concentrated organic extract were used for injection into the HPLC system. One milliliter fractions were collected in scintillation vials. Nine milliliters of Safety Solve were added to each fraction, and was measured by liquid scintillation spectrometry measured the radioactivity.
The results of the HPLC analysis of TNT being biodegraded by white-rot fungus in liquid cultures is illustrated in FIG. 4. FIG. 4 is an HPLC profile of methylene chloride extract of nutrient nitrogen limited culture of Phanerochaete chrysosporium BKM strain VKM F-1767 incubated with [ 14 C]TNT for 18 days. Each culture consisted of 57.9 nmol of [ 14 C]TNT.
At the end of a 30 day incubation period a mass balance analysis was also performed on soil cultures using extraction procedures fully described in a publication entitled "Development of an Analytical Method for Explosive Residues in Soil", by T. F. Jenkins and M. E. Walsh, Report 87-7 Cold Regions Research and Engineering Laboratory, U.S. Printing Office, Springfield, Va. The contents of each 250 ml Wheaton bottle were extracted three times with 30 ml of acetonitrile. First, the soil/corn cob mixture was dispersed using a vortex mixer for a time period of 10 minutes and followed by sonication in an ultrasonic bath for 18 hours. The acetonitrile extracts were next combined and concentrated by evaporation under a gentle stream of nitrogen. The concentrated extract was then centrifuged for 5 minutes at 1500 rpm and a ten milliliter clear supernatant was removed using a volumetric pipet and mixed with an equal volume of water in a glass scintillation vial. The contents of the vial were thoroughly mixed, allowed to stand for 15 minutes and filtered through a 0.45 μm ARCO LS-25 disposable filter assembly. The filtrate/organic extract was collected and saved for HPLC analysis. Twenty microliters of the extract was used for HPLC analysis as described above. Metabolite formation in soil from [ 14 C]TNT was monitored by liquid scintillation spectrometry of the HPLC fractions. Fractions (1 ml) were collected and radioactivity was determined in the same manner as set forth for the liquid cultures. Radiolabeled compounds which were found to the soil/corn cob matrix and were not recovered by organic solvent extraction were combusted to CO 2 in a Biological Oxidizer and radioactivity was measured by liquid scintillation spectrometry. The vortex mixer utilized the during the extraction procedure was a model Genie 2 manufactured by Scientific Industry, Inc. of Bohemia N.Y.; the ultrasonic bath was manufactured by Branson Equipment Company of Shelton, Conn.; the biological oxidizer was manufactured by R. J. Harvey Instrument Corporation and the filter assembly was manufactured by Gelman Sciences.
The results of the HPLC analysis of TNT being biodegraded by white-rot fungus in soil cultures are illustrated in FIG. 5. FIG. 5 is an HPLC profile of an acetonitrile extract of a soil-corncob culture incubated with Phanerochaete chrysosporium strain BKM-F-1767 and [ 14 C]TNT for a time period of 30 days. Each culture contained 57.9 nmol of [ 14 C]TNT.
In other experiments, white-rot fungus/Phanerochaete chrysosporium strain VFM-F-1767 was tested for its ability to mineralize radiolabeled TNT in both liquid and soil at levels that may be encountered in environment, i.e., 100 mg/liter in water and 10,000 mg/kg in soil. Culture conditions were as the conditions for the first and second experiments except for the concentration of TNT and the time of incubation. Rates of mineralization were obtained and mass balance analyses were performed as described for the first and second experiment after time periods of 30, 60 and 90 days for the liquid and soil cultures. One culture was extracted at each time except for the 90 day time period for soil cultures, for which two cultures were used.
The results for mass balance analysis of TNT by white-rot fungus in liquid cultures (100 mg/liter) and soil cultures (10,000 mg/kg) are set out respectively in Tables I and II.
TABLE I______________________________________Mass balances for 2,4,6-trinitrotoluene metabolism byPhanerochaete chrysosporium in liquid culture (100 mg/liter)______________________________________ % ExtractedIncubation % Metabolites methylenePeriod % in water chloride.sup.a(Days) Mineralized fraction fraction______________________________________30 18.4 ± 2.4 52.0 12.160 19.0 ± 3.0 51.6 19.590 19.6 ± 3.5 50.1 22.7______________________________________Incubation % AdsorbedPeriod to fungal % Mass % TNT(Days) mat fraction Recovery Remaining______________________________________30 11.0 93.5 22.160 5.1 95.2 14.990 2.2 94.6 12.3______________________________________ .sup.a In liquid cultures, 6day-old ligninoytic cultures of P. chrysosporium contained 57.9 nmol of [.sup.14 C]TNT and 1 mg of TNT. Mass balances were quantitated as described in Materials and Methods.
TABLE II______________________________________Mass balance for 2,4,6-trinitrotolene metabolism byPhanerochaete chrysosporium in soil (10,000 mg/kg)______________________________________Incubation % AbsorbedPeriod % % Extracted in to soil-(Days) Mineralized acetonitrile.sup.b corncob.sup.b______________________________________30 9.8 ± 1.9 69.5 14.460 17.1 ± 2.2 59.8 15.390 18.4 ± 2.9 62.6 11.5______________________________________IncubationPeriod % Mass % TNT(Days) Recovery Remaining______________________________________30 93.7 50.860 92.2 29.390 92.5 14.9______________________________________ .sup.a In soil cultures, 57.9 nmol of [.sup.14 C]TNT and 100 mg of TNT, dissolved in acetone, were adsorbed onto 10 g of nonsterile soil. The acetone solvent was allowed to evaporate, 6.7 g of preinoculated corncobs was added, and the water content was adjusted to 40% (wt/wt). Mass balances were quantitated as described in Materials and Methods.
EXPERIMENTAL RESULTS
FIG. 1 shows that Phanerochaete chrysosporium strain VKM-F-1767 mineralized or biodegraded 35% of the [ 14 C]TNT to 14 CO 2 during the first twelve days of incubation in a liquid culture. Supplemental glucose equivalent to 56 Mm was added to the cultures on day 18 and did not affect the evolution of 14 CO 2 . The liquid culture experiment was discontinued after 24 days of incubation and a mass balance analysis was performed. A total of 35.4 ±3.6% of the total radioactivity was evolved as 14 CO 2 , 25.1% was present as water-soluble metabolites, 15.7% was found in the methylene chloride fraction, and 17.3% was associated with the mycelial fraction. A total mass recovery of 93.5% was achieved. HPLC analysis, FIG. 4, of the methylene chloride extract demonstrated that only about 3.3% of the [ 14 C]TNT initially present might be identified as undegraded TNT. The remaining 12.4% represented unidentified metabolites formed during the 18-day incubation period. Almost all of the unidentified metabolites remaining in the methylene chloride extract were more polar than TNT. None of the metabolites corresponded to mono- or dinitrotoluenes. In control cultures incubated under the same culture conditions but not inoculated with Phanerochaete chrysosporium strain VKM-F-1767, 98% of the radioactivity was found in the methylene chloride fraction and was unmetabolized [ 14 C]TNT.
Biodegradation was also examined in a system in which [ 14 C]TNT was adsorbed into soil and mixed with corncobs previously inoculated with Phanerochaete chrysosporium strain VKM-F-1767. In this soil-corncob mixture, 6.3% ±0.6% of the recovered radioactivity was evolved as 14 CO 2 during 30 days as is best illustrated by FIG. 2. Mass balance analysis of cultures of Phanerochaete chrysosporium strain VKM-F-1767 incubated with [ 14 C]TNT in a soil-corncob matrix for 30 days revealed that 6.3±0.6% of the recovered radioactivity was evolved as 14 CO 2 , 63.6% was present in the acetonitrile extract, and 25.2% was unextractable and was present in the soil-corncob matrix. This material could not be identified as it could not be extracted from the matrix. A total mass recovery of 95.1% was achieved. HPLC analysis, FIG. 5, of the radiolabeled material in the acetonitrile extract revealed that only about 2.2% of the [ 14 C]TNT initially present might be identified as undegraded TNT.
At the end of 30, 60, and 90 days, liquid and soil cultures contaminated with 100 mg of TNT per liter and 10,000 mg of TNT per kg, respectively, were extracted and mass balance analyses were performed. As set forth in Table I, the results of mass balance analysis of 100 milligrams of TNT per liter of contaminated liquid cultures showed that 19.6±35% of the recovered radioactivity was evolved as 14 CO 2 , 22.7% was found in the methylene chloride extract, 50.1% was present as water-soluble compounds, and 2.2% was bound to the fungal mat after a period of 90 days of incubation. A total mass recovery of 94.6% was achieved. When the methylene chloride fraction was analyzed by HPLC, the amounts of unmetabolized [ 14 C]TNT remaining in liquid cultures were 22.1%, 14.9% and 12.3% over a period of 30, 60, and 90 days of incubation, respectively. In control cultures, which were incubated under the same conditions but which were not inoculated with Phanerochaete chrysosporium strain BKM-F-1767, greater than 99% of the radioactivity was found in the methylene chloride extract and was identified as TNT by HPLC.
As set forth in Table II, the results of mass balance analysis of soil cultures contaminated with 10,000 milligrams of TNT per kilograms showed that 18.4%±2.9% was evolved as 14 CO 2 , 62.6% was found in the acetonitrile extract, and 11.5% was bound to the soil-corncob-fungal matrix after 90 days. The total mass recovery was 92.5% after a period of 90 days of incubation. When the acetonitrile extracts of the 30, 60, and 90 day cultures were analyzed by HPLC, the extracts showed that the amounts of residual [ 14 C]TNT that was not degraded to 14 CO 2 or intermediates were 50.8%, 29.3%, and 14.9%, respectively. In control cultures incubated under the same nonsterile conditions but not inoculated with Phanerochaete chrysosporium, greater than 99% of the radioactivity was found in the acetonitrile fraction and was unmetabolized [ 14 C]TNT. The assay for radioactivity in the volatile organic trap revealed that less than 0.5% of the [ 14 C]TNT was volatilized or air stripped during the flushing of the cultures with oxygen. From the foregoing description, it may readily be seen that the present invention comprises a new, unique and exceeding useful process for biodegrading TNT by using white-rot fungus, which constitutes a considerable improvement over the known prior art. Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described. | There is provided a process for biodegradation of TNT (2,4,6-Trinitrotoluene) wherein the biodegradation is done utilizing the fungus Phanerochaete chrysosporium strain BKM F-1767, wherein waste containing TNT is treated with the fungus under predetermined conditioning and for a time period sufficient for biodegradation to occur rendering the waste ecologically acceptable to the environment. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to United Kingdom Patent Application No. GB1203433.6 filed on Feb. 28, 2012, and United Kingdom Patent Application No. GB1211300.7 filed on Jun. 26, 2012, the contents of each one incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a torque control device for a downhole drilling assembly.
BACKGROUND OF THE INVENTION
[0003] When drilling for oil and gas, the downhole drill bit is connected to surface equipment by way of a drill string. The drill string is hollow whereby drilling fluid or mud can be pumped down the borehole, the mud acting to lubricate the drill bit and to carry drill cuttings back to the surface. The mud and entrained drill cuttings return to the surface along the outside of the drill string, the drill string being smaller than the diameter of the borehole.
[0004] In some drilling applications the drill string is rotated at the surface, with the rotation being communicated to the drill bit by the drill string. In other drilling applications a downhole motor such as a mud motor is provided, which uses the flowing mud to drive the drill bit to rotate. A downhole motor may be used with a rotating, or a non-rotating, drill string.
[0005] The surface equipment applies a downhole force upon the drill string, which force is communicated to the drill bit. In addition to the torque seeking to rotate the drill bit there is also a force acting to advance the bit into the rock at the leading end of the borehole, the latter force typically being referred to as “weight on bit”.
[0006] The drill operator will typically seek to maximise the weight on bit so that the drill advances as quickly as possible through the rock. However, there is a maximum limit for the weight on bit which depends upon the bit design and the drilling conditions. Exceeding the maximum weight on bit for the particular bit design and drilling conditions will increase the drag upon the drill bit and cause the drill bit to slow down or stall, i.e. the drill bit will rotate more slowly, or in extreme cases stop rotating altogether.
[0007] If the drill bit does rotate more slowly than the drill string, or than the output of the downhole motor, then the drill string will be caused to twist as torque output from the surface equipment (or downhole motor) increases in response to maintain the original rate of rotation. Eventually, torque at the drill bit will exceed the resistance to rotation and the drill bit will start to rotate again.
[0008] Such a phenomenon is known as “stick-slip” and is a major concern to drill operators. Firstly, the drill string may be damaged by the requirement to twist as the drill bit slows down or stops. Secondly, the drill bit will often rotate very rapidly, and uncontrolledly, as the torque in the twisted drill string is relieved. Periods of slow or non-rotation of the drill bit followed by rapid and uncontrolled rotation of the drill bit will often be repeated if they are not countered.
[0009] Drill operators seek to avoid stick-slip by reacting to reductions in the rate of rotation of the drill bit by reducing the weight on bit, so that the drill bit resumes its desired rate of rotation quickly without undue twisting of the drill string. A reduction in the rate of rotation of the drill bit can be detected directly by measuring the rate of rotation of the drill bit, or (more typically) by measuring the torque being applied to the drill bit, the torque increasing as the rate of rotation reduces.
[0010] The prior art includes torque control devices which can automatically reduce the weight on bit if the torque upon the drill bit exceeds a certain threshold. One prior art arrangement is described in WO 2004/090278 (Tomax). This document has an outer sleeve connected to the drill string and an inner shaft connected to the drill bit. The outer sleeve and the inner shaft are interconnected by a helical thread. A spring biases the inner shaft outwardly of the outer sleeve, into engagement with a fixed stop upon the outer sleeve. During normal drilling operations the inner shaft is driven to rotate by the sleeve, and in turn drives the drill bit to rotate at the same rate as the drill string. If the drill bit slows down or stops, however, the torque upon the drill bit increases sufficiently to drive the sleeve to rotate relative to the shaft, compressing the spring. The helical thread between the inner shaft and the outer sleeve means that rotation of the inner shaft relative to the outer sleeve causes the inner shaft to retract into the sleeve, thereby retracting the drill bit and reducing the weight on bit. As the weight on bit is reduced a point is reached where the drill bit can resume its rotation. The spring causes the inner sleeve to return to its extended position in engagement with the fixed stop, during which the drill bit rotates faster than the drill string.
[0011] The Tomax arrangement can include an oil damper, i.e. the spring and cooperating helical threaded components can lie within an oil reservoir which damps out the movement of the inner shaft relative to the outer sleeve, preventing uncontrolled rotation of the inner sleeve and therefore the drill bit.
[0012] A similar arrangement is described in U.S. Pat. No. 7,044,240 (McNeilly), and also in Tomax's later U.S. Pat. No. 7,654,344, which uses a helical spring rather than a helical thread to interconnect the outer sleeve and the inner shaft.
[0013] The prior art arrangements all rely upon compression springs, and it will be understood that the force provided by those springs must exceed the weight on bit. The design of the tools must therefore include a calculation for the maximum weight on bit which can be catered for, and once the spring rate has been determined it cannot be adjusted. When drilling for oil and gas, however, the rock type through which the drill must pass can vary significantly during a drilling operation, and if the spring force is set too low the tool may reduce the drilling torque even if the drill is not sticking, i.e. the drill operator cannot exceed the weight on bit determined by the spring force, even if the drilling conditions are more favourable than expected and the drill bit would not stick with a greater weight on bit. If, on the other hand, the spring force is set too high for the particular drilling conditions, the drill bit may undergo significant stick-slip without actuation of the torque control device.
SUMMARY OF THE INVENTION
[0014] The inventor has realised that an improved device is required for reducing the weight on bit and thereby reducing the torque upon a drill bit whereby to reduce or avoid the likelihood of stick-slip. One object of the invention is to provide a device which enables the torque at which the weight on bit is reduced to be adjusted downhole to match the drilling conditions.
[0015] According to the invention there is provided a torque control device for a downhole drilling assembly, the torque control device being adapted for connection to a drill bit, the torque control device including an outer sleeve and an inner shaft, the inner shaft being movable longitudinally relative to the outer sleeve, the inner shaft having a through-bore for carrying drilling fluid to the drill bit, the device having a piston and cylinder arrangement and a controller which controls the volume of the cylinder.
[0016] It is arranged that the relative position of the inner shaft relative to the outer sleeve (in the direction of the longitudinal axis of the torque control device) is determined by the volume of the cylinder, so that the controller controls the (longitudinal) movement of the inner shaft relative to the outer sleeve. The controller preferably has a memory in which is stored a threshold value, the controller causing the inner shaft to move relative to the outer sleeve when the threshold value is reached or exceeded. The controller can desirably be adjusted (preferably downhole) whereby the threshold value can be adjusted to match the drilling conditions.
[0017] The controller can be connected to a torque sensor adapted to measure the torque in a part of the downhole assembly, suitably the torque in a part of the downhole assembly connected to the drill bit. Alternatively, the controller can be connected to a sensor such as an accelerometer which measures the rate of rotation of the drill bit (or a part of the downhole assembly connected to the drill bit) whereby to detect reductions in the rate of rotation of the drill bit. The controller can in some embodiments receive and compare the inputs from two accelerometers, one accelerometer located close to the drill bit and the other accelerometer located remote from the drill bit. Sticking of the drill bit can be detected by changes in the relative outputs of the two accelerometers.
[0018] Preferably the inner shaft is connected to the drill string and the outer sleeve is connected to the drill bit, but it will be understood that the orientation of these components can be reversed without departing from the invention.
[0019] Desirably, the cylinder is connected to the through-bore whereby the cylinder will be filled with drilling fluid in use. The drilling fluid can therefore provide the hydraulic fluid for the piston and cylinder arrangement. In such an arrangement, the cylinder can also be open to the periphery of the downhole assembly, so that in use drilling fluid can flow out of the cylinder into the annulus surrounding the downhole assembly, and along which the drilling fluid returns to the surface. Such arrangements take advantage of the pressure differential which occurs between the drilling fluid within the through-bore (i.e. upstream of the drill bit) and in the annulus (i.e. downstream of the drill bit).
[0020] Preferably, the controller controls the position of an actuating valve whereby to control the flow of drilling fluid into the cylinder. It can be arranged that the port from the through-bore into the cylinder is of larger cross-section than the port in the periphery of the downhole assembly. This arrangement avoids the requirement for a separate actuating valve controlling the egress of drilling fluid from the cylinder, it being arranged that the larger entry port will act to increase the volume of the cylinder when the actuating valve is opened, and the (always open) exit port will allow the drilling fluid to drain out of the cylinder, so as to reduce the volume of the cylinder, when the actuating valve is closed.
[0021] Desirably, a return spring is provided to bias the piston so as to reduce the volume of the cylinder. It is arranged that when the actuating valve is closed the biasing force of the return spring is sufficient to force drilling fluid out of the cylinder and into the surrounding annulus so as to reduce the volume of the cylinder and drive the inner shaft to move longitudinally relative to the outer sleeve.
[0022] In certain embodiments the threshold value of the controller can be adjusted during use. It is known to communicate from the surface to a downhole tool, and it is also know to communicate by way of the drilling fluid. In the “RipTide” drilling reamer of Weatherford, Inc. radio frequency identification (RFID) units are injected into the drilling fluid and sent downhole with the fluid. As the RFID units pass a controller of the reamer they are read and used to adjust the status of the reamer. A similar system can be used with the present invention, with the controller being adapted to react to messages sent downhole, for example by way of RFID units, whereby the threshold value for actuation of the device can be adjusted during use. It is therefore not necessary to trip the downhole assembly in order to adjust the threshold value, and if the drilling conditions become more (or less) favourable and a greater (or lesser) weight on bit can be accommodated without incurring stick-slip, the threshold value can be increased (or decreased) accordingly.
[0023] Certain embodiments of the present invention can avoid the requirement for sensors communicating torque and/or acceleration to the controller. In such embodiments the controller is in the form of a rotary valve, and admission of drilling fluid into the cylinder is controlled by the rotary valve which automatically moves to an open position (or to a more open position) when the torque within the downhole assembly exceeds a predetermined threshold.
[0024] Whilst in the simplest embodiments of the present invention the drilling fluid is caused to flow into and out of the cylinder in order to determine the volume of the cylinder, in other embodiments a closed hydraulic system is used. In those other embodiments the volume of the cylinder, and therefore the position of the inner shaft relative to the outer sleeve, is determined by a hydraulic fluid which is isolated from, and independent of, the drilling fluid. Such alternative embodiments are more mechanically complex, but avoid the possible problems associated with the use of drilling fluid as the hydraulic fluid. The electrical and hydraulic power for a closed hydraulic system can be provided by a downhole pump in known fashion.
[0025] The inventors have also realised that the device of the present invention can be used for other downhole applications where the torque transmitted to the drill bit requires adjustment. One such application is in drilling applications using an under-reamer for example. An under-reamer, such as the aforementioned “RipTide” drilling reamer of Weatherford, Inc., uses a reamer as well as a drill bit, the reamer following the drill bit and reaming out a larger diameter borehole along chosen lengths of the borehole. It is advantageous to balance the drilling torque provided by the drill string between the drill bit and the reamer so as to maximise the rate of advance of the downhole assembly. The present invention can be located in the downhole assembly between the reamer and the drill bit and can control the torque transmitted to the drill bit and thereby control the proportion of the drilling torque utilised by the drill bit and that used by the reamer.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The invention will now be described in more detail, by way of example, with reference to the accompanying schematic drawings, in which:
[0027] FIG. 1 shows a side view of a tool according to the present invention, in a normal, non-actuated, condition of use;
[0028] FIG. 2 shows a side view of the tool of FIG. 1 , in an actuated condition;
[0029] FIG. 3 shows a representation of the tool of the present invention located in a downhole assembly between a reamer and a drill bit; and
[0030] FIG. 4 shows a side view of a tool according to the present improvement.
DETAILED DESCRIPTION
[0031] The torque control device 10 of the present invention is part of a downhole assembly 12 which is adapted to drill a borehole 14 into the Earth 16 . The longitudinal axis A-A of the downhole assembly 12 (which corresponds to the longitudinal axis of the torque control device 10 ) is shown horizontal in FIGS. 1 and 2 , but the orientation is unimportant and the present invention can be used with the longitudinal axis at any chosen angle.
[0032] The downhole assembly 12 includes a female threaded connector 20 by which the assembly may be connected to a length of drill string (not shown) connected to the surface. Alternatively, the connector 20 can be connected to a downhole motor such as a mud motor, or to a downhole steering tool such as that of EP 1 024 245. It will be understood, however, that the tool can be located uphole of a steering tool if desired.
[0033] The connector 20 is connected to an inner shaft 22 , which has a through-bore 24 through which drilling fluid can flow to the drill bit 26 , in known fashion. In common with prior art downhole assemblies, the drilling fluid passes out through ports (not shown) in the drill bit 26 , and then returns to the surface by way of the annulus 30 surrounding the downhole assembly 12 and the drill string.
[0034] Though not shown in the drawings, it will be understood that the torque control device 10 will typically include a plurality of blades which engage the borehole 14 and serve to centralise the torque control device 10 within the borehole 14 . The downhole assembly may in practice also include a stabiliser located between the torque control device 10 and the drill bit 26 , and/or between the connector 20 and the drill string.
[0035] The drill bit 26 is connected (in the embodiment of FIGS. 1 and 2 directly, but in other embodiments indirectly) to an outer sleeve 32 which surrounds a part of the inner shaft 22 . At least one set of splines 34 interconnect the inner shaft 22 and the outer sleeve 32 , so that the inner shaft 22 can slide longitudinally relative to the outer sleeve 32 , but cannot rotate relative to the outer sleeve. The number and disposition of the splines will depend upon the torque which is to be transmitted from the inner shaft 22 to the outer sleeve 32 .
[0036] During normal drilling operations, in the absence of stick-slip, the torque control device 10 is in the condition shown in FIG. 1 . Rotation of the drill string (and/or downhole motor) is communicated to the connector 20 and, by way of the inner shaft 22 and splines 34 , to the outer sleeve 32 and the drill bit 26 .
[0037] The through-bore 24 has a port 36 which opens into a valve chamber within the body of a piston 40 , the piston 40 comprising an enlargement of the inner shaft 22 . An actuating valve 42 is located within the valve chamber of the piston 44 , the actuating valve 42 being controlled by a controller 44 . The actuating valve 42 controls the passage of drilling fluid from the through-bore 24 , through the port 36 and into a cylinder 46 . The cylinder 46 has another port 50 which is open to the periphery of the device 10 , and therefore to the annulus 30 surrounding the downhole assembly 12 .
[0038] It will be understood that the pressure of the drilling fluid within the through-bore 24 is substantially higher than the pressure of the drilling fluid within the annulus 30 , the difference in pressure being caused primarily by the pressure drop across the drill bit 26 . It is arranged that the entry port 36 is of significantly larger area than the exit port 50 , so that when the actuating valve 42 is opened drilling fluid flows into the cylinder 46 from the through-bore 24 at a faster rate than fluid can flow out of the cylinder 46 through the port 50 .
[0039] If the weight on bit is too great for the particular drilling conditions, the rotation of the drill bit 26 will slow relative to the rotation of the connector 20 . In the present embodiment this is detected by a strain gauge 52 located upon the shaft 22 . It will be understood that the strain gauge 52 is sufficiently sensitive to detect very small angular twisting movements of the inner shaft 22 , as caused by small angular deviations of the drill bit 26 relative to the connector 20 , which are indicative of the drill bit slowing and the possible onset of stick-slip. The strain gauge 52 detects the strain in the inner shaft 22 and communicates this to the controller 44 . The communication is preferably by wires (not shown), but the form of data transmission is not critical to the invention.
[0040] The controller 44 has a memory in which is stored a high threshold strain value, and against which the strain measured by the strain gauge 52 is continuously or repeatedly compared. If the comparison is not continuous, it is sufficiently frequent so as quickly to identify unacceptable increases in the measured strain. The high threshold strain value may be determined by calculation or experiment. If the measured strain exceeds the high threshold strain value the controller opens the actuating valve 42 and permits drilling fluid to flow into the cylinder 46 .
[0041] As shown in FIG. 2 , when the actuating valve 42 is opened, drilling fluid flows into the cylinder 46 through the entry port 36 . Since the flow rate through the entry port 36 and past the valve 42 into the cylinder 46 is greater than the flow rate out of the cylinder through the exit port 50 , the volume of the cylinder 46 is thereby caused to increase. The piston 40 is fixed to the inner shaft 22 and does not move relative to the inner shaft 22 . Instead, as the volume of the cylinder 46 increases the outer sleeve 32 moves to the right as drawn. This rightwards movement is represented in FIG. 2 by the drill bit 26 being lifted from the bottom of the borehole 14 ; in practice the actual movement may be very small, but the force with which the drill bit 26 engages the end of the borehole (i.e. the weight on bit) can be reduced significantly.
[0042] During this retracting movement of the outer sleeve 32 , the connector 20 continues to rotate, and at some point the torque upon the drill bit 26 will exceed the frictional resistance to rotational movement and the drill bit will resume rotation (and will unwind any twist which has been imparted into the drill string).
[0043] As the drill bit 26 resumes is rotation, the strain upon the inner shaft 22 will reduce, and will be detected by the strain gauge 52 . The memory of the controller 44 also stores a low threshold strain value, the low threshold strain value being a chosen amount lower than the high threshold strain value so as to avoid “hunting”. When the low threshold strain value is passed the controller 44 closes the actuating valve 42 .
[0044] In other embodiments the controller 44 stores only a single threshold strain value, the controller opening the valve 42 when the measured strain rises above that value, and closing the valve 42 when the measured strain falls below that value.
[0045] The controller 44 can if desired close the actuating valve 42 to an intermediate position at which the rate of drilling fluid flowing into the cylinder 46 closely matches the rate of fluid flowing out of the cylinder, and it may be arranged to maintain the intermediate position for a predetermined period of time, perhaps a few seconds, so that the device dwells in that operational position (with the volume of the cylinder 46 remaining substantially constant).
[0046] When the actuating valve 42 is closed the compression spring 54 acts to drive the drilling fluid out of the cylinder 46 , through the exit port 50 , so that the tool returns to the condition of FIG. 1 . Desirably, the exit port 50 is sufficiently small so that it takes several seconds (e.g. 2-3 seconds) for the device to move from the condition of FIG. 2 to the condition of FIG. 1 , it being preferred that the weight on bit be gradually increased back to its desired level rather than suddenly increased.
[0047] The drill operator at the surface will be aware that the torque control device 10 has been actuated by virtue of the reduction in pressure of the drilling fluid caused by the opening of the actuating valve 42 . The drill operator will typically react by reducing the weight on bit at the surface so as to avoid the onset of stick-slip. The operator can check that the device 10 does not undergo repeated actuation, and if so can steadily increase the weight on bit back to the desired level.
[0048] Since the actuation of the torque control device 10 is not dependent upon the force exerted by a spring, the drill operator can set the maximum weight on bit for the drilling conditions. The spring 54 can therefore be made sufficiently strong to exceed the maximum weight on bit which the surface equipment can impart (so that the spring 54 can drive the tool from the condition of FIG. 2 to the condition of FIG. 1 when the actuating valve 42 is closed, regardless of the actual weight on bit. It is not necessary to set the spring force dependent upon the likelihood of stick-slip as in the Tomax and other prior art arrangements.
[0049] The drill operator can also adjust the high and low threshold strain values for the actuating valve downhole, without needing to trip the downhole assembly. Specifically, the drill operator at the surface can communicate with the tool 10 , and in particular with the controller 44 , whilst the tool 10 is downhole. Such communication may be effected by any of the known means for communicating with downhole tools, for example by wire, radio waves, mud pulsing, or RFID units injected into the drilling fluid. Thus, if it is determined that the threshold for actuating the valve 42 is set too low, so that the valve is actuated at strain levels which would not result in damaging stick-slip, the high threshold strain value may be increased without tripping the tool. The drill operator can also switch the torque control device 10 on and off remotely, it perhaps being desirable to switch the torque control device off in certain situations so as to save power.
[0050] An alternative embodiment of torque control device 110 is shown in FIG. 4 . Though not shown in FIG. 4 , the downhole assembly 112 will also include a drill bit (perhaps similar to the drill bit 26 of the embodiment of FIGS. 1 and 2 ) which is secured by way of a male threaded connector 56 . Alternatively, a mud motor for example may be located between the drill bit and the torque control device 110 .
[0051] The connector 120 is connected to an upper shaft 60 , which has a through-bore 124 by which drilling fluid can flow to the drill bit (not shown), in known fashion.
[0052] The connector 56 is connected to an outer sleeve 132 which surrounds a lower shaft 122 and part of the upper shaft 60 . At least one set of splines 134 interconnects the lower shaft 122 and the outer sleeve 132 , so that the lower shaft 122 can slide longitudinally relative to the outer sleeve 132 , but cannot rotate relative to the outer sleeve. As with the embodiment of FIGS. 1 and 2 , the number and disposition of the splines will depend upon the torque which is to be transmitted from the lower shaft 122 to the outer sleeve 132 .
[0053] The upper shaft 60 is separate from the lower shaft 122 , FIG. 4 showing an exaggerated gap 62 between the facing ends of these shafts. The upper shaft 60 has an enlarged end which forms a piston 140 as described below. A part of the piston 140 surrounds the end of the lower shaft 122 , and a set of axial bearings 64 interconnect the piston 140 and the lower shaft 122 . The axial bearings 64 permit relative rotation between the piston 140 and the lower shaft 122 , but resist relative longitudinal movement. It is therefore arranged that the piston 140 is fixed upon the upper shaft 60 , and can rotate relative to the lower shaft 122 .
[0054] The through-bore 124 within the lower shaft 122 has a port 136 which lies within the region of the lower shaft 122 which is surrounded by the piston 140 . The piston has a conduit 66 which can be aligned with the port 136 whereby drilling fluid can pass from the through-bore 124 into a cylinder 146 .
[0055] The cylinder 146 has an exhaust conduit 150 which in this embodiment passes through the piston 140 , and opens into a spring chamber 68 . An exhaust port 70 is provided for the spring chamber 68 , the exhaust port 70 being open to the periphery of the downhole assembly 112 .
[0056] It is arranged that the port 136 and conduit 66 are of larger cross-sectional area than the exhaust conduit 150 , so that when the conduit 66 is fully aligned with the port 136 drilling fluid flows into the cylinder 146 from the through-bore 124 at a faster rate than fluid can flow out of the cylinder 146 through the conduit 150 .
[0057] A spring 72 is located within the spring chamber 68 . One end of the spring 72 is located in a piston spring pocket 74 and the other end of the spring is located in a sleeve spring pocket 76 . The spring 72 acts primarily as a torsion spring, and seeks to rotate the piston 140 relative to the sleeve 132 . Since the sleeve 132 is non-rotatably connected to the lower shaft 122 by way of the splines 134 , the spring 72 also acts to rotate the piston 140 relative to the lower shaft 122 . It is arranged that the spring 72 is biased to move the conduit 66 out of alignment with the port 136 .
[0058] Thus, in normal operation the conduit 66 is out of alignment (or at least out of full alignment) with the port 136 , whereby drilling fluid either cannot flow into the cylinder 146 at all, or at most flows into the cylinder 146 at a rate below that at which it flows out along the conduit 150 . The volume of the cylinder 146 is therefore minimised, and the sleeve 132 is extended (to the left as drawn) to its farthest extent relative to the upper shaft 60 and piston 140 .
[0059] If the weight on bit exceeds the maximum for the drilling conditions, the rate of rotation of the drill bit will reduce. The drill bit is connected to the sleeve 132 so that the rate of rotation of the sleeve, and thereby the lower shaft 122 , also reduce. The drill string and therefore the upper shaft 60 , however, continue to rotate, so that there is relative rotation between the piston 140 and the lower shaft 122 . The conduit 66 and the port 136 will thereby be forced into greater alignment, against the torsional bias of the spring 72 , and perhaps into full alignment as shown in FIG. 4 . When so aligned, the flow rate of drilling fluid into the cylinder 146 will exceed the flow rate of fluid out of the cylinder 146 , so that the volume of the cylinder 146 increases and the sleeve 132 is forced towards the right as viewed, automatically reducing the weight on bit.
[0060] As the weight on bit is reduced the rate of rotation of the drill bit increases and the torque within the downhole assembly 110 is reduced. The spring 72 can then rotate the conduit 66 and port 136 out of alignment and the drilling fluid bleeds out of the cylinder 146 .
[0061] It will therefore be understood that the port 136 and conduit 66 act as a rotary valve to automatically control the volume of the cylinder 146 by allowing drilling fluid (or more drilling fluid) into the cylinder when the rate of rotation of the drill bit drops below that of the drill string.
[0062] The spring 72 can determine a threshold value for the torque which will be required to open the rotary valve. It will be understood that the piston 140 needs to rotate through only a few tens of degrees in order to move a totally misaligned conduit 66 and port 136 into full alignment, and the range of relative rotation may be limited by stops (not shown). The torque control device 110 can be assembled with the spring 72 under a chosen pretension, i.e. the spring 72 can in normal conditions bias the piston 140 against a rotational stop.
[0063] Whilst the primary function of the spring 72 is to control the rotary valve 66 , 136 , it also acts as a compression spring and assists the movement of the sleeve 132 (and therefore the drill bit) to the left as drawn as the drilling fluid drains from the cylinder 146 . However, unlike the prior art arrangements, the compression force of the spring 72 does not provide the upper limit for the weight on bit.
[0064] In the embodiment shown in FIG. 4 the relative rotation of the piston 140 and the lower shaft 122 is directly dependent upon the torque applied to the drill bit by the drill string. In a further modification, a detent mechanism can be provided between the piston 140 and the lower shaft 122 , the detent mechanism allowing relative rotation only when a predetermined threshold torque has been exceeded. With such a modification, the opening movement of the rotary valve would be less progressive than the embodiment of FIG. 4 .
[0065] It will be understood that a small gap is shown between the inner shaft 22 and the outer sleeve 32 in FIGS. 1 and 2 , and similarly between the inner shafts 60 and 122 and the outer sleeve 132 in FIG. 4 , for the purposes of clarity. In practice, these components would be in sliding engagement, with suitable seals for the cylinder 46 , 146 etc.
[0066] FIG. 3 represents schematically another useful application of the torque control device 10 , 110 . In this application, the torque control device 10 , 110 is located between the drill bit 26 and a reaming tool 60 . In known fashion, the reaming tool 60 includes cutting blades 62 which can be refracted into the body of the tool 60 when not required (during passage through a borehole casing for example) and then actuated to their extended condition as shown at a chosen location downhole. When the cutting blades 62 are extended, the drill bit 26 and the reaming tool 60 are both engaging respective sections of rock. To maximise the rate of advance of the downhole assembly it is desirable to impart a proportion of the torque provided by the drill string to the drill bit 26 and another proportion of the torque to the reaming tool 60 , the actual proportions depending on the drilling conditions and the cross-sectional area of rock being removed by the respective components. The tool 10 , 110 can be used to reduce the torque being imparted to the drill bit 26 , and thereby to increase the torque being imparted to the reaming tool 60 , the respective proportions being determined by the threshold strain value set for the actuating valve 42 in the embodiment of FIGS. 1 and 2 , or that set for the rotary valve 66 , 136 in the embodiment of FIG. 4 . If the threshold strain value is set correctly, the efficiency of the downhole assembly will be increased, i.e. both the drill bit 26 and the reamer blades 62 will be driven against the respective rock faces with an appropriate force and the advance of the downhole assembly will be maximised.
[0067] The torque control device 10 , 110 is expected to have its greatest utility when used with PDC drill bits, but the invention can be used with other types of drill bit if desired. | This invention relates to a torque control device for a downhole drilling assembly. The torque control device is adapted for connection to a drill bit, and has an outer sleeve and an inner shaft, the outer sleeve being movable longitudinally relative to the inner shaft. The torque control device also has a cylinder, a piston located within the cylinder, and a controller to control the volume of the cylinder. Changing the volume of the cylinder causes relative longitudinal movement between the outer sleeve and the inner shaft. The controller can receive inputs from a torque sensor and/or an accelerometer in order to determine if a threshold torque has been exceeded. Alternatively the controller can comprise a rotary valve which automatically responds to torque in the assembly. | 4 |
BACKGROUND OF INVENTION
[0001] This disclosure relates generally to a turbine part and more particularly to performing an electronic triage of a turbine part such as a blade or bucket.
[0002] The market for long-term contractual agreements has grown at high rates over recent years for many of today's power systems businesses. As the power systems businesses establish long-term contractual agreements with their customers, it becomes important to provide a variety of service solutions for each of their products. One area where adequate service solutions are lacking is with the repair of turbine parts, in particular buckets. For example, buckets for a gas turbine are currently repaired using a manual process that is slow and fails to take into account historical information that could be useful in making repair decisions. In particular, when a set of buckets is brought into a service center, they are logged as one single job. The individual buckets are visually inspected to determine whether to repair or scrap them. Information on individual buckets is captured as verbose text that is not searchable for future use. Therefore, each decision to repair or not to repair a bucket is made without regard to historical information of other buckets that may have exhibited similar symptoms. Without adequate information available to make a repair decision, some buckets may be subjected to repair when it is not necessary and some buckets may not undergo repair when it is necessary. The buckets that do not undergo repair that need it will eventually have to receive repair. This is not a very efficient approach to servicing a bucket.
[0003] In order to avoid the problems associated with the above repair process, there is a need for an approach that uses historical information to quickly and accurately facilitate the decision process in determining whether to repair the buckets or to scrap them.
SUMMARY OF INVENTION
[0004] In one embodiment of this disclosure, there is a system and method that facilitates the repair of a turbine part. In this embodiment there is a triage storage unit that stores a plurality of repair information. A repair triage application facilitates the repair of the part in accordance with the plurality of repair information stored in the triage storage unit. A computing unit is configured to execute the repair triage application.
[0005] In a second embodiment of this disclosure, there is a system and method that facilitates the repair of a turbine part. In this embodiment there is a triage storage unit that stores a plurality of repair information. A repair triage application facilitates the repair of the part in accordance with the plurality of repair information stored in the triage storage unit. A first computing unit is configured to execute the repair triage application. A second computing unit is configured to serve the triage storage unit and the repair triage application to the first computing unit over a network.
BRIEF DESCRIPTION OF DRAWINGS
[0006] [0006]FIG. 1 shows a schematic of a general-purpose computer system in which a system that facilitates the repair of a turbine part operates on;
[0007] [0007]FIG. 2 shows a schematic diagram of the turbine part repair system that operates on the computer system shown in FIG. 1;
[0008] [0008]FIG. 3 shows a system architecture diagram for implementing the system shown in FIG. 2;
[0009] [0009]FIG. 4 shows a flow chart describing the acts performed during the parts tracking module shown in FIG. 2;
[0010] [0010]FIG. 5 shows an example of a screen view of job information details presented to a user and filled in by the user while running the parts tracking module;
[0011] [0011]FIG. 6 shows another example of a screen view taken from the parts tracking module;
[0012] [0012]FIG. 7 shows an additional example of a screen view taken from the parts tracking module;
[0013] [0013]FIG. 8 shows an example of a screen view of an inspection planning schedule that may be presented to a user while running the parts tracking module;
[0014] [0014]FIG. 9 shows an example of a screen view that may be presented to a user that provides inspection results for a particular part while running the parts tracking module;
[0015] [0015]FIG. 10 shows a flow chart describing the acts performed during the decision support module shown in FIG. 2; and
[0016] [0016]FIG. 11 shows a flow chart describing the acts performed during the customer tracking module shown in FIG. 2.
DETAILED DESCRIPTION
[0017] [0017]FIG. 1 shows a schematic of a general-purpose computer system 10 in which a system for facilitating the repair of a turbine part such as a blade or bucket operates on. The computer system 10 generally comprises at least one processor 12 , memory 14 , input/output devices, and data pathways (e.g., buses) 16 connecting the processor, memory and input/output devices. The processor 12 accepts instructions and data from the memory 14 and performs various calculations. The processor 12 includes an arithmetic logic unit (ALU) that performs arithmetic and logical operations and a control unit that extracts instructions from memory 14 and decodes and executes them, calling on the ALU when necessary. The memory 14 generally includes a random-access memory (RAM) and a read-only memory (ROM), however, there may be other types of memory such as programmable read-only memory (PROM), erasable programmable read-only memory (EPROM) and electrically erasable programmable read-only memory (EEPROM). Also, the memory 14 preferably contains an operating system, which executes on the processor 12 . The operating system performs basic tasks that include recognizing input, sending output to output devices, keeping track of files and directories and controlling various peripheral devices.
[0018] The input/output devices may comprise a keyboard 18 and a mouse 20 that enter data and instructions into the computer system 10 . A display 22 allows a user to see what the computer has accomplished. Other output devices could include a printer, plotter, synthesizer and speakers. A communication device 24 such as a telephone or cable modem or a network card such as an Ethernet adapter, local area network (LAN) adapter, integrated services digital network (ISDN) adapter, or Digital Subscriber Line (DSL) adapter, that enables the computer system 10 to access other computers and resources on a network such as a LAN or a wide area network (WAN). A mass storage device 26 allows the computer system 10 to permanently retain large amounts of data. The mass storage device may include all types of disk drives such as floppy disks, hard disks and optical disks, as well as tape drives that can read and write data onto a tape that could include digital audio tapes (DAT), digital linear tapes (DLT), or other magnetically coded media. The above-described computer system 10 can take the form of a hand-held digital computer, personal digital assistant computer, personal computer, workstation, mini-computer, mainframe computer or supercomputer.
[0019] [0019]FIG. 2 shows a top-level component architecture diagram of a system 28 for facilitating the repair of a turbine part that operates on the computer system 10 shown in FIG. 1. In FIG. 2 there is a triage storage unit 30 that contains information that users of the system 28 access. The triage storage unit 30 comprises a variety of information such as part pedigree information, component design criteria, operational parameters, repair history, repair statistics and repair analytics for a plurality of turbines. The part pedigree information comprises the life history of a plurality of turbine parts for the turbines. Each life history of a part includes the turbines on which the part was placed, the conditions under which the turbines were run and the part repair history of the part. The component design criteria comprise information such as engineering drawings for the various turbine parts of the turbines. The operational parameters comprise the conditions under which the turbines were operated. Examples of some operational parameters are load, type of start and ambient temperature and type of fuel used and the number of trips. The repair history comprises information on the type of repairs made to the turbines. The repair statistics comprise information gathered during repairs of any of the turbines. Examples of repair statistics are inspection tests performed, the results of the tests, the repairs made, the time taken to perform the repairs, cost of the repairs and the number of repairs performed on any of the parts in the turbines. Repair analytics comprise information (e.g., trends in the part condition, prediction of remaining life) on repairs made to any of the parts of the turbines. These examples are illustrative of only a few items of information that may be stored in the triage storage unit 30 and one of ordinary skill in the art will recognize that other items of information can be stored therein.
[0020] A user information database 32 contains identity and security information for users of the system 28 . Specifically, the user database 32 contains general information such as phone numbers, addresses, the type of user (e.g., customers, engineers, administrators, etc.), e-mail addresses, passwords, login identification, etc. This information enables the system 28 to authenticate all on-line users accessing the system and have an access control mechanism for different users such as shop personnel, design engineers and customers. The user information database 32 can take the form of a lightweight directory access protocol (LDAP) database, however, other types of databases can be used.
[0021] A repair triage application 34 facilitates the repair of the turbine part in accordance with the plurality of repair information stored in the triage storage unit 30 . The repair triage application 34 comprises a parts tracking module 36 that tracks parts of the turbine during repair and inspection such as buckets, nozzles, rotors, shafts, etc. The parts tracking module 36 comprises a job module that assigns a job number for the part and provides job information for the part during inspection and repair. The job information comprises an inspection schedule for the part and any inspection results for the part and a repair schedule and any repair results. In addition, the parts tracking module comprises an inspection schedule module that plans the inspection for the part. Also, the parts tracking module 36 comprises a repair schedule module that plans the repair of the part.
[0022] The repair triage application 34 also comprises a decision support module 38 that determines whether a part needs to be repaired or should be scrapped. The decision support module comprises a search module that searches the triage storage unit 30 for other parts that have experienced conditions similar to the bucket undergoing examination. In addition, the decision support module comprises a cost benefit analysis module that determines the costs and benefits associated with repairing the part or scrapping the part.
[0023] Another module associated with the repair triage application 34 is the customer tracking module 40 . This module enables a customer to track the progress of a job being performed for them without having to call a service engineer. In this module, a customer enters the assigned job number on a screen and the system will display the status of the job. In addition, the customer tracking module 40 shows the customer the steps that are planned, those that are completed, those that the part has passed and those that the part has failed. Also, the customer tracking module 40 informs the customer of the expected date that the job will be finished.
[0024] In addition to the above modules, the repair triage application 34 may comprise other modules that run utilities for performing special tasks. For example, there can be utilities for administering and performing maintenance functions. Other utilities that may be used are utilities for creating, modifying and deleting user profiles.
[0025] [0025]FIG. 3 shows a system 42 architecture diagram for implementing the system shown in FIG. 2. FIG. 3 shows that there are several ways of accessing the system 28 . A computing unit 44 allows shop personnel, design engineers, decision makers, administrators, etc. to access the system 28 . Also, customers access the system 28 through a computing unit 44 . The computing unit 44 can take the form of a hand-held digital computer, personal digital assistant computer, personal computer or workstation. The shop personnel, design engineers, decision makers, administrators, customers and any other users use a web browser 46 such as Microsoft INTERNET EXPLORER or Netscape NAVIGATOR to locate and display the system 28 on the computing unit 44 . A communication network connects the computing unit 44 to the system 28 . FIG. 3 shows that the computing units 44 may connect to the system 28 through a private network 48 such as an extranet or intranet or a global network 48 such as a WAN (e.g., Internet). For example, shop personnel, design engineers, decision makers and administrators can access the system 28 via an extranet or intranet, while other users such as customers could access it through an extranet or the Internet. The system 28 resides in a triage server 50 , which comprises a web server 52 that serves the repair triage application 34 , triage storage unit 30 and the user information database 32 .
[0026] [0026]FIG. 4 shows a flow chart describing the acts performed during the parts tracking module shown in FIG. 2. At block 54 , a user such as a design engineer, service personnel, turbine operator, administrator or customer signs into the system 28 . The sign-in act can include entering identity and security information (e.g., a valid username and password). As previously mentioned, the user information database 32 contains identity and security information for users of the system 28 . Furthermore, the user information database 32 may have an access control mechanism that allows users (e.g., design engineers, service personnel, turbine operators, administrators or customers) to have different roles in accessing the system 28 . For example, the parts tracking module and the decision support module can be made accessible only to design engineers, service personnel, turbine operators, or administrators and off limits to other users. Similar restrictions can be made for the customer tracking module 40 .
[0027] A user continues with the parts tracking module once access control and authentication has been completed. Initially, the user enters job information for a part at 56 . Entering the job information comprises information such as the assigned job number, the number of parts in the job, the number assigned to the turbine which the part belongs to, etc. If the parts tracking module is unable to find the job in the triage storage unit 30 that matches the entered criteria, then a message is displayed to the user instructing him or her to enter the details of the job. FIG. 5 shows an example of a screen view of job information details that is presented to the user and filled in by the user. Details of the job as the user enters them are displayed in a screen view similar to the one shown in FIG. 6.
[0028] Referring back to FIG. 4, in addition to the job information, the user enters customer information at 58 for the particular job. The customer information comprises information such as the customer name, location and address of the customer, customer contact, phone number of the customer contact, etc. FIG. 7 shows a screen view that prompts a user to enter job information, customer information and other miscellaneous information while running the parts tracking module. One skilled in the art will recognize that other information can be entered into the system upon initiating the parts tracking module.
[0029] Referring again to FIG. 4, at 60 , the user enters the inspection planning schedule of the job. The inspection planning schedule comprises a series of steps to be performed on the parts in the job. In an exemplary embodiment, each part of the turbine has a template of steps that have to be followed to complete the inspection phase. For instance, there is an inspection planning schedule for the various parts of a turbine such as a bucket, nozzle, rotor, shaft, etc. FIG. 8 shows a screen view of an inspection planning schedule that may be presented to a user while running the parts tracking module. Note that this screen view does not show a particular template; however, one skilled in the art will know of various steps that have to be performed when inspecting parts of a turbine and will be able to generate an appropriate schedule. For example, an inspection schedule could comprise performing steps such as a manual inspection, photo inspection, water flow test of cooling holes, a heat treatment, etc. These inspection steps are illustrative of only a few steps that can be performed and are not exhaustive of other possibilities.
[0030] In FIG. 4, a user enters the inspection results at 62 . The inspection results may comprise information such as the condition of the part at each of the various steps of the inspection schedule. In addition, the inspection results may indicate whether the part has passed or failed each of the steps of the inspection schedule. One skilled in the art will recognize that other information can be captured for the inspection results. FIG. 9 shows an example of a screen view that may be presented to a user that provides inspection results for a particular part. If the inspection results are not clear as determined at 64 then the inspection schedule is revised and the part or parts of the job are inspected again and the results are reviewed.
[0031] Upon receipt of the inspection results, the user then enters a repair schedule at 66 . The repair schedule comprises a series of steps to be performed on the parts in the job to make it operate in a satisfactory manner. Like the inspection schedule, the repair schedule for each part of the turbine has a template of steps that have to be followed to complete the repair phase. For instance, there is a repair schedule for the various parts of a turbine such as a bucket, nozzle, rotor, shaft, etc. For example, a repair schedule could comprise performing some of the following repairs: a blend repair of an airfoil, a blend repair of a cooling hole, a touchup of buckets, a weld repair, a wire check of cooling holes, etc. These repairs are illustrative of only a few types that can be performed and are not exhaustive of other possibilities.
[0032] The user enters the repair results at 68 after the repair schedule has been run. The repair results may comprise information such as the person that performed the repairs, the start time of the repairs, the end time of the repairs, a description of the repairs performed, the amount of material used to make the repairs, the equipment used to make the repairs, whether the repairs were a success or failure, etc. One skilled in the art will recognize that other information can be captured for the results. If the repair has to be repeated as determined at 70 then the part or parts of the job are subjected to the repair schedule again. If the repair results are okay as determined at 70 then the part or parts are considered repaired at 72 . Alternatively, if the repair results are not okay as determined at 70 then the part or parts of the job are considered scrap at 74 .
[0033] [0033]FIG. 10 shows a flow chart describing the acts performed during the decision support module shown in FIG. 2. At block 76 , a user signs in and selects the decision support module. Afterwards, the user obtains the conditions of the part of the turbine undergoing a repair decision at 78 . Specifically, the user obtains the conditions by entering the job number that has been assigned to the part. Next, the user searches the triage storage unit for parts having similar conditions as the part undergoing review at 80 . More specifically, the user selects the data from the information received that best describes the condition of the part. Based on that data the system 28 searches the triage storage unit 30 for parts that had similar conditions when undergoing previous repair decisions. This search also provides other information such as the repair process of those similar parts and the costs to repair. The system 28 then uses the search results to perform a history and cost benefit analysis at 82 . The history of the parts shows the part pedigree, the conditions under which the turbine operated and the repair statistics. The cost benefit analysis provides the historical cost of repair for a similar part versus the remaining life of the part. The cost benefit analysis also shows the difference in cost between repair and a replacement part. Note that the replacement part could be new or refurbished.
[0034] Referring again to FIG. 10, the system 28 recommends a repair solution for the subject part at 84 in accordance with the history and cost benefit analysis. Generally, the repair solution will entail fixing the part or scrapping it. If the part is to be fixed, the repair solution corresponds to the repair solutions of the parts that most closely relate to the subject part. All of the search results and the repair solution are displayed to the user at 86 . If there are any more parts that have to be reviewed for a repair decision as determined at 88 , then blocks 78 - 86 are repeated until there are no more parts.
[0035] [0035]FIG. 11 shows a flow chart describing the acts performed during the customer tracking module shown in FIG. 2. As mentioned above, this module enables a customer to track the progress of a job being performed for them without having to call a service engineer. At block 90 , a customer signs in and selects the customer tracking module. After signing in, the customer enters the job number assigned to the customer at 92 . Upon entering the job number, the customer tracking module generates the status of the job at 94 and displays the results to the customer at 96 . The status information comprises information such as the planned inspection schedule, those inspection steps that have been completed, the inspection results, the repair schedule, the results of any completed repair steps and the time that the job is expected to be completed. If the customer wants to track the status of another job as determined at 98 , then blocks 92 - 96 are repeated until there are no more jobs to be tracked. Alternatively, if there are no more jobs then the customer tracking module ends.
[0036] The foregoing flow charts of this disclosure show the functionality and operation of a possible implementation of the system and method for performing electronic triage of a turbine part. In this regard, each block represents a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures, or for example, may in fact be executed substantially concurrently or in the reverse order, depending upon the functionality involved. Furthermore, the functions can be implemented in programming languages such as C++ or JAVA, however, other languages such as Visual Basic can be used.
[0037] The above-described system and method for performing electronic triage of a turbine part comprises an ordered listing of executable instructions for implementing logical functions. The ordered listing can be embodied in any computer-readable medium for use by or in connection with a computer-based system that can retrieve the instructions and execute them. In the context of this application, the computer-readable medium can be any means that can contain, store, communicate, propagate, transmit or transport the instructions. The computer readable medium can be an electronic, a magnetic, an optical, an electromagnetic, or an infrared system, apparatus, or device. An illustrative, but non-exhaustive list of computer-readable mediums can include an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (magnetic), a read-only memory (ROM) (magnetic), an erasable programmable read-only memory (EPROM or Flash memory) (magnetic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical). It is even possible to use paper or another suitable medium upon which the instructions are printed. For instance, the instructions can be electronically captured via optical scanning of the paper or other medium, then compiled, interpreted or otherwise processed in a suitable manner if necessary, and then stored in a computer memory.
[0038] It is apparent that there has been provided in accordance with this disclosure, a system, method, and computer product for performing electronic triage of a turbine part. While the invention has been particularly shown and described in conjunction with a preferred embodiment thereof, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention. | A system and method for performing electronic triage of a turbine part. A triage storage unit stores a variety of repair information. A repair triage application facilitates the repair of the turbine part in accordance with the repair information stored in the triage storage unit. A computing unit is configured to execute the repair triage application. A second computing unit is configured to serve the triage storage unit and the repair triage application to the first computing unit over a network. | 5 |
FIELD OF THE INVENTION
The present invention relates to the field of medicine. Specifically to a substituted diphenylamine compounds and uses thereof as antitumor agents.
BACKGROUND OF THE INVENTION
The following compounds, which can be used as intermediates to synthetise a kind of multi-halogenated acridone compounds having fluorescence and pharmaceutical activity, were reported in patent CN101391981A. The invention discloses compounds KC1(IV-A), KC2(IV-B), KC3(IV-D), KC4(IV-E), KC5(IV-H) and KC6(IV-C), but there are no bioactivity reported. The compound KC1(XXIX) was also reported in Pesticide Science (1988), 24(2), 111-21, showing fungicidal activity against grape downy mildew ( Plasmopora viticola ).
The compounds having the following general formulas were reported as insecticides, acaricides, fungicides, herbicides, rodenticide or others in the prior art:
Such as patents BR7900462, CH626323, CN1188757, DE2509416, DE2642147, DE2642148, EP26743, EP60951, GB1544078, GB1525884, JP58113151, JP64001774, JP01186849, WO2002060878, WO2005035498, WO2009037707, U.S. Pat. No. 3,948,957, U.S. Pat. No. 3,948,990, U.S. Pat. No. 4,041,172, U.S. Pat. No. 4,152,460, U.S. Pat. No. 4,187,318, U.S. Pat. No. 4,215,145, U.S. Pat. No. 4,304,791, U.S. Pat. No. 4,316,988, U.S. Pat. No. 4,407,820, U.S. Pat. No. 4,459,304, U.S. Pat. No. 4,670,596 and so on, and ACS Symposium Series (1992), 504 (Synth. Chem. Agrochem. III), 336-48; Journal of the Chemical Society (1951), 110-15, etc. all reported the compounds having above general formulas.
In addition, the compounds of the following general formulas were mentioned in Chemische Berichte (1962), 95 1711-21; Chemische Berichte (1963), 96(7), 1936-44; Journal of Organic Chemistry (1954), 19, 1641-5; Journal of the Chemical Society; Transactions (1913), 103 982-8 and Journal of the Chemical Society, Transactions (1921), 119, 187-92 and so on, but without any bioactivity reported:
The compounds having the following general formulas as fungicide were reported in patent WO2012171484:
The compounds having the following general formulas as fungicide were reported in patent WO2011116671:
The compounds having the structure of general formula I were not reported in the prior art as antitumor agents.
SUMMARY OF THE INVENTION
The object of the present invention is to provide substituted diphenylamine compounds having general formula I, which can be applied to antitumor agents.
Detailed description of the invention is as follows:
Substituted diphenylamine compounds use thereof as antitumor agents, the compounds having the structure of general formula I:
Wherein:
R 1 is selected from H, C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 halo alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkylamino carbonyl, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxyC 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylaminothio, C 2 -C 8 dialkylaminothio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 2 -C 8 haloalkenyl, C 2 -C 8 haloalkynyl, aryl C 1 -C 8 alkyl or CO—X—CO 2 R 12 , in which X is selected from (CHR 12 )n, CR 12 ═CR 13 or C 6 H 4 , n=1-6;
R 2 and R 6 may be the same or different, respectively selected from H, halogen, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 3 and R 5 may be the same or different, respectively selected from H, halogen, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylamino, C 1 -C 8 halo alkylamino, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkoxycarbonyloxy, C 1 -C 8 alkylaminocarbonyloxy, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 halo alkoxyC 1 -C 8 halo alkoxy, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 4 is selected from H, halogen, CN, NO 2 , COOH, CO 2 Na, CO 2 NH 4 , C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 haloalkoxyC 1 -C 8 haloalkoxy, SO 2 NR 12 R 13 , or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 7 is selected from Cl or CH 3 ;
R 8 is selected from H, halogen, OH, CN, NO 2 , COOH, C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylamino, C 1 -C 8 halo alkylamino, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 1 -C 8 alkylsulfonyl, C 3 -C 8 cycloalkyl, C 2 -C 8 dialkylamino, C 3 -C 8 alkenyloxy, C 3 -C 8 haloalkenyloxy, C 3 -C 8 alkynyloxy, C 3 -C 8 halo alkynyloxy, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkylcarbonylamino, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy, or the following groups unsubstituted or substituted with 1-5 R 14 : aryloxy, arylamino, arylmethoxy, arylmethylamino, heteroaryloxy or heteroarylamino, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 9 is selected from H, halogen, NO 2 , CN, C(═O)NR 12 R 13 , C(═S)NR 12 R 13 , C 1 -C 8 alkylaminocarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 haloalkyl or C 1 -C 8 alkylsulfonyl;
R 10 is selected from H, halogen, OH, CN, NO 2 , COOH, C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylamino, C 1 -C 8 halo alkylamino, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 1 -C 8 alkylsulfonyl, C 2 -C 8 dialkylamino, C 3 -C 8 alkenyloxy, C 3 -C 8 haloalkenyloxy, C 3 -C 8 alkynyloxy, C 3 -C 8 halo alkynyloxy, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkylcarbonylamino, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy or C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy;
R 11 is selected from CN or NO 2 ,
R 12 and R 13 may be the same or different, respectively selected from H, C 1 -C 6 alkyl or C 3 -C 6 cycloalkyl;
R 14 is selected from halogen, NO 2 , CN, C 1 -C 6 alkyl, C 1 -C 6 haloalkyl, C 1 -C 6 alkoxy, C 1 -C 6 haloalkoxy, C 1 -C 6 alkylthio, C 1 -C 6 alkylcarbonyl, C 1 -C 6 alkoxycarbonyl, C 2 -C 6 alkenyl, C 2 -C 6 haloalkenyl, C 3 -C 6 alkenyloxy, C 3 -C 6 haloalkenyloxy, C 2 -C 6 alkynyl, C 2 -C 6 haloalkynyl, C 3 -C 6 alkynyloxy, C 3 -C 6 haloalkynyloxy, C 1 -C 6 haloalkylthio, C 1 -C 6 haloalkylcarbonyl, C 1 -C 6 alkylamino, C 1 -C 6 haloalkylamino, C 2 -C 8 dialkylamino, C 1 -C 6 alkylcarbonylamino, C 1 -C 6 haloalkylcarbonylamino, C 1 -C 6 alkylaminocarbonyl or C 1 -C 6 haloalkylaminocarbonyl;
Or the salts of the compounds having general formula I.
Furthermore, the preferred uses as antitumor compounds of general formula I of this invention include two kinds of compounds:
The first kind of compound is: R 7 is Cl, R 9 and R 11 are CN in compounds of general formula I, the structures are as general formula II:
Wherein:
R 1 is selected from H, C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 halo alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkylamino carbonyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxyC 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 2 -C 8 haloalkenyl, C 2 -C 8 haloalkynyl, aryl C 1 -C 8 alkyl or CO—X—CO 2 R 12 , in which X is selected from (CHR 12 )n, CR 12 ═CR 13 or C 6 H 4 , n=1-6;
R 2 and R 6 may be the same or different, respectively selected from H, halogen, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 3 and R 5 may be the same or different, respectively selected from H, halogen, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylamino, C 1 -C 8 halo alkylamino, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkoxycarbonyloxy, C 1 -C 8 alkylaminocarbonyloxy, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 haloalkoxyC 1 -C 8 haloalkoxy, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 4 is selected from H, halogen, CN, NO 2 , COOH, CO 2 Na, CO 2 NH 4 , C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 haloalkoxyC 1 -C 8 haloalkoxy, SO 2 NR 12 R 13 , or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl or arylaminocarbonyl, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 8 and R 10 may be the same or different, respectively selected from H, halogen, OH, CN, NO 2 , COOH, C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkoxy, C 1 -C 8 haloalkoxy, C 1 -C 8 alkylamino, C 1 -C 8 haloalkylamino, C 1 -C 8 alkylthio, C 1 -C 8 haloalkylthio, C 1 -C 8 alkylsulfonyl, C 2 -C 8 dialkylamino, C 3 -C 8 alkenyloxy, C 3 -C 8 haloalkenyloxy, C 3 -C 8 alkynyloxy, C 3 -C 8 haloalkynyloxy, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkylcarbonylamino, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy or C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy;
R 12 and R 13 may be the same or different, respectively selected from H, C 1 -C 6 alkyl or C 3 -C 6 cycloalkyl;
R 14 is selected from halogen, NO 2 , CN, C 1 -C 6 alkyl, C 1 -C 6 haloalkyl, C 1 -C 6 alkoxy, C 1 -C 6 halo alkoxy, C 1 -C 6 alkylthio, C 1 -C 6 alkylcarbonyl, C 1 -C 6 alkoxycarbonyl, C 2 -C 6 alkenyl, C 2 -C 6 haloalkenyl, C 3 -C 6 alkenyloxy, C 3 -C 6 haloalkenyloxy, C 2 -C 6 alkynyl, C 2 -C 6 haloalkynyl, C 3 -C 6 alkynyloxy, C 3 -C 6 haloalkynyloxy, C 1 -C 6 haloalkylthio, C 1 -C 6 haloalkylcarbonyl, C 1 -C 6 alkylamino, C 1 -C 6 halo alkylamino, C 2 -C 8 dialkylamino, C 1 -C 6 alkylcarbonylamino, C 1 -C 6 halo alkylcarbonylamino, C 1 -C 6 alkylamino carbonyl or C 1 -C 6 halo alkylamino carbonyl;
Or the salts of the compounds having general formula II.
The preferred uses as antitumor compounds of general formula II of this invention are:
R 1 is selected from H, C 1 -C 4 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 halo alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxyC 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 2 -C 4 haloalkenyl, C 2 -C 4 haloalkynyl, benzyl, phenethyl or CO—X—CO 2 R 12 , in which X is selected from (CHR 12 )n, CR 12 ═CR 13 or C 6 H 4 , n=1-3;
R 2 and R 6 may be the same or different, respectively selected from H, Cl, Br, F, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 4 alkyl, C 1 -C 4 halo alkyl, C 1 -C 4 alkoxy, C 1 -C 4 halo alkoxy, C 1 -C 4 alkylthio, C 1 -C 4 halo alkylthio, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, or the following groups unsubstituted or substituted with 1-3 R 14 : phenoxy, phenylamino, phenylcarbonyl, benzylcarbonyl, phenoxycarbonyl, phenylaminocarbonyl or pyridyloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 3 and R 5 may be the same or different, respectively selected from H, Cl, Br, F, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 1 -C 4 alkylamino, C 1 -C 4 halo alkylamino, C 1 -C 4 alkylthio, C 1 -C 4 haloalkylthio, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, or the following groups unsubstituted or substituted with 1-3 R 14 : phenoxy, phenylamino, phenylcarbonyl, benzylcarbonyl, phenoxycarbonyl, phenylaminocarbonyl or pyridyloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 4 is selected from H, Cl, Br, F, CN, NO 2 , COOH, CO 2 Na, CO 2 NH 4 , C(═O)NR 12 R 13 , C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 2 -C 4 alkenyl, C 2 -C 4 alkynyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 1 -C 4 alkoxyC 1 -C 4 alkoxy, SO 2 NHCH 3 , SO 2 N(CH 3 ) 2 , or the following groups unsubstituted or substituted with 1-3 R 14 : phenylcarbonyl, benzylcarbonyl, phenoxycarbonyl or phenylaminocarbonyl, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 8 and R 10 may be the same or different, respectively selected from Cl, Br, F, OH, CN, NO 2 , C 1 -C 4 alkyl, C 1 -C 4 halo alkyl, C 1 -C 4 alkoxy, C 1 -C 4 halo alkoxy, C 1 -C 4 alkylamino, C 1 -C 4 halo alkylamino, C 1 -C 4 alkylthio, C 1 -C 4 halo alkylthio, C 1 -C 4 alkylsulfonyl, C 2 -C 6 dialkylamino, C 3 -C 4 alkenyloxy, C 3 -C 4 haloalkenyloxy, C 3 -C 4 alkynyloxy, C 3 -C 4 haloalkynyloxy, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonylamino, C 1 -C 4 alkylsulfonyloxy, C 1 -C 4 alkoxyC 1 -C 4 alkoxy or C 1 -C 4 alkoxycarbonylC 1 -C 4 alkoxy;
R 12 and R 13 may be the same or different, respectively selected from H or C 1 -C 4 alkyl; R 14 is selected from F, Cl, Br, NO 2 , CN, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxy, C 1 -C 4 halo alkoxy, C 1 -C 4 alkylthio, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl or C 1 -C 4 alkylaminocarbonyl;
Or the salts of the compounds having general formula II.
Furthermore, the preferred uses as antitumor compounds of general formula II of this invention are:
R 1 is selected from H, CH 3 , acetyl, methylsulfonyl, benzyl or phenethyl;
R 2 and R 6 may be the same or different, respectively selected from H, F, Cl, Br, CN, NO 2 , COOH, CONH 2 , CONHCH 3 , CON(CH 3 ) 2 , CONHCH(CH 3 ) 2 , CONHC(CH 3 ) 3 , CH 3 , C 2 H 5 , CH(CH 3 ) 2 , C(CH 3 ) 3 , ClCH 2 , CF 3 , CH 3 O, C 2 H 5 O, CF 3 O, CF 3 CH 2 O, CH 3 S, CH 3 OCO or CH 3 OCH 2 ;
R 3 and R 5 may be the same or different, respectively selected from H, F, Cl, Br, CN, NO 2 , COOH, CONH 2 , CONHCH 3 , CON(CH 3 ) 2 , CONHCH(CH 3 ) 2 , CONHC(CH 3 ) 3 , CH 3 , C 2 H 5 , CH(CH 3 ) 2 , C(CH 3 ) 3 , ClCH 2 , CF 3 , CH 3 O, C 2 H 5 O, CF 3 O, CF 3 CH 2 O, CH 3 S, CH 3 OCO or CH 3 OCH 2 ;
R 4 is selected from H, F, Cl, Br, CN, NO 2 , COOH, CO 2 Na, CO 2 NH 4 , CONH 2 , CONHCH 3 , CON(CH 3 ) 2 , CONHCH(CH 3 ) 2 , CONHC(CH 3 ) 3 , CF 3 , CF 3 O, CH 3 OCO, C 2 H 5 OCO, CH 3 SO 2 , SO 2 NHCH 3 , SO 2 N(CH 3 ) 2 , phenoxycarbonyl, phenylaminocarbonyl, 4-CH 3 -phenylaminocarbonyl or 4-Cl-phenylaminocarbonyl;
R 8 and R 10 may be the same or different, respectively selected from Cl, F, CH 3 O, CF 3 O, CF 3 CH 2 O, CH 3 NH, (CH 3 ) 2 N, (C 2 H 5 ) 2 N, CF 3 CH 2 NH, ClCH 2 CH 2 NH, CH 3 S, C 2 H 5 S, CH 3 SO 2 , C 2 H 5 SO 2 , (CH 3 ) 2 N, CH 2 ═CHCH 2 O, C≡CCH 2 O, ClC≡CCH 2 O, IC≡CCH 2 O, CH 3 CO 2 , CH 3 CONH, CH 3 OCH 2 CH 2 O, C 2 H 5 OCH 2 CH 2 O, CH 3 OC(═O)CH 2 O or CH 3 OC(═O)CH 2 CH 2 O;
Or the salts formed from the compounds of general formula II with hydrochloric acid, sulfuric acid, nitric acid, hydrogen carbonic acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid.
Even more preferred uses as antitumor compounds of general formula II of this invention are:
R 1 is selected from H;
R 2 is selected from H, F, Cl, Br, CH 3 , C 2 H 5 , NO 2 or CN;
R 3 is selected from H, F, Cl, Br, CH 3 or CF 3 ;
R 4 is selected from H, F, Cl, Br, CF 3 , CF 3 O, CH 3 OCO, CN, NO 2 , COOH, CO 2 Na, phenylaminocarbonyl or 4-Cl-phenylaminocarbonyl;
R 5 is selected from H, Cl, Br, CH 3 or CF 3 ;
R 6 is selected from H, F, Cl, Br, CH 3 , C 2 H 5 , NO 2 or CN;
R 8 is selected from Cl, CH 3 O, CH 3 NH, (CH 3 ) 2 N or (C 2 H 5 ) 2 N;
R 10 is selected from Cl, CH 3 O or CH 3 NH;
Or the salts formed from the compounds of general formula II with hydrochloric acid, sulfuric acid, nitric acid, hydrogen carbonic acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid.
The more preferred uses as antitumor compounds of general formula II of this invention are:
R 1 , R 3 and R 5 are selected from H;
R 2 and R 6 are selected from H, Cl or Br;
R 4 is selected from H, Cl, Br, NO 2 , CF 3 , CF 3 O or CH 3 OCO;
R 8 and R 10 are selected from Cl;
Or the salts formed from the compounds of general formula II with hydrochloric acid, sulfuric acid, nitric acid, hydrogen carbonic acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid.
The most preferred uses as antitumor compounds of general formula II of this invention are:
The following structure in the most preferred uses as antitumor compounds of general formula II of this invention has never been reported before (refer to compound Table 6-112):
The second kind of compound of the preferred uses as antitumor compounds of general formula I of this invention is: R 7 is CH 3 , R 10 is H, R 11 is NO 2 , the structures are as general formula III:
Wherein:
R 1 is selected from H, C 1 -C 8 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 halo alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkylamino carbonyl, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxyC 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylaminothio, C 2 -C 8 dialkylaminothio or CO—X—CO 2 R 12 , in which X is selected from (CHR 12 )n, CR 12 ═CR 13 or C 6 H 4 , n=1-6;
R 2 and R 6 may be the same or different, respectively selected from H, halogen, CN, NO 2 , C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkoxy, C 1 -C 8 haloalkoxy, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 3 and R 5 may be the same or different, respectively selected from H, halogen, CN, NO 2 , C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylamino, C 1 -C 8 halo alkylamino, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkoxycarbonyloxy, C 1 -C 8 alkylaminocarbonyloxy, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 halo alkoxyC 1 -C 8 halo alkoxy, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 4 is selected from H, halogen, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 2 -C 8 alkenyl, C 2 -C 8 alkynyl, C 1 -C 8 alkylsulfonyl, C 1 -C 8 alkylcarbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 alkoxyC 1 -C 8 alkyl, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkyl, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 haloalkoxyC 1 -C 8 haloalkoxy, or the following groups unsubstituted or substituted with 1-5 R 14 : aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl, arylaminocarbonyl or heteroaryloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 8 is selected from H, halogen, C 1 -C 8 halo alkyl, C 1 -C 8 alkoxy, C 1 -C 8 halo alkoxy, C 1 -C 8 alkylamino, C 1 -C 8 halo alkylamino, C 1 -C 8 alkylthio, C 1 -C 8 halo alkylthio, C 1 -C 8 alkylsulfonyl, C 3 -C 8 cyclo alkyl, C 2 -C 8 dialkylamino, C 3 -C 8 alkenyloxy, C 3 -C 8 haloalkenyloxy, C 3 -C 8 alkynyloxy, C 3 -C 8 haloalkynyloxy, C 1 -C 8 alkylcarbonyloxy, C 1 -C 8 alkylcarbonylamino, C 1 -C 8 alkylsulfonyloxy, C 1 -C 8 alkoxyC 1 -C 8 alkoxy, C 1 -C 8 alkoxycarbonylC 1 -C 8 alkoxy, or the following groups unsubstituted or substituted with 1-5 R 14 : aryloxy, arylamino, arylmethoxy, arylmethylamino, heteroaryloxy or heteroarylamino, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 9 is selected from H, halogen, NO 2 , CN, C(═O)NR 12 R 13 , C(═S)NR 12 R 13 , C 1 -C 8 alkylamino carbonyl, C 1 -C 8 alkoxycarbonyl, C 1 -C 8 halo alkyl or C 1 -C 8 alkylsulfonyl;
R 12 and R 13 may be the same or different, respectively selected from H or C 1 -C 6 alkyl;
R 14 is selected from halogen, NO 2 , CN, C 1 -C 6 alkyl, C 1 -C 6 haloalkyl, C 1 -C 6 alkoxy, C 1 -C 6 haloalkoxy, C 1 -C 6 alkylthio, C 1 -C 6 alkylcarbonyl, C 1 -C 6 alkoxycarbonyl, C 2 -C 6 alkenyl, C 2 -C 6 haloalkenyl, C 3 -C 6 alkenyloxy, C 3 -C 6 haloalkenyloxy, C 2 -C 6 alkynyl, C 2 -C 6 haloalkynyl, C 3 -C 6 alkynyloxy, C 3 -C 6 haloalkynyloxy, C 1 -C 6 haloalkylthio, C 1 -C 6 haloalkylcarbonyl, C 1 -C 6 alkylamino, C 1 -C 6 halo alkylamino, C 2 -C 8 dialkylamino, C 1 -C 6 alkylcarbonylamino, C 1 -C 6 halo alkylcarbonylamino, C 1 -C 6 alkylaminocarbonyl or C 1 -C 6 haloalkylaminocarbonyl;
Or the salts of the compounds having general formula III.
The preferred uses as antitumor compounds of general formula III of this invention are:
R 1 is selected from H, C 1 -C 4 alkyl, C 3 -C 6 cycloalkyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 haloalkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylthio, C 1 -C 4 halo alkylthio, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxyC 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 1 -C 4 alkylaminothio, C 2 -C 4 dialkylaminothio or CO—X—CO 2 R 12 , in which X is selected from (CHR 12 )n, CR 12 ═CR 13 or C 6 H 4 , n=1-3;
R 2 and R 6 may be the same or different, respectively selected from H, halogen, CN, NO 2 , C(═O)NR 12 R 13 , C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, or the following groups unsubstituted or substituted with 1-4 R 14 : phenoxy, phenylamino, phenylcarbonyl, benzylcarbonyl, phenoxycarbonyl, phenylaminocarbonyl or pyridyloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 3 and R 5 may be the same or different, respectively selected from H, halogen, CN, NO 2 , C(═O)NR 12 R 13 , C 1 -C 4 alkyl, C 1 -C 4 halo alkyl, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 1 -C 4 alkylamino, C 1 -C 4 haloalkylamino, C 1 -C 4 alkylthio, C 1 -C 4 halo alkylthio, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl or C 1 -C 4 alkoxyC 1 -C 4 alkyl;
R 4 is selected from H, halogen, CN, NO 2 , COOH, C(═O)NR 12 R 13 , C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, C 1 -C 4 halo alkoxy, C 2 -C 6 alkenyl, C 2 -C 6 alkynyl, C 1 -C 4 alkylsulfonyl, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkoxyC 1 -C 4 alkyl, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkyl, C 1 -C 4 alkoxyC 1 -C 4 alkoxy, or the following groups unsubstituted or substituted with 1-4 R 14 : phenoxy, phenylamino, phenylcarbonyl, benzylcarbonyl, phenoxycarbonyl, phenylaminocarbonyl or pyridyloxy, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 8 is selected from H, halogen, C 1 -C 4 alkoxy, C 1 -C 4 haloalkoxy, C 1 -C 4 alkylamino, C 1 -C 4 haloalkylamino, C 1 -C 4 alkylthio, C 1 -C 4 haloalkylthio, C 1 -C 4 alkylsulfonyl, C 2 -C 4 dialkylamino, C 3 -C 4 alkenyloxy, C 3 -C 4 haloalkenyloxy, C 3 -C 6 alkynyloxy, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonylamino, C 1 -C 4 alkylsulfonyloxy, C 1 -C 4 alkoxyC 1 -C 4 alkoxy, C 1 -C 4 alkoxycarbonylC 1 -C 4 alkoxy, or the following groups unsubstituted or substituted with 1-3 R 14 : phenoxy, phenylamino, benzyloxy, benzylamino, pyridyloxy or pyridylamino, and when the number of the substitutes is more than 1, R 14 may be the same or different;
R 9 is selected from Cl, Br, F, NO 2 , CN, C(═O)NR 12 R 13 , C(═S)NR 12 R 13 , CO 2 CH 3 , CF 3 or CH 3 SO 2 ;
R 12 and R 13 may be the same or different, respectively selected from H or C 1 -C 3 alkyl;
R 14 is selected from halogen, NO 2 , CN, C 1 -C 3 alkyl, C 1 -C 3 haloalkyl, C 1 -C 3 alkoxy, C 1 -C 3 haloalkoxy, C 1 -C 3 alkylthio, C 1 -C 3 alkylcarbonyl, C 1 -C 3 alkoxycarbonyl, C 1 -C 3 alkylamino, C 2 -C 4 dialkylamino, C 1 -C 3 alkylcarbonylamino or C 1 -C 3 alkylaminocarbonyl;
Or the salts of the compounds having general formula III.
Furthermore, the preferred uses as antitumor compounds of general formula III of this invention are:
R 1 is selected from H, CH 3 , C 2 H 5 , cyclopropyl, formyl, acetyl, COCF 3 , CO 2 CH 3 , CO 2 C 2 H 5 , SCCl 3 , SO 2 CH 3 , SO 2 C 2 H 5 , CH 2 OCH 3 , CH 2 OC 2 H 5 , CH 2 CH 2 OCH 3 , COCH 2 OCH 3 , CH 2 COOCH 3 , SNHCH 3 , SN(CH 3 ) 2 , COCH 2 CO 2 H, COCH 2 CO 2 CH 3 , COCH 2 CH 2 CO 2 H, COCH 2 CH 2 CO 2 CH 3 , COCHCH 3 CO 2 H, COCHCH 3 CO 2 CH 3 , COC 6 H 4 CO 2 H, COC 6 H 4 CO 2 CH 3 , COCH═CHCO 2 H or COCH═CHCO 2 CH 3 ;
R 2 and R 6 may be the same or different, respectively selected from H, Cl, Br, F, CN, NO 2 , C(═O)NH 2 , C(═O)NHCH 3 , C(═O)N(CH 3 ) 2 , CH 3 , C 2 H 5 , CF 3 , OCH 3 , OC 2 H 5 , OCF 3 , SO 2 CH 3 , SO 2 C 2 H 5 , COCH 3 , CO 2 CH 3 , CO 2 C 2 H 5 , phenoxy, phenylamino, phenoxycarbonyl or phenylaminocarbonyl;
R 3 and R 5 may be the same or different, respectively selected from H, Cl, Br, F, CN, NO 2 , C(═O)NH 2 , CH 3 , CF 3 , OCH 3 , OCF 3 , NHCH 3 , SCH 3 , SO 2 CH 3 , SO 2 C 2 H 5 , COCH 3 , CO 2 CH 3 , CO 2 C 2 H 5 or CH 2 OCH 3 ;
R 4 is selected from H, Cl, Br, F, CN, NO 2 , CO 2 H, C(═O)NH 2 , C(═O)NHCH 3 , C(═O)N(CH 3 ) 2 , CH 3 , CF 3 , CF(CF 3 ) 2 , OCF 3 , OCH 2 CF 3 , OCF 2 CHFCF 3 , SO 2 CH 3 , SO 2 C 2 H 5 , COCH 3 , CO 2 CH 3 , CO 2 C 2 H 5 , phenoxy, phenylamino, phenylcarbonyl, benzylcarbonyl, phenoxycarbonyl, phenylaminocarbonyl, pyridyloxy or 3-chloro-5-(trifluoromethyl)pyridin-2-yloxy;
R 8 is selected from H, Cl, Br, F, C 1 -C 3 alkoxy, C 1 -C 3 haloalkoxy, C 1 -C 3 alkylamino, C 1 -C 3 haloalkylamino, SCH 3 , SC 2 H 5 , N(CH 3 ) 2 , N(C 2 H 5 ) 2 , OCH 2 OCH 3 , phenoxy, phenylamino, benzyloxy, benzylamino, 4-chlorophenoxy, 4-chlorophenylamino, 2-chloro-4-(trifluoromethyl)phenoxy, 2-chloro-4-(trifluoromethyl)phenylamino, 3-chloro-5-(trifluoromethyl)pyridin-2-yloxy or 3-chloro-5-(trifluoromethyl)pyridin-2-ylamino;
R 9 is NO 2 ;
Or the salts formed from the compounds of general formula III with hydrochloric acid, sulfuric acid, nitric acid, hydrogen carbonic acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid.
Even more preferred uses as antitumor compounds of general formula III of this invention are:
R 1 is selected from H or CH 3 ;
R 2 and R 6 may be the same or different, respectively selected from H, Cl, Br, F, CN, NO 2 , C(═O)NH 2 , C(═O)NHCH 3 , C(═O)N(CH 3 ) 2 , CH 3 , CF 3 , CO 2 CH 3 or phenoxycarbonyl;
R 3 and R 5 may be the same or different, respectively selected from H, Cl, Br, F, CN, NO 2 , CH 3 , CF 3 or OCH 3 ;
R 4 is selected from H, Cl, Br, F, CN, NO 2 , CO 2 H, C(═O)NH 2 , C(═O)NHCH 3 , CH 3 , CF 3 , OCF 2 CHFCF 3 , CO 2 CH 3 or 3-chloro-5-(trifluoromethyl)pyridin-2-yloxy;
R 8 is selected from H, Cl, OCH 3 , OCH 2 CF 3 , NHCH 3 , SCH 3 or N(CH 3 ) 2 ;
R 9 is NO 2 ,
Or the salts formed from the compounds of general formula III with hydrochloric acid, sulfuric acid, nitric acid, hydrogen carbonic acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid.
The more preferred uses as antitumor compounds of general formula III of this invention are:
R 1 , R 3 and R 5 are selected from H;
R 2 is selected from Cl or F;
R 4 is selected from H, Cl, CN, NO 2 or CF 3 ;
R 6 is selected from F, Cl, CN or NO 2 ;
R 8 is selected from H, Cl or OCH 2 CF 3 ;
R 9 is NO 2 ,
Or the salts formed from the compounds of general formula III with hydrochloric acid, sulfuric acid, nitric acid, hydrogen carbonic acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid.
The most preferred uses as antitumor compounds of general formula III of this invention are:
The terms used above to definite the compounds of general formula I represent substitutes as follow:
The “halogen” or “halo” is fluorine, chlorine, bromine or iodine.
The “alkyl” stands for straight or branched chain alkyl, such as methyl, ethyl, propyl, isopropyl or tert-butyl.
The “cycloalkyl” is substituted or unsubstituted cyclic alkyl, such as cyclopropyl, cyclopentyl or cyclohexyl. The substitute(s) is(are) methyl, halogen, etc.
The “haloalkyl” stands for straight or branched chain alkyl, in which hydrogen atoms can be all or partly substituted with halogen, such as chloromethyl, dichloromethyl, trichloromethyl, fluoromethyl, difluoromethyl, trifluoromethyl, etc.
The “alkoxy” refers to straight or branched chain alkyl, which is linked to the structure by oxygen atom.
The “haloalkoxy” refers to straight or branched chain alkoxy, in which hydrogen atoms may be all or partly substituted with halogen, such as chloromethoxy, dichloromethoxy, trichloromethoxy, fluoromethoxy, difluoromethoxy, trifluoromethoxy, chlorofluoromethoxy, trifluoroethoxy, etc.
The “alkylthio” refers to straight or branched chain alkyl, which is linked to the structure by sulfur atom.
The “haloalkylthio” refers to straight or branched chain alkylthio, in which hydrogen atoms may be all or partly substituted with halogen, such as chloromethylthio, dichloromethylthio, trichloromethylthio, fluoromethylthio, difluoromethylthio, trifluoromethylthio, chlorofluoromethylthio, etc.
The “alkylamino” refers to straight or branched chain alkyl, which is linked to the structure by nitrogen atom.
The “haloalkylamino” refers to straight or branched chain alkylamino, in which hydrogen atoms may be all or partly substituted with halogen.
The “alkenyl” refers to straight or branched chain alkenyl, such as ethenyl, 1-propenyl, 2-propenyl and different isomer of butenyl, pentenyl and hexenyl. Alkenyl also includes polyene, such as propa-1,2-dienyl and hexa-2,4-dienyl.
The “haloalkenyl” stands for straight or branched chain alkenyl, in which hydrogen atoms can be all or partly substituted with halogen.
The “alkynyl” refers to straight or branched chain alkynyl, such as ethynyl, 1-propynyl, 2-propynyl and different isomer of butynyl, pentynyl and hexynyl. Alkynyl also includes groups including more than one triple bonds, such as hexa-2,5-diynyl.
The “haloalkynyl” stands for straight or branched chain alkynyl, in which hydrogen atoms can be all or partly substituted with halogen.
The alkenyloxy refers to straight or branched chain alkenyl, which is linked to the structure by oxygen atom.
The alkynyloxy refers to straight or branched chain alkynyl, which is linked to the structure by oxygen atom.
The alkylsulfonyl refers to straight or branched chain alkyl, which is linked to the structure by sulfuryl(—SO 2 —), such as SO 2 CH 3 .
The alkylcarbonyl refers to straight or branched chain alkyl, which is linked to the structure by carbonyl(—CO—), such as CH 3 CO—, CH 3 CH 2 CO—.
The alkylcarbonyloxy: such as CH 3 COO—, CH 3 CH 2 NHCOO—.
The alkylcarbonylamino: such as CH 3 CONH—, CH 3 CH 2 NHCONH—.
The alkylsulfonyloxy: such as alkyl-S(O) 2 —O—.
The alkoxycarbonyl: alkyl-O—CO—.
The phenylaminocarbonyl: phenyl-NH—CO—.
The aryl in aryl, arylmethyl, aryloxy, arylamino, arylcarbonyl, arylmethylcarbonyl, aryloxycarbonyl and arylaminocarbonyl refers to phenyl or naphthyl, etc.
The “heteroaryl” stands for five member ring or six member ring containing one or more N, O, S hetero atoms. Such as furanyl, pyrazolyl, thiazolyl, pyridinyl, pyrimidinyl, pyrazinyl, pyridazinyl, triazinyl, quinolinyl, etc.
Part of the substitutes of R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 8 and R 10 in formula I are separately listed in table 1, table 2, table 3, table 4 and table 5, but without being restricted thereby.
TABLE 1
substitute R 1
R 1
R 1
R 1
H
CO 2 CH 3
CH 2 C≡C—Cl
CH 3
CO 2 CH 2 CH 3
CH 2 C≡CCH 3
C 2 H 5
SO 2 CH 2 CH 3
PhCH 2
n-C 3 H 7
CH 2 OCH 3
PhCH 2 CH 2
i-C 3 H 7
CH 2 CH 2 OCH 3
4-Cl—PhCH 2
n-C 4 H 9
CH 2 CH 2 OCH 2 CH 3
COCH 2 CO 2 CH 3
t-C 4 H 9
COCH 2 OCH 3
COCH 2 CH 2 CO 2 CH 3
COCH 2 OCH 2 CH 3
COCHCH 3 CO 2 CH 3
CH 2 Cl
CH 2 CO 2 CH 3
COCH 2 COOH
CF 3
CH 2 CO 2 CH 2 CH 3
COCH 2 CH 2 COOH
CH 2 CF 3
CH 2 CH═CH 2
COCHCH 3 COOH
COCH 3
CH 2 CH═CF 2
COCH═CHCOOH
COCH 2 CH 3
CH 2 CH 2 CH═CF 2
COCH═CHCO 2 CH 3
COCH 2 CH 2 CH 3 CONHCH 3
CH 2 CH 2 CF═CF 2 CH 2 CH═CCl 2
CONHCH 2 CH 3 SO 2 CH 3
CH 2 C≡CH CH 2 C≡C—I
TABLE 2
substitute R 2 (R 6 )
R 2 (R 6 )
R 2 (R 6 )
R 2 (R 6 )
R 2 (R 6 )
H
CH 3
OCH(CH 3 ) 2
CH 2 CO 2 CH 2 CH 3
F
CH 2 CH 3
OCF 3
Ph
Cl
n-C 3 H 7
OCH 2 CF 3
CH 2 Ph
Br
i-C 3 H 7
OCF 2 CF 3
OPh
I
n-C 4 H 9
CH═CH 2
NHPh
CN
t-C 4 H 9
CH 2 CH═CH 2
COPh
NO 2
CF 3
C≡CH
CO 2 Ph
COOH
CHF 2
CH 2 C≡CH
CO 2 Ph-4-Cl
CONH 2
CH 2 F
SO 2 CH 3
CO 2 Ph-2-Cl-4-CF 3
CONHCH 3
CH 2 Cl
SO 2 CH 2 CH 3
CO 2 Ph-2-Cl-4-NO 2
CON(CH 3 ) 2
CH 2 Br
COCH 3
CONHPh
CONHCH 2 CH 3
CH 2 CF 3
COCH 2 CH 3
CONHPh-4-Cl
CON(CH 2 CH 3 ) 2
CF 2 CHF 2
CO 2 CH 3
CONHPh-2-Cl
CONH(CH 2 ) 2 CH 3
CF 2 CF 3
CO 2 CH 2 CH 3
CONHPh-4-NO 2
CONHCH(CH 3 ) 2
OCH 3
CH 2 OCH 3
CONHPh-2-Cl-4-CF 3
CONH(CH 2 ) 3 CH 3
OCH 2 CH 3
CH 2 OCH 2 CH 3
CONHPh-2-Cl-4-NO 2
CONHC(CH 3 ) 3
O(CH 2 ) 2 CH 3
CH 2 CO 2 CH 3
TABLE 3
substitute R 3 (R 5 )
R 3 (R 5 )
R 3 (R 5 )
R 3 (R 5 )
R 3 (R 5 )
H
n-C 3 H 7
OCH 2 CF 3
CH 2 Ph
F
i-C 3 H 7
OCF 2 CF 3
OPh
Cl
n-C 4 H 9
CH═CH 2
NHPh
Br
t-C 4 H 9
CH 2 CH═CH 2
COPh
I
CF 3
C≡CH
CO 2 Ph
CN
CHF 2
CH 2 C≡CH
CO 2 Ph-4-Cl
NO 2
CH 2 F
SO 2 CH 3
CO 2 Ph-2-Cl-4-CF 3
COOH
CH 2 Cl
SO 2 CH 2 CH 3
CO 2 Ph-2-Cl-4-NO 2
CONH 2
CH 2 Br
COCH 3
CONHPh
CONHCH 3
CH 2 CF 3
COCH 2 CH 3
CONHPh-4-Cl
CON(CH 3 ) 2
CF 2 CHF 2
CO 2 CH 3
CONHPh-2-Cl
CONHCH 2 CH 3
CF 2 CF 3
CO 2 CH 2 CH 3
CONHPh-4-NO 2
CON(CH 2 CH 3 ) 2
OCH 3
CH 2 OCH 3
CONHPh-2-Cl-4-CF 3
CONH(CH 2 ) 2 CH 3
OCH 2 CH 3
CH 2 OCH 2 CH 3
CONHPh-2-Cl-4-NO 2
CONHCH(CH 3 ) 2 CH 3 CH 2 CH 3
O(CH 2 ) 2 CH 3 OCH(CH 3 ) 2 OCF 3
CH 2 CO 2 CH 3 CH 2 CO 2 CH 2 CH 3 Ph
TABLE 4
substitute R 4
R 4
R 4
R 4
R 4
H
CHF 2
CH 2 C≡CH
CONHCH(CH 3 ) 2
F
CH 2 F
SO 2 CH 3
CON(CH 2 CH 3 ) 2
Cl
CH 2 Cl
SO 2 CH 2 CH 3
CONHC(CH 3 ) 3
Br
CH 2 Br
COCH 3
SO 2 NH 2
I
CH 2 CF 3
COCH 2 CH 3
SO 2 NHCH 3
CN
CF 2 CHF 2
CO 2 CH 3
SO 2 N(CH 3 ) 2
NO 2
CF 2 CF 3
CO 2 CH 2 CH 3
Ph
COOH
OCH 3
CH 2 OCH 3
CH 2 Ph
CO 2 Na
OCH 2 CH 3
CH 2 OCH 2 CH 3
COPh
CO 2 NH 4
O(CH 2 ) 2 CH 3
CH 2 CO 2 CH 3
COCH 2 Ph
CH 3
OCH(CH 3 ) 2
CH 2 CO 2 CH 2 CH 3
CO 2 Ph
CH 2 CH 3
OCF 3
OCH 2 OCH 3
CO 2 Ph-2-Cl-4-CF 3
n-C 3 H 7
OCH 2 CF 3
OCH 2 OCH 2 CH 3
CONHPh
i-C 3 H 7
OCF 2 CF 3
CONH 2
CONHPh-4-Cl
n-C 4 H 9
CH═CH 2
CONHCH 3
CONHPh-4-CH 3
t-C 4 H 9
CH 2 CH═CH 2
CON(CH 3 ) 2
CONHPh-2-Cl-4-NO 2
CF 3
C≡CH
CONH(CH 2 ) 2 CH 3
CONHPh-2-Cl-4-CF 3
TABLE 5
substitute R 8 (R 10 )
R 8 (R 10 )
R 8 (R 10 )
R 8 (R 10 )
R 8 (R 10 )
R 8 (R 10 )
H
CH 3
OCH 3
SCH 3
OCOCH 3
F
C 2 H 5
OCH 2 CH 3
SCH 2 CH 3
OCOCH 2 CH 3
Cl
n-C 3 H 7
OCF 3
SO 2 CH 3
NHCOCH 3
Br
i-C 3 H 7
OCH 2 CF 3
SO 2 CH 2 CH 3
NHCOCH 2 CH 3
I
n-C 4 H 9
NHCH 3
N(CH 3 ) 2
OSO 2 CH 3
OH
t-C 4 H 9
NHCH 2 CH 3
N(C 2 H 5 ) 2
OSO 2 CH 2 CH 3
CN
CH 2 Cl
NH(CH 2 ) 2 CH 3
OCH 2 CH═CH 2
OCH 2 OCH 3
NO 2
CF 3
NHCH(CH 3 ) 2
OCH 2 CH═CCl 2
OCH 2 OCH 2 CH 3
COOH
CH 2 CF 3
NHCH 2 CF 3
OCH 2 C≡CH
OCH 2 CO 2 CH 3
The present invention is also explained by the following compounds having general formula II with antitumor activity in Table 6-Table 21, but without being restricted thereby.
Table 6: In formula II, R 1 is H, R 8 and R 10 are Cl, R 2 , R 3 , R 4 , R 5 and R 6 (hereinafter abbreviated to R 2 -R 6 ) are listed in following Table, the numbers of representative compounds are Table 6-1 to Table 6-208.
TABLE 6
Num-
ber
R 2
R 3
R 4
R 5
R 6
1
H
H
H
H
H
2
F
H
H
H
H
3
Cl
H
H
H
H
4
Br
H
H
H
H
5
I
H
H
H
H
6
CH 3
H
H
H
H
7
OCH 3
H
H
H
H
8
NO 2
H
H
H
H
9
CF 3
H
H
H
H
10
CN
H
H
H
H
11
H
F
H
H
H
12
H
Cl
H
H
H
13
H
Br
H
H
H
14
H
CF 3
H
H
H
15
H
H
F
H
H
16
H
H
Cl
H
H
17
H
H
Br
H
H
18
H
H
CH 3
H
H
19
H
H
t-C 4 H 9
H
H
20
H
H
OCH 3
H
H
21
H
H
OCF 3
H
H
22
H
H
NO 2
H
H
23
H
H
CN
H
H
24
H
H
CF 3
H
H
25
H
H
CO 2 CH 3
H
H
26
H
H
SO 2 CH 3
H
H
27
H
H
CONHPh
H
H
28
H
H
CONHPh-4-CH 3
H
H
29
H
H
CONHPh-4-Cl
H
H
30
F
F
H
H
H
31
F
H
F
H
H
32
F
H
H
F
H
33
F
H
H
H
F
34
F
H
Cl
H
H
35
F
H
H
CF 3
H
36
H
F
F
H
H
37
H
F
H
F
H
38
Cl
Cl
H
H
H
39
Cl
H
Cl
H
H
40
Cl
H
H
Cl
H
41
Cl
H
H
H
Cl
42
Cl
H
H
H
CH 3
43
H
Cl
Cl
H
H
44
H
Cl
H
Cl
H
45
Cl
H
Br
H
H
46
Br
H
Cl
H
H
47
Cl
H
CF 3
H
H
48
Cl
H
H
CF 3
H
49
Cl
H
NO 2
H
H
50
Cl
H
H
NO 2
H
51
Cl
H
H
CN
H
52
Cl
H
H
CH 3
H
53
NO 2
H
H
Cl
H
54
CN
H
H
Cl
H
55
CH 3
H
H
Cl
H
56
CF 3
H
CN
H
H
57
F
H
CN
H
H
58
Cl
H
CN
H
H
59
Br
H
CN
H
H
60
NO 2
H
CN
H
H
61
t-C 4 H 9
H
CN
H
H
62
OCH 3
H
CN
H
H
63
CO 2 CH 3
H
CN
H
H
64
SO 2 CH 3
H
CN
H
H
65
H
F
CN
H
H
66
H
Cl
CN
H
H
67
H
Br
CN
H
H
68
H
NO 2
CN
H
H
69
H
CH 3
CN
H
H
70
H
OCH 3
CN
H
H
71
CN
H
Cl
H
H
72
CF 3
H
Cl
H
H
73
CO 2 CH 3
H
Cl
H
H
74
H
CN
Cl
H
H
75
H
CH 3
Cl
H
H
76
H
CF 3
Cl
H
H
77
CH 3
H
Cl
H
H
78
CH 3
Cl
H
H
H
79
CH 3
H
CH 3
H
H
80
CH 3
H
H
CH 3
H
81
CH 3
H
CN
H
H
82
CH 3
H
CF 3
H
H
83
CH 3
H
CO 2 CH 3
H
H
84
CH 3
H
H
H
CO 2 CH 3
85
H
CF 3
CN
H
H
86
H
CH 3
CN
H
H
87
NO 2
H
Cl
H
H
88
CN
H
NO 2
H
H
89
F
F
F
H
H
90
F
H
F
H
F
91
F
H
NO 2
H
F
92
Cl
Cl
Cl
H
H
93
Cl
H
Cl
H
Cl
94
Cl
Cl
H
Cl
H
95
Cl
H
CF 3
H
Cl
96
Cl
H
OCF 3
H
Cl
97
Cl
H
CH 3
H
Cl
98
Cl
H
CN
H
Cl
99
Cl
H
NO 2
H
Cl
100
Cl
H
CO 2 CH 3
H
Cl
101
Cl
H
SO 2 CH 3
H
Cl
102
Cl
H
t-C 4 H 9
H
Cl
103
Cl
H
CONHPh
H
Cl
104
Cl
H
CONHPh-4-Cl
H
Cl
105
Cl
H
CO 2 Na
H
Cl
106
Cl
H
COOH
H
Cl
107
Cl
H
NO 2
H
CH 3
108
Cl
CH 3
Cl
H
H
109
Cl
H
Cl
H
CN
110
Cl
H
NO 2
H
F
111
Br
H
OCF 3
H
Br
112
Br
H
Br
H
Br
113
Br
H
NO 2
H
Cl
114
Br
H
NO 2
H
Br
115
CH 3
H
CH 3
H
CH 3
116
CH 3
H
t-C 4 H 9
H
CH 3
117
C 2 H 5
H
Cl
H
C 2 H 5
118
CH 3
H
CO 2 CH 3
H
Br
119
CH 3
H
CO 2 CH 3
H
NO 2
120
CH 3
H
CO 2 CH 3
H
CN
121
CH 3
H
CO 2 CH 3
H
OCH 3
122
CH 3
H
CO 2 CH 3
H
CF 3
123
CH 3
H
CO 2 CH 3
H
Cl
124
CH 3
H
Cl
H
NO 2
125
C 2 H 5
H
NO 2
H
F
126
C 2 H 5
H
NO 2
H
Cl
127
C 2 H 5
H
NO 2
H
Br
128
C 2 H 5
H
NO 2
H
NO 2
129
C 2 H 5
H
NO 2
H
CN
130
C 2 H 5
H
NO 2
H
OCH 3
131
C 2 H 5
H
NO 2
H
CF 3
132
C 2 H 5
H
NO 2
H
CO 2 CH 3
133
C 2 H 5
H
NO 2
H
SO 2 CH 3
134
C 2 H 5
Cl
H
H
C 2 H 5
135
Cl
H
CN
H
F
136
Cl
H
CN
H
Br
137
Cl
H
CN
H
NO 2
138
Cl
H
CN
H
OCH 3
139
Cl
H
CN
H
CO 2 CH 3
140
F
H
CN
H
Br
141
F
H
CN
H
NO 2
142
F
H
CN
H
OCH 3
143
F
H
CN
H
CO 2 CH 3
144
Cl
H
SO 2 NHCH 3
H
Cl
145
Cl
H
SO 2 N(CH 3 ) 2
H
Cl
146
Cl
H
CO 2 NH 4
H
Cl
147
Cl
H
CONH 2
H
Cl
148
Cl
H
CONHCH 3
H
Cl
149
Cl
H
CON(CH 3 ) 2
H
Cl
150
Cl
H
CONHCH(CH 3 ) 2
H
Cl
151
Cl
H
CONHC(CH 3 ) 3
H
Cl
152
CH 3
H
Cl
CH 3
H
153
NO 2
H
Cl
H
NO 2
154
CN
H
Cl
H
NO 2
155
CN
H
Cl
H
CH 3
156
CN
H
Cl
H
CN
157
CN
H
Cl
H
CF 3
158
CO 2 CH 3
H
Cl
H
Cl
159
CH 3
H
Cl
H
Cl
160
NO 2
H
Cl
H
Cl
161
CF 3
H
Cl
H
Cl
162
OCH 3
H
Cl
H
Cl
163
NO 2
H
Cl
H
F
164
NO 2
H
Cl
H
Br
165
NO 2
H
Cl
H
CF 3
166
NO 2
H
Cl
H
CO 2 CH 3
167
NO 2
H
Cl
H
CH 3
168
CN
H
NO 2
H
NO 2
169
COOH
H
CN
H
CH 3
170
COOH
H
Cl
H
Cl
171
COOH
H
Cl
H
CH 3
172
COOH
H
Br
H
CH 3
173
COOH
H
CN
H
Cl
174
CO 2 CH 3
H
Cl
H
CH 3
175
CO 2 CH 3
H
Br
H
CH 3
176
CONHCH 3
H
CN
H
CH 3
177
CONHCH 3
H
Cl
H
Cl
178
CONHCH 3
H
Cl
H
CH 3
179
CONHCH 3
H
Br
H
CH 3
180
CONHCH 3
H
H
H
H
181
CONH 2
H
CN
H
CH 3
182
CONH 2
H
Cl
H
Cl
183
CONH 2
H
Cl
H
CH 3
184
CONH 2
H
Br
H
CH 3
185
CONH 2
H
CN
H
Cl
186
CON(CH 3 ) 2
H
CN
H
CH 3
187
CON(CH 3 ) 2
H
Cl
H
Cl
188
CON(CH 3 ) 2
H
Cl
H
CH 3
189
CON(CH 3 ) 2
H
Br
H
CH 3
190
CON(CH 3 ) 2
H
CN
H
Cl
191
CONHCH(CH 3 ) 2
H
CN
H
CH 3
192
CONHCH(CH 3 ) 2
H
Cl
H
Cl
193
CONHCH(CH 3 ) 2
H
Cl
H
CH 3
194
CONHCH(CH 3 ) 2
H
Br
H
CH 3
195
CONHCH(CH 3 ) 2
H
CN
H
Cl
196
CONHC(CH 3 ) 3
H
CN
H
CH 3
197
CONHC(CH 3 ) 3
H
Cl
H
Cl
198
CONHC(CH 3 ) 3
H
Cl
H
CH 3
199
CONHC(CH 3 ) 3
H
Br
H
CH 3
200
CONHC(CH 3 ) 3
H
CN
H
Cl
201
Cl
H
Br
H
Cl
202
Cl
H
SO 2 NH 2
H
Cl
203
Cl
H
SO 2 NH 2
H
Br
204
Br
H
SO 2 NH 2
H
Br
205
Cl
CH 3
CN
Cl
H
206
CH 3
Cl
NO 2
H
NO 2
207
NO 2
CH 3
Cl
H
NO 2
208
CN
Cl
CN
Cl
Cl
Table 7: In formula II, R 1 is CH 3 , R 8 and R 10 are Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 7-1 to Table 7-208.
Table 8: In formula II, R 1 is H, R 8 and R 10 are F, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 8-1 to Table 8-208.
Table 9: In formula II, R 1 is H, R 8 is N(C 2 H 5 ) 2 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 9-1 to Table 9-208.
Table 10: In formula II, R 1 is H, R 8 is N(CH 3 ) 2 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 10-1 to Table 10-208.
Table 11: In formula II, R 1 is H, R 8 is NHCH 3 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 11-1 to Table 11-208.
Table 12: In formula II, R 1 is H, R 8 is OCH 3 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 12-1 to Table 12-208.
Table 13: In formula II, R 1 is H, R 8 is SCH 3 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 13-1 to Table 13-208.
Table 14: In formula II, R 1 is H, R 8 and R 10 are OCH 3 , R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 14-1 to Table 14-208.
Table 15: In formula II, R 1 is H, R 8 and R 10 are N(CH 3 ) 2 , R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 15-1 to Table 15-208.
Table 16: In formula II, R 1 is H, R 8 and R 10 are NHCH 3 , R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 16-1 to Table 16-208.
Table 17: In formula II, R 1 is H, R 8 and R 10 are SCH 3 , R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 17-1 to Table 17-208.
Table 18: In formula II, R 1 is H, R 8 is SO 2 CH 3 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 18-1 to Table 18-208.
Table 19: In formula II, R 1 is H, R 8 is OCH 2 CH═CH 2 , R 10 is Cl, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 19-1 to Table 19-208.
Table 20: In formula II, R 1 is H, R 8 is OCH 3 , R 10 is F, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 20-1 to Table 20-208.
Table 21: In formula II, R 1 is H, R 8 is N(CH 3 ) 2 , R 10 is F, R 2 -R 6 are listed in Table 6, the number of representative compounds are Table 21-1 to Table 21-208.
The present invention is also explained by the following compounds having general formula III with antitumor activity in Table 22-Table 30, but without being restricted thereby.
Table 22: In general formula III, R 1 is H, R 8 is Cl, R 9 is NO 2 , R 2 , R 3 , R 4 , R 5 and R 6 (hereinafter abbreviated to R 2 -R 6 ) are listed in following Table, the numbers of representative compounds are Table 22-1 to Table 22-208.
TABLE 22
Number
R 2
R 3
R 4
R 5
R 6
1
H
H
H
H
H
2
F
H
H
H
H
3
Cl
H
H
H
H
4
Br
H
H
H
H
5
I
H
H
H
H
6
CH 3
H
H
H
H
7
OCH 3
H
H
H
H
8
NO 2
H
H
H
H
9
CF 3
H
H
H
H
10
CN
H
H
H
H
11
CO 2 Ph
H
H
H
H
12
H
F
H
H
H
13
H
Cl
H
H
H
14
H
Br
H
H
H
15
H
CF 3
H
H
H
16
H
H
F
H
H
17
H
H
Cl
H
H
18
H
H
Br
H
H
19
H
H
CH 3
H
H
20
H
H
OCH 3
H
H
21
H
H
OCF 3
H
H
22
H
H
NO 2
H
H
23
H
H
CN
H
H
24
H
H
CF 3
H
H
25
H
H
CO 2 CH 3
H
H
26
H
H
SO 2 CH 3
H
H
27
H
H
CONHPh
H
H
28
H
H
CONHPh-4-CH 3
H
H
29
H
H
CONHPh-4-Cl
H
H
30
F
F
H
H
H
31
F
H
F
H
H
32
F
H
H
F
H
33
F
H
H
H
F
34
F
H
Cl
H
H
35
F
H
H
CF 3
H
36
H
F
F
H
H
37
H
F
H
F
H
38
Cl
Cl
H
H
H
39
Cl
H
Cl
H
H
40
Cl
H
H
Cl
H
41
Cl
H
H
H
Cl
42
Cl
H
H
H
CH 3
43
H
Cl
Cl
H
H
44
H
Cl
H
Cl
H
45
Cl
H
Br
H
H
46
Br
H
Cl
H
H
47
Cl
H
CF 3
H
H
48
Cl
CH 3
H
H
H
49
Cl
H
H
CF 3
H
50
Cl
H
NO 2
H
H
51
Cl
H
H
NO 2
H
52
Cl
H
H
CN
H
53
Cl
H
H
CH 3
H
54
NO 2
H
H
Cl
H
55
CN
H
H
Cl
H
56
CH 3
H
H
Cl
H
57
CH 3
H
H
H
Cl
58
CH 3
Cl
H
H
H
59
CF 3
H
CN
H
H
60
F
H
CN
H
H
61
Cl
H
CN
H
H
62
Br
H
CN
H
H
63
NO 2
H
CN
H
H
64
t-C 4 H 9
H
CN
H
H
65
OCH 3
H
CN
H
H
66
CO 2 CH 3
H
CN
H
H
67
SO 2 CH 3
H
CN
H
H
68
H
F
CN
H
H
69
H
Cl
CN
H
H
70
H
Br
CN
H
H
71
H
NO 2
CN
H
H
72
H
CH 3
CN
H
H
73
H
OCH 3
CN
H
H
74
CN
H
Cl
H
H
75
CF 3
H
Cl
H
H
76
CO 2 CH 3
H
Cl
H
H
77
H
CN
Cl
H
H
78
H
CH 3
Cl
H
H
79
H
CF 3
Cl
H
H
80
CH 3
H
Cl
H
H
81
CH 3
H
CH 3
H
H
82
CH 3
H
H
CH 3
H
83
CH 3
H
CN
H
H
84
CH 3
H
CF 3
H
H
85
CH 3
H
CO 2 CH 3
H
H
86
H
CF 3
CN
H
H
87
H
CH 3
CN
H
H
88
NO 2
H
Cl
H
H
89
NO 2
H
NO 2
H
H
90
CN
H
NO 2
H
H
91
F
F
F
H
H
92
F
H
F
H
F
93
F
H
Cl
H
F
94
F
H
F
H
NO 2
95
F
H
NO 2
H
F
96
Cl
Cl
Cl
H
H
97
Cl
H
Cl
Cl
H
98
Cl
H
Cl
H
Cl
99
Cl
Cl
H
Cl
H
100
Cl
H
Br
H
Cl
101
Cl
H
CF 3
H
Cl
102
Cl
H
OCF 3
H
Cl
103
Cl
H
CH 3
H
Cl
104
Cl
H
CN
H
Cl
105
Cl
H
NO 2
H
Cl
106
Cl
H
NO 2
Cl
H
107
Cl
H
CO 2 CH 3
H
Cl
108
Cl
H
SO 2 CH 3
H
Cl
109
Cl
H
SO 2 NH 2
H
Cl
110
Cl
H
SO 2 NH 2
H
Br
111
Br
H
SO 2 NH 2
H
Br
112
Cl
H
t-C 4 H 9
H
Cl
113
Cl
H
CONHPh
H
Cl
114
Cl
H
CONHPh-4-Cl
H
Cl
115
Cl
H
CO 2 Na
H
Cl
116
Cl
H
COOH
H
Cl
117
Cl
H
NO 2
H
CH 3
118
Cl
H
NO 2
H
NO 2
119
Cl
CH 3
Cl
H
H
120
Cl
H
Cl
H
CN
121
Cl
H
Cl
H
NO 2
122
Cl
H
NO 2
H
F
123
Cl
H
NO 2
H
Br
124
Cl
H
OCF 2 CHFCF 3
Cl
H
125
H
Cl
Cl
H
126
Br
H
OCF 3
H
Br
127
Br
H
Br
H
Br
128
Br
H
NO 2
H
Cl
129
Br
H
NO 2
H
Br
130
Br
H
NO 2
H
CN
131
CH 3
H
CH 3
H
CH 3
132
CH 3
H
t-C 4 H 9
H
CH 3
133
C 2 H 5
H
Cl
H
C 2 H 5
134
CH 3
H
CO 2 CH 3
H
Br
135
CH 3
H
CO 2 CH 3
H
NO 2
136
CH 2
H
CO 2 CH 3
H
CN
137
CH 3
H
CO 2 CH 3
H
OCH 3
138
CH 3
H
CO 2 CH 3
H
CF 3
139
CH 3
Cl
NO 2
H
H
140
CH 3
H
NO 2
H
Cl
141
C 2 H 5
H
NO 2
H
F
142
C 2 H 5
H
NO 2
H
Cl
143
C 2 H 5
H
NO 2
H
Br
144
C 2 H 5
H
NO 2
H
NO 2
145
C 2 H 5
H
NO 2
H
CN
146
C 2 H 5
H
NO 2
H
OCH 3
147
C 2 H 5
H
NO 2
H
CF 3
148
C 2 H 5
H
NO 2
H
CO 2 CH 3
149
C 2 H 5
H
NO 2
H
SO 2 CH 3
150
Cl
H
CF 3
H
F
151
Cl
H
CF 3
H
Br
152
Cl
H
CF 3
H
NO 2
153
Cl
H
CN
H
NO 2
154
Cl
H
CF 3
H
OCH 3
155
Cl
H
CF 3
H
CO 2 CH 3
156
F
H
CF 3
H
Br
157
F
H
CF 3
H
NO 2
158
F
H
CF 3
H
OCH 3
159
F
H
CF 3
H
CO 2 CH 3
160
Cl
H
SO 2 NHCH 3
H
Cl
161
Cl
H
SO 2 N(CH 3 ) 2
H
Cl
162
Cl
H
CO 2 NH 4
H
Cl
163
Cl
H
CONH 2
H
Cl
164
Cl
H
CONHCH 3
H
Cl
165
Cl
H
CON(CH 3 ) 2
H
Cl
166
Cl
H
CONHCH(CH 3 ) 2
H
Cl
167
Cl
H
CONHC(CH 3 ) 3
H
Cl
168
CH 3
H
Cl
H
CH 3
169
NO 2
H
Cl
H
NO 2
170
NO 2
H
NO 2
H
NO 2
171
NO 2
H
CF 3
H
NO 2
172
NO 2
H
CN
CF 3
H
173
CN
H
Cl
H
NO 2
174
CN
H
Cl
H
CH 3
175
CN
H
Cl
H
CN
176
CN
H
Cl
H
CF 3
177
CO 2 CH 3
H
Cl
H
Cl
178
CH 3
H
Cl
H
Cl
179
NO 2
H
Cl
H
Cl
180
NO 2
H
Cl
Cl
H
181
CF 3
H
Cl
H
Cl
182
OCH 3
H
Cl
H
Cl
183
NO 2
H
Cl
H
F
184
NO 2
H
Cl
H
Br
185
NO 2
H
Cl
H
CF 3
186
NO 2
H
Cl
H
CO 2 CH 3
187
NO 2
H
Cl
H
CH 3
188
CN
H
NO 2
H
NO 2
189
COOH
H
CN
H
CH 3
190
COOH
H
Cl
H
Cl
191
COOH
H
Cl
H
CH 3
192
COOH
H
Br
H
CH 3
193
COOH
H
CN
H
Cl
194
CO 2 CH 3
H
Cl
H
CH 3
195
CO 2 CH 3
H
Br
H
CH 3
196
CONHCH 3
H
CN
H
CH 3
197
CONHCH 3
H
Cl
H
Cl
198
CONHCH 3
H
Cl
H
CH 3
199
CONHCH 3
H
Br
H
CH 3
200
CONHCH 3
H
CN
H
Cl
201
CONH 2
H
CN
H
CH 3
202
CONH 2
H
Cl
H
Cl
203
CONH 2
H
Cl
H
CH 3
204
CONH 2
H
Br
H
CH 3
205
CONH 2
H
CN
H
Cl
206
NO 2
Cl
CF 3
H
NO 2
207
Cl
H
NO 2
Cl
NO 2
208
Cl
H
Cl
Cl
NO 2
Table 23: In formula III, R 1 and R 9 are H, R 8 is Cl, R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 23-1 to Table 23-208.
Table 24: In formula III, R 1 is CH 3 , R 8 is Cl, R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 24-1 to Table 24-208.
Table 25: In formula III, R 1 is H, R 8 is OCH 3 , R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 25-1 to Table 25-208.
Table 26: In formula III, R 1 is H, R 8 is SCH 3 , R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 26-1 to Table 26-208.
Table 27: In formula III, R 1 is H, R 8 is NHCH 3 , R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 27-1 to Table 27-208.
Table 28: In formula III, R 1 is H, R 8 is N(CH 3 ) 2 , R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 28-1 to Table 28-208.
Table 29: In formula III, R 1 is H, R 8 is OCH 2 CF 3 , R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 29-1 to Table 29-208.
Table 30: In formula III, R 1 and R 8 is H, R 9 is NO 2 , R 2 -R 6 are listed in Table 22, the number of representative compounds are Table 30-1 to Table 30-208.
The compounds having formula I in present invention have been reported in prior art, which are commercial available or can be prepared according to the following method. The reaction is as follow, wherein the definitions of substituents are as defined above:
Wherein: X and Y are different, respectively selected from halogen atom or amino; Z is halogen atom; R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 and R 11 are defined respectively as mentioned above; R 1 are defined as mentioned above, but R 1 ≠H.
According to the above preparation method, treatment of intermediate IV with intermediate V at the presence of base gives compounds I-a of general formula I (R 1 ═H), which react with Z—R 1 to give compounds I-b of general formula I (R 1 ≠H).
The proper base mentioned above may be selected from potassium hydroxide, sodium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate, triethylamine, pyridine, sodium methoxide, sodium ethoxide, sodium hydride, potassium tert-butoxide or sodium tert-butoxide and so on.
The reaction can be carried out in proper solvent, and the proper solvent mentioned may be selected from tetrahydrofuran, acetonitrile, toluene, xylene, benzene, DMF, N-methylpyrrolidone, DMSO, acetone or butanone and so on.
The proper reaction temperature is from room temperature to boiling point of solvent, generally is 20-100° C.
The reaction time is in the range of 30 minutes to 20 hours, generally is 1-10 hours.
Intermediates IV are commercially available, or prepared according to the known methods, such as referring to Indian Journal of Chemistry, Section B: Organic Chemistry Including Medicinal Chemistry, 45B(4), 972-975, 2006; Tetrahedron Letters, 44(21), 4085-4088, 2003; PL174903, etc.
Intermediate V can be prepared according to the known methods, such as referring to JP2003292476, 052010160695, etc.
The nitration of compounds of general formula I, in which at least one of R 2 , R 4 , R 6 , R 9 or R 11 is H, can add one or several NO 2 groups to these compounds of general formula I.
The halogenation of substituted diphenylamine compounds of general formula I, in which R 2 , R 4 , R 6 , R 7 , R 9 or R 11 is not halogen atom, can add one or several halogen atoms to these compounds of general formula I.
The compounds of general formula I, in which R 8 and R 10 are alkylamino, alkoxy or alkylthio, can be prepared from the reaction of compounds of general formula I whose R 8 and R 10 are halogen atom with amine, alcohol or mercaptan (or their salts), or referring to the preparation method in Journal of Medicinal Chemistry, 1978, 21(9), 906-913.
The compounds of general formula I, in which R 8 and R 10 are alkylsulfonyl and alkylcarbonyloxy, can be prepared according to the preparation method in Journal of Medicinal Chemistry, 1978, 21(9), 906-913.
The salts of compounds having general formula I can be prepared from the reaction of the compounds of general formula I with corresponding acid according to routine method. The proper acid may be selected from hydrochloric acid, sulfuric acid, nitric acid, carbonic acid, phosphoric acid, formic acid, acetic acid, trifluoroacetic acid, phenylsulfonic acid, p-toluenesulfonic acid, methylsulfonic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or oxalic acid; The preferred acid are selected from hydrochloric acid, sulfuric acid, phosphoric acid, trifluoroacetic acid, methylsulfonic acid or p-toluenesulfonic acid.
The present invention includes the formulations, which were made from the compounds having the general formula I as active ingredient, and preparation thereof. The preparation of formulations: Dissolve the compounds of present invention in water soluble organic solvents, the ionicity of surfactant, water soluble lipid, all kinds of cyclodextrin, fatty acid, fatty acid ester, phospholipids or their combination solvents, and add physiological saline or 1-20% of carbohydrates. Mentioned organic solvents include polyethylene glycol (PEG), ethanol, propylene glycol or their combination solvents.
The compounds having the general formula I in present invention and their salt and prodrug can be used to prepare the drugs or formulations to cure, prevent or alleviate cancer. The active ingredients are composed of one or more than two diphenylamine compounds having the general formula I. Especially to cure or alleviate the cancer causing by cancer cells of human tissue or organ. The preferred cancers are: colon cancer, liver cancer, lymph cancer, lung cancer, esophageal cancer, breast cancer, central nervous system cancer, melanoma, ovarian cancer, cervical cancer, renal cancer, leukemia, prostatic cancer, pancreatic cancer, bladder cancer, rectal cancer, osteosarcoma, nasopharynx cancer or stomach cancer.
The compounds in present invention can be used as active ingredients of antitumor drug, which can be used alone or combined with other antitumorantiviral drugs. The drug combination process in present invention, using at least one of the compounds and its active derivatives with other one or more antitumorantiviral drugs, are used together to increase the overall effect. The dose and drug administration time of combination therapy are based on the most reasonable treatment effect in the different situations.
The formulations include the effective dose of the compounds having general formula I. The “effective dose” refers to the compound dosage, which are effective to cure cancer. The effective dose or dose can be different based on the suggestions of experienced person at different conditions. For instance, the different usage of drug based on different cancers; the dose of drug also can be changed based on whether it shares with other therapeutic method, such as antitumor or antiviral drugs. The drug can be prepared for any useable formulations. The salts of compounds also can be used if the alkaline or acidic compounds can formed the non-toxic acids or salts. The organic acids/salts in pharmacy include anion salts, which are formed with acids, such as p-toluenesulfonic acid, methylsulfonic acid, acetic acid, benzoic acid, citric acid, malic acid, tartaric acid, maleic acid, succinic acid, ascorbic acid or glycerophosphoric acid; the inorganic salts include chloride, bromide, fluoride, iodide, sulfate, nitrate, bicarbonate, carbonate or phosphate. For example, the alkaline compounds, such as amines can form salts with suitable acids; acids can form salts with alkalis or alkaline earth.
The compounds in present invention having general formula I general easily dissolves in organic solvent, water soluble solvent and their mixture with water. The water soluble solvents prefer alcohol, polyethylene glycol, N-methyl-2-pyrrolidone, N,N-dimethyl acetamide, N,N-dimethyl formamide, dimethylsulfoxide, acetonitrile and their mixture. Mentioned alcohols prefer methanol, ethanol, isopropanol, glycerol or ethylene glycol. The compounds in present invention mix with common drug carrier to form formulations. Dissolve the compounds of present invention in water soluble organic solvents, aprotic solvent, water soluble lipid, cyclodextrin, fatty acid, phospholipids or their combination solvents, and add physiological saline or 1-20% of carbohydrates, such as glucose aqueous solution. The stability formulations made by this way are used for animal and clinical.
The drugs were made from the active ingredients of general formula I compounds, which can dose by oral medication or parenteral route, also by implantable medication pump and other methods. Where the parenteral route refer to injection or drip technology through subcutaneous intradermal, intramuscular, intravenous, arteries, atrium, synovium, sternum, intrathecal, wound area, encephalic, etc. The formulations were mixed using conventional method by technicist, which are used for animal and clinical, including tablets, pills, capsule, granule, syrup, injection, freeze-dried powder injection, emulsion, powder, freeze-dried powder, drop pill, milk suspension, aqueous suspension, colloid, colloidal solution, sustained-release suspensions, nanoparticle or other formulations.
The compounds having the general formula I in present invention can be used to cure or alleviate the cancer causing by cancer cells of human tissue or organ. The cancers include but not limited to colon cancer, liver cancer, lymph cancer, lung cancer, esophageal cancer, breast cancer, central nervous system cancer, melanoma, ovarian cancer, cervical cancer, renal cancer, leukemia, prostatic cancer, pancreatic cancer, bladder cancer, rectal cancer, osteosarcoma, nasopharynx cancer or stomach cancer.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is illustrated by the following examples, but without being restricted thereby. (All raw materials are commercially available unless otherwise specified.)
PREPARATION EXAMPLES
Example 1
Preparation of Compound Table 6-1
0.35 g (3.76 mmol) of aniline and 0.30 g (7.52 mmol) of sodium hydroxide were added into 40 mL of DMF, and 1.00 g (3.76 mmol) of 2,4,5,6-tetrachloroisophthalonitrile was added slowly under stirring, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and filtered to give white solid. The solid was washed twice by 30 ml water and twice by 20 ml petroleum ether, 0.65 g of compound Table 6-1 as white solid was obtained, m.p. 226-228° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 7.22 (d, 2H, Ph-2,6-2H, J=7.5 Hz), 7.40-7.46 (m, 3H, Ph-3,4,5-3H).
Example 2
Preparation of Compound Table 6-33
1.03 g (8 mmol) of 2,6-difluoroaniline and 0.64 g (16 mmol) of sodium hydroxide were added into 40 mL of DMF, and 2.13 g (8 mmol) of 2,4,5,6-tetrachloroisophthalonitrile was added slowly under stirring, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/4, as an eluent) to give 1.65 g of compound table 6-33 as yellow solid, m.p. 264-266° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 6.70 (s, 1H, NH), 7.07 (t, 2H, Ph-3,5-2H, J=8.1 Hz), 7.37 (m, 1H, Ph-4-1H).
Example 3
Preparation of Compound Table 6-39
The preparation is same to compound Table 6-1, brown black solid, m.p. 209-212° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 6.95 (s, 1H, NH), 7.20 (d, 1H, Ph-6-H, J=8.1 Hz), 7.36 (dd, 1H, Ph-5-H, 3 J=8.7 Hz, 4 J=2.7 Hz), 7.54 (d, 1H, Ph-3-H, J=2.4 Hz).
Example 4
Preparation of Compound Table 6-91
0.68 g (2 mmol) of compound table 6-33 was dissolved in 20 mL of concentrated sulfuric acid and cooled by ice-bath, the mixed acid (4 mmol of nitric acid and 6 mmol of sulfuric acid) was added dropwise to the reaction solution under stirring to keep the temperature below 20° C. Then the reaction mixture was stirred for another 5 min. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into ice water, extracted with ethyl acetate, the extract was washed by saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/4, as an eluent) to give 0.40 g of compound table 6-91 as white solid, m.p. 204-206° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 6.70 (s, 1H, NH), 7.97-8.01 (dd, 2H, Ph-3,5-2H, 3 J=10.8 Hz, 4 J=3.0 Hz).
Example 5
Preparation of Compound Table 6-93
1.57 g (8 mmol) of 2,4,6-trichloroaniline and 0.64 g (16 mmol) of sodium hydroxide were added into 40 mL of DMF, and 2.13 g (8 mmol) of 2,4,5,6-tetrachloroisophthalonitrile was added slowly under stirring, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/4, as an eluent) to give 1.91 g of compound table 6-39 as light yellow solid, m.p. 182-184° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 6.86 (s, 1H, NH), 7.48 (s, 2H, Ph-3,5-2H).
Example 6
Preparation of Compound Table 6-99
0.35 g (1.3 mmol) of 2,6-dichloro-4-nitroaniline and 0.10 g (2.6 mmol) of sodium hydroxide were added into 40 mL of DMF, and 0.27 g (1.3 mmol) of 2,4,5,6-tetrachloroisophthalonitrile was added slowly under stirring, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/4, as an eluent) to give 0.48 g of compound table 6-99 as yellow solid, m.p. 250-252° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 6.93 (s, 1H, NH), 8.34 (s, 2H, Ph-3,5-2H).
Example 7
Preparation of Compound Table 6-100
10.33 g (39 mmol) of methyl 4-amino-3,5-dichlorobenzoate (preparation refer to WO2010060379, CN101337940) and 3.12 g (78 mmol) of sodium hydroxide were added into 60 mL of DMF, and 10.37 g (39 mmol) of 2,4,5,6-tetrachloroisophthalonitrile was added slowly under stirring, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/5, as an eluent) to give 13.65 g of compound table 6-100 as yellow solid, m.p. 229-231° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 3.96 (s, 3H, CH 3 ), 6.92 (s, 1H, NH), 8.11 (s, 2H, Ph-2,6-2H).
Example 8
Preparation of Compound Table 6-104
(1) Preparation of Compound Table 6-106
13.31 g (31 mmol) of compound Table 6-100 was dissolved in mixed solution of THF and water (volume ratio=1/1), and 2.45 g (61 mmol) of sodium hydroxide was added to the reaction solution followed by heating for 5 h at 50° C. in oil-bath. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the aqueous phase was acidized by diluted hydrochloric acid, and filtered to give compound Table 6-106 as yellow solid, dried for the next step.
(2) Preparation of Compound Table 6-106a
5.54 g (12.72 mmol) of compound Table 6-106 was added to 100 ml of petroleum ether, and two drops of DMF and 2.27 g (19.08 mmol) of thionyl chloride were added to the reaction solution followed by refluxing for 2 h at 85° C. in oil-bath. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was concentrated under reduced pressure to obtain compound Table 6-106a.
(3) Preparation of Compound Table 6-104
0.12 g (0.91 mmol) of p-chloroaniline and 0.23 g (2.27 mmol) of triethylamine were dissolved in anhydrous THF, then 0.40 g (0.91 mmol) of compound Table 6-106a was added dropwise to the reaction solution followed by heating for 5 h at 45° C. in oil-bath. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/3, as an eluent) to give 0.23 g of compound table 6-104 as white solid, m.p. 275-276° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 7.31-7.35 (m, 2H, 4-Cl-Ph-2,6-2H), 7.81 (d, 2H, 4-Cl-Ph-3,5-2H, J=9.0 Hz), 8.13 (dd, 2H, Ph-2,6-2H, 3 J=15.7 Hz, 4 J=1.2 Hz), 10.50 (d, 1H, CONH, J=12.9 Hz).
Example 9
Preparation of Compound Table 6-112
2.63 g (8 mmol) of 2,4,6-trichloroaniline and 0.64 g (16 mmol) of sodium hydroxide were added into 40 mL of DMF, and 2.13 g (8 mmol) of 2,4,5,6-tetrachloroisophthalonitrile was added slowly under stirring, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/4, as an eluent) to give 3.22 g of compound table 6-112 as brown solid, m.p. 238-239° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 6.86 (s, 1H, NH), 7.48 (s, 2H, Ph-3,5-2H).
Example 10
Preparation of Compound Table 14-99
0.55 g (1.3 mmol) of compound Table 6-99 and 0.14 g (2.5 mmol) of sodium methoxide were dissolved in 20 ml of DMSO, followed by heating for 8 h at 95° C. in oil-bath. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into water, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/4, as an eluent) to give 0.16 g of compound table 14-99 as yellow solid, m.p. 151-153° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 4.23 (t, 6H, OCH 3 , J=6.6 Hz), 6.78 (br, 1H, NH), 8.31 (d, 2H, Ph-3,5-2H, J=3.9 Hz).
Example 11
Preparation of Compound Table 22-39
0.81 g (0.005 mol) of 2,4-dichloroaniline was added in portions to a suspension of 0.4 g (0.01 mol) of NaH (60%) and 20 mL of THF, the mixture was stirred for 30 min after addition, 1.56 g (0.006 mol) of 2,6-dichloro-3,5-dinitrotulune in 30 mL of THF was added within 30 min, then stirred for another 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was filtered. The filtrate was concentrated under reduced pressure, then the residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/20, as an eluent) to give 1.37 g of compound table 22-39 as yellow solid, m.p. 136-137° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.14 (s, 3H), 6.53 (d, 1H), 7.17 (d, 1H), 7.49 (s, 1H), 8.68 (s, 1H), 8.93 (s, 1H).
Example 12
Preparation of Compound Table 22-101
The preparation is same to compound Table 22-39, m.p. 143-144° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 1.98 (s, 3H), 7.66 (s, 2H), 8.70 (s, 1H), 9.10 (s, 1H).
Example 13
Preparation of Compound Table 22-105
0.83 g (0.004 mol) of 2,6-dichloro-4-nitroaniline was added in portions to a suspension of 0.32 g (0.008 mol) of NaH (60%) and 10 mL of DMF, the mixture was stirred for 30 min after addition, 1.20 g (0.0048 mol) of 2,6-dichloro-3,5-dinitrotulune was added in portions within 30 min, then stirred for another 3 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into 50 mL of saturated brine and extracted with ethyl acetate, the extract was dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/10, as an eluent) to give 1.20 g of compound table 22-105 as yellow solid, m.p. 157-158° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.02 (s, 3H), 8.29 (s, 2H), 8.65 (s, 1H), 8.95 (s, 1H).
Example 14
Preparation of Compound Table 22-120
The preparation is same to compound Table 22-39, m.p. 148-150° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.07 (s, 3H), 7.53 (s, 1H), 7.72 (s, 1H), 8.71 (s, 1H), 8.97 (s, 1H).
Example 15
Preparation of Compound Table 22-121
0.56 g (0.0015 mol) of compound table 22-39 was dissolved in 5 mL of concentrated sulfuric acid (96%, the same below) and cooled to 0° C., 0.15 g of fuming nitric acid (95%) and 3 mL of concentrated sulfuric acid was mixed evenly and added to the flask, then the reaction mixture was stirred for another 5 min. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into ice water, the solid precipitated was filtered, and the filter mass was washed with water and dried to give 0.59 g of compound table 22-121 as brown solid, m.p. 156-158° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.09 (s, 3H), 7.66 (s, 1H), 8.01 (s, 1H), 8.60 (s, 1H), 9.75 (s, 1H).
Example 16
Preparation of Compound Table 22-153
The preparation is same to compound Table 22-39, m.p. 204-206° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.23 (s, 3H), 7.87 (s, 1H), 8.38 (s, 1H), 8.51 (s, 1H), 10.00 (s, 1H).
Example 17
Preparation of Compound Table 22-206
The intermediate M prepared by the procedure of Example 13 was nitrated according to Example 2 to give compound Table 22-206 as reddish-brown solid, m.p. 136-138° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.41 (s, 3H), 8.50 (s, 1H), 8.72 (s, 1H), 10.10 (s, 1H).
Example 18
Preparation of Compound Table 24-39
0.38 g (0.001 mol) of compound table 22-39 was added to a suspension of 0.10 g (0.0025 mol) of NaH (60%) and 10 mL of DMF, the mixture was stirred for 1 h and then added thereto 0.43 g (0.003 mol) of CH 3 I, the resulting mixture was allowed to react for 5 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into 50 mL of saturated brine and extracted with ethyl acetate, the extract was dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/10, as an eluent) to give 0.15 g of compound table 22-39 as yellow solid, m.p. 142-144° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 2.54 (s, 3H), 3.31 (s, 3H), 7.09 (d, 1H), 7.25 (d, 2H), 8.04 (s, 1H).
Example 19
Preparation of Compound Table 27-105
0.42 g of compound table 22-105 (0.001 mol) was added to a microwave vial and dissolved with 2.5 mL of DMSO, 1 mL of methylamine aqueous solution (25%) was added, the vial was lidded and put into the microwave reactor, then the reaction was carried out at 150° C. for 40 min. The reaction mixture was poured into 50 mL of saturated brine and extracted with ethyl acetate, the extract was dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=120, as an eluent) to give 0.25 g of compound table 27-105 as yellow solid, m.p. 218-219° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 1.70 (s, 3H), 3.09 (d, 3H), 8.25 (d, 1H), 8.31 (s, 2H), 9.12 (s, 1H), 9.58 (s, 1H).
Example 20
Preparation of Compound Table 29-105
0.42 g (1 mmol) of compound Table 22-105 and 2 mmol of sodium 2,2,2-trifluoroethanolate (made from trifluoroethanol and sodium) were dissolved in 3 ml of DMSO, heating to 150° C. for 10 min in microwave synthesizer (Biotage). Then the reaction mixture was poured into saturated brine, and extracted with ethyl acetate, the extract was washed by water and saturated brine, dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=120, as an eluent) to give 0.21 g of compound table 29-105 as yellow solid, m.p. 126-128° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 1.83 (s, 3H), 4.42 (q, 2H), 8.30 (s, 2H), 8.85 (s, 1H), 9.20 (s, 1H).
Example 21
Preparation of Compound Table 30-105
0.83 g (0.004 mol) of 2,6-dichloro-4-nitroaniline was added in portions to a suspension of 0.32 g (0.008 mol) of NaH (60%) and 10 mL of DMF, the mixture was stirred for 30 min after addition, 1.04 g (0.0048 mol) of 2-chloro-1-methyl-3,5-dinitrobenzene was added in portions within 30 min, then stirred for another 3 h. After the reaction was over by Thin-Layer Chromatography monitoring, the reaction mixture was poured into 50 mL of saturated brine and extracted with ethyl acetate, the extract was dried over anhydrous magnesium sulfate and concentrated under reduced pressure. The residue was purified through silica column (ethyl acetate/petroleum ether (boiling point range 60-90° C.)=1/10, as an eluent) to give 0.96 g of compound Table 30-105 as yellow solid, m.p. 146-148° C.
1 H-NMR spectrum (300 MHz, internal standard: TMS, solvent CDC 3 ) δ(ppm): 1.96 (s, 3H), 8.26 (d, 1H), 8.29 (s, 2H), 8.95 (d, 1H), 9.00 (s, 1H).
Other compounds of the present invention were prepared according to the above examples.
Physical properties and 1 HNMR spectrum ( 1 HNMR, 300 MHz, internal standard: TMS, ppm) of some compounds of this invention are as follows:
Table
Compound
Mp. (° C.) and 1 HNMR (300 MHz, internal standard: TMS, solvent
No.
No.
CDCl 3 )
6
3
m.p. 208-210° C. δ (CDCl 3 ): 7.03 (s, 1H, NH), 7.27-7.38 (m, 3H,
Ph-3,5,6-3H), 7.49-7.55 (m, 1H, Ph-4-H).
6
6
m.p. 212-214° C. δ (CDCl 3 ): 2.29 (s, 3H, CH 3 ), 7.00 (s, 1H, NH),
7.15 (d, H, Ph-6-H, J = 7.5 Hz), 7.28-7.34 (m, 3H, Ph-3,4,5-3H).
6
10
m.p. 258-260° C. δ (CDCl 3 ): 7.12 (s, 1H, NH), 7.24 (d, 1H,
Ph-6-H, J = 7.5 Hz), 7.47 (t, 1H, Ph-4-H, J = 7.2 Hz), 7.68 (t, 1H,
Ph-5-H, J = 7.5 Hz), 7.78 (d, 1H, Ph-3-H, J = 7.8 Hz).
6
14
m.p. 236-238° C. δ (CDCl 3 ): 7.12 (s, 1H, NH), 7.28-7.40 (m, 1H,
Ph-6-H), 7.41-7.52 (m, 2H, Ph-2,4-2H), 7.54-7.62 (m, 1H,
Ph-5-H).
6
19
m.p. 144-146° C. δ (CDCl 3 ): 1.30 (s, 9H, t-C 4 H 9 ), 6.65 (m, 2H,
Ph-2,6-2H), 7.16 (s, 1H, NH), 7.18 (m, 2H, Ph-3,5-2H).
6
21
m.p. 204-206° C. δ (CDCl 3 ): 7.09 (s, 1H, NH), 7.22-7.32 (m, 4H,
Ph-2,3,5,6-4H).
6
23
m.p. 259-261° C. δ (CDCl 3 ): 7.00 (s, 1H, NH), 7.17 (d, 2H,
Ph-2,6-2H, J = 8.7 Hz), 7.42 (d, 2H, Ph-3,5-2H, J = 9.0 Hz).
6
25
m.p. 246-248° C. δ (CDCl 3 ): 2.29 (s, 3H, COOCH 3 ), 7.08 (s, 1H,
NH), 7.17 (d, 2H, Ph-3,5-2H, J = 8.7 Hz), 8.10 (d, 2H, Ph-2,6-2H,
J = 8.7 Hz).
6
31
m.p. 206-208° C. δ (CDCl 3 ): 6.88 (s, 1H, NH), 6.99 (t, 2H,
Ph-5,6-2H, J = 8.1 Hz), 7.32 (d, 1H, Ph-3-H, J = 2.4 Hz).
6
35
m.p. 209-212° C. 6.93 (s, 1H, NH), 7.34 (t, 1H, Ph-3-H,
J = 9.0 Hz), 7.52 (d, 1H, Ph-4-H, J = 7.2 Hz), 7.58-7.65 (m, 1H,
Ph-3-H).
6
38
m.p. 218-220° C. δ (CDCl 3 ): 7.03 (s, 1H, NH), 7.13 (dd, 1H,
Ph-6-H, 3 J = 8.1 Hz, 4 J = 0.9 Hz), 7.28 (t, 1H, Ph-5-H, J = 8.1 Hz),
7.47 (dd, 1H, Ph-4-H, 3 J = 8.1 Hz, 4 J = 0.9 Hz).
6
41
m.p. 235-237° C. δ (CDCl 3 ): 6.61 (s, 1H, NH), 7.36 (t, 1H,
Ph-4-H, J = 7.2 Hz), 7.45 (d, 2H, Ph-3,5-2H, J = 7.2 Hz).
6
42
m.p. 240-242° C. δ (CDCl 3 ): 2.32 (s, 3H, Ph—CH 3 ), 6.93 (s, 1H,
NH), 7.22-7.35 (m, 3H, Ph-3,4,5-H).
6
44
m.p. 238-242° C. δ (CDCl 3 ): 6.95 (s, 1H, NH), 7.05 (d, 2H,
Ph-2,6-2H, J = 1.8 Hz), 7.32 (d, 1H, Ph-4-H, J = 1.5 Hz).
6
47
m.p. 166-168° C. δ (CDCl 3 ): 7.00 (s, 1H, NH), 7.20 (d, 1H,
Ph-6-H, J = 8.4 Hz), 7.57 (dd, 1H, Ph-5-H, 3 J = 8.4 Hz, 4 J = 1.5 Hz),
7.78 (s, 1H, Ph-3-H).
6
48
m.p. 197-199° C. δ (CDCl 3 ): 7.02 (s, 1H, NH), 7.45 (s, 1H,
Ph-6-H), 7.55 (d, 1H, Ph-4-H, J = 8.4 Hz), 7.65 (d, 1H, Ph-3-H,
J = 8.4 Hz).
6
49
m.p. 220-222° C. 7.04 (d, 1H, Ph-6-H, J = 8.7 Hz), 7.07 (s, 1H,
NH), 8.20 (dd, 1H, Ph-5-H, 3 J = 9.0 Hz, 4 J = 2.7 Hz), 8.42 (d, 1H,
Ph-3-H, J = 2.7 Hz).
6
77
m.p. 200-202° C. δ (CDCl 3 ): 2.27 (s, 3H, Ph-2-CH 3 ), 6.86 (s, 1H,
NH), 7.07 (d, 1H, Ph-6-H, J = 8.4 Hz), 7.23 (dd, 1H, Ph-5-H,
3 J = 8.4 Hz, 4 J = 2.1 Hz), 7.33 (s, 1H, Ph-3-H).
6
78
m.p. 140-142° C. δ (CDCl 3 ): 2.35 (s, 3H, CH 3 ), 6.99 (s, 1H, NH),
7.08 (d, 1H, Ph-6-H, J = 8.1 Hz), 7.19-7.25 (m, 1H, Ph-5-H), 7.46 (d,
1H, Ph-4-H, J = 8.7 Hz).
6
80
m.p. 198-200° C. δ (CDCl 3 ): 2.23 (s, 3H, CH 3 ), 2.34 (s, 3H,
CH 3 ), 6.95 (s, 1H, NH), 6.95 (s, 1H, Ph-6-H), 7.13-7.22 (m, 2H,
Ph-3,4-2H).
6
83
m.p. 204-205° C. δ (CDCl 3 ): 2.36 (s, 3H, COOCH 3 ), 3.92 (s, 3H,
Ph-3-CH 3 ), 6.85 (s, 1H, NH), 7.12 (d, 1H, Ph-5-1H, J = 8.4 Hz),
7.92 (d, 1H, Ph-6-1H, J = 8.4 Hz), 8.02 (s, 1H, Ph-2-1H).
6
84
m.p. 216-218° C. δ (CDCl 3 ): 2.16 (s, 3H, CH 3 ), 3.89 (s, 3H,
COOCH 3 ), 7.39 (t, 1H, Ph-4-H, J = 7.8 Hz), 7.51 (d, 1H, Ph-5-H,
J = 7.8 Hz), 7.93 (d, 1H, Ph-3-H, J = 7.8 Hz).
6
85
m.p. 242-243° C. δ (CDCl 3 ): 7.07 (s, 1H, NH), 7.25 (d, 1H,
Ph-6-H, J = 2.1 Hz), 7.42 (d, 1H, Ph-2-H, J = 2.4 Hz), 7.83 (d, 1H,
Ph-5-H, J = 8.4 Hz).
6
87
m.p. 232-234° C. δ (CDCl 3 ): 6.94 (d, 1H, Ph-6-H, J = 9.3 Hz),
7.58 (dd, 1H, Ph-5-H, 3 J = 9.0 Hz, 4 J = 2.7 Hz), 8.26 (d, 1H, Ph-3-H,
J = 2.7 Hz), 9.36 (s, 1H, NH).
6
88
m.p. 236-238° C. δ (DMSO): 7.02 (dd, 1H, Ph-6-H, 3 J = 9.6 Hz,
4 J = 2.7 Hz), 8.32 (dd, 1H, Ph-5-H, 3 J = 9.3 Hz, 4 J = 2.7 Hz), 8.63 (d,
1H, Ph-3-H, J = 2.7 Hz).
6
95
m.p. 201-203° C. δ (CDCl 3 ): 6.91 (s, 1H, NH), 7.72 (s, 2H,
Ph-3,5-2H).
6
98
m.p. 259-261° C. δ (CDCl 3 ): 6.91 (s, 1H, NH), 7.74 (s, 2H,
Ph-3,5-2H).
6
103
m.p. 267-269° C. δ (CDCl 3 ): 7.28-7.30 (m, 1H, NHPh-4-H),
7.40 t, 2H, NHPh-3,5-2H, J = 6.9 Hz), δ = 7.62 (d, 2H, NHPh-2,6-2H,
J = 7.8 Hz), δ = 7.89-7.95 (m, 2H, NHCOPh-2,6-2H).
6
107
m.p. 232-234° C. δ (CDCl 3 ): 2.43 (s, 3H, Ph—CH 3 ), 6.86 (s, 1H,
NH), 8.14 (s, 1H, Ph-5-1H), 8.26 (s, 1H, Ph-3-1H).
6
108
m.p. 196-198° C. δ (CDCl 3 ): 2.55 (s, 3H, CH 3 ), 6.99 (s, 1H, NH),
7.04 (d, 1H, Ph-6-H, J = 8.4 Hz), 7.36 (d, 1H, Ph-5-H, J = 8.4 Hz).
6
109
m.p. 194-196° C. δ (CDCl 3 ): 6.96 (s, 1H, NH), 7.67 (d, 1H,
Ph-5-H, J = 2.1 Hz), 7.77 (d, 1H, Ph-3-H, J = 2.4 Hz).
6
110
m.p. 197-199° C. 6.86 (s, 1H, NH), 8.05 (dd, 1H, Ph-5-H,
3 J = 9.9 Hz, 4 J = 2.7 Hz), 8.28 (d, 1H, Ph-3-H, J = 2.4 Hz).
6
113
m.p. 248-250° C. δ (CDCl 3 ): 6.95 (s, 1H, NH), 8.37 (d, 1H,
Ph-3-H, J = 2.7 Hz), 8.49 (d, 1H, Ph-5-H, J = 2.4 Hz).
6
114
m.p. 247-249° C. δ (CDCl 3 ): 6.96 (s, 1H, NH), 8.51 (s, 2H,
Ph-3,5-2H).
6
134
m.p. 176-178° C. δ (CDCl 3 ): 1.15-1.27 (m, 6H, CH 3 ), 2.49 (q,
4H, CH 2 , J = 7.5 Hz), 6.98 (s, 1H, NH), 7.14 (d, 1H, Ph-5-H,
J = 8.4 Hz), 7.47 (d, 1H, Ph-3-H, J = 8.4 Hz).
6
152
m.p. 222-223° C. δ (CDCl 3 ): 2.22 (s, 3H, CH 3 ), 2.34 (s, 3H, CH 3 ),
6.88 (s, 1H, NH), 7.00 (s, 1H, Ph-6-H), 7.30 (s, 1H, Ph-3-H).
6
176
m.p. 260-262° C. δ (CDCl 3 ): 2.06 (s, 3H, CH 3 ), 2.98 (d, 3H,
NHCH 3 , J = 4.8 Hz), 6.38 (s, 1H, CONH), 7.67 (s, 2H, Ph-3,5-2H),
9.38 (s, 1H, NH).
6
178
m.p. 240-242° C. δ (CDCl 3 ): 2.08 (s, 3H, CH 3 ), 2.93 (d, 3H,
NCH 3 , J = 5.1 Hz), 6.22 (s, 1H, CONH), 7.35-7.38 (m, 2H,
Ph-3,5-2H), 8.59 (s, 1H, NH).
6
180
m.p. 180-182° C. δ (CDCl 3 ): 2.69 (s, 3H, CH 3 ), 7.12 (s, 1H, NH),
7.24-7.68 (m, 4H, Ph).
6
206
m.p. 156-158° C. δ (CDCl 3 ): 2.51 (s, 3H, CH 3 ), 8.67 (s, 1H, Ph),
8.89 (s, 1H, NH).
9
8
Yellow oil. δ (CDCl 3 ): 1.13-1.21 (m, 6H, CH 3 ), 3.46 (q, 4H,
CH 2 , J = 7.2 Hz), 6.90 (s, 1H, NH), 7.13 (t, 2H, Ph-2,6-2H,
J = 7.5 Hz), 7.31 (d, 1H, Ph-4-H, J = 7.5 Hz), 7.42 (t, 2H,
Ph-3,5-2H, J = 7.2 Hz).
10
99
m.p. 127-129° C. δ (CDCl 3 ): 3.22 (s, 6H, CH 3 ), 6.85 (s, 1H, NH),
8.32 (s, 2H, Ph-3,5-2H).
12
99
m.p. 198-200° C. δ (CDCl 3 ): 4.25 (s, 3H, CH 3 ), 6.87 (s, 1H, NH),
8.32 (s, 2H, Ph-3,5-2H).
14
4
m.p. 142-144° C. δ (CDCl 3 ): 4.14 (s, 3H, OCH 3 ), 4.17 (t, 3H,
OCH 3 , J = 4.2 Hz), 6.91 (s, 1H, Ph—NH—Ph), 7.18 (d, 2H,
Ph-2,6-2H, J = 7.8 Hz), 7.32 (t, 1H, Ph-4-H, J = 7.2 Hz), 7.42 (t,
2H, Ph-3,5-2H, J = 7.5 Hz).
16
2
m.p. 176-178° C. δ (CDCl 3 ): 3.26 (d, 3H, NCH 3 , J = 8.7 Hz),
3.37 (d, 3H, NCH 3 J = 8.1 Hz), 5.04 (br, 1H, Ph—NH—C), 5.26 (br, 1H,
Ph—NH—C), 6.35 (s, 1H, Ph—NH—Ph), 7.04 (d, 2H, Ph-2,6-2H,
J = 8.1 Hz), 7.14 (t, 1H, Ph-4-H, J = 7.2 Hz), 7.35 (t, 2H,
Ph-3,5-2H, J = 7.5 Hz).
22
11
m.p. 158-160° C. δ (CDCl 3 ): 2.10 (s, 3H), 6.83 (d, 4H), 7.12 (m,
2H), 7.34 (m, 4H), 8.56 (s, 1H).
22
22
m.p. 172-174° C. δ (DMSO): 2.34 (s, 3H), 6.83 (d, 2H), 8.06 (d,
2H), 8.64 (s, 1H), 9.49 (s, 1H).
22
23
m.p. 184-186° C. δ (CDCl 3 ): 2.22 (s, 3H), 6.87 (d, 2H), 7.62 (d,
2H), 8.66 (s, 1H), 8.93 (s, 1H).
22
24
m.p. 91-94° C. δ (CDCl 3 ): 2.14 (s, 3H), 6.91 (d, 2H), 7.21 (d, 2H),
8.71 (s, 1H), 9.20 (s, 1H).
22
31
m.p. 136-138° C. δ (CDCl 3 ): 2.12 (s, 3H), 7.21 (m, 2H), 7.26 (m,
1H), 8.72 (s, 1H), 9.00 (s, 1H).
22
47
m.p. 106-108° C. δ (CDCl 3 ): 2.22 (s, 3H), 6.55 (d, 1H), 7.43 (d,
1H), 7.75 (s, 1H), 8.65 (s, 1H), 8.87 (s, 1H).
22
48
m.p. 110-112° C. δ (CDCl 3 ): 2.03 (s, 3H), 2.50 (s, 3H), 6.50 (d,
1H), 7.05 (t, 1H), 7.24 (d, 1H), 8.73 (s, 1H), 9.06 (s, 1H).
22
50
m.p. 191-193° C. δ (CDCl 3 ): 2.29 (s, 3H), 6.48 (d, 1H), 8.06 (d,
1H), 8.41 (s, 1H), 8.62 (s, 1H), 8.79 (s, 1H).
22
56
m.p. 146-148° C. δ (CDCl 3 ): 1.86 (s, 3H), 2.40 (s, 3H), 7.18 (m,
2H), 7.28 (m, 1H), 8.80 (s, 1H), 9.52 (s, 1H).
22
58
m.p. 133-135° C. δ (CDCl 3 ): 2.03 (s, 3H), 2.50 (s, 3H), 6.53 (d,
1H), 7.06 (t, 1H), 7.21 (d, 1H), 8.74 (s, 1H), 9.08 (s, 1H).
22
61
m.p. 206-208° C. δ (CDCl 3 ): 2.25 (s, 3H), 6.48 (d, 1H), 7.47 (d,
1H), 7.77 (s, 1H), 8.62 (s, 1H), 8.80 (s, 1H).
22
63
m.p. 259-261° C. δ (CDCl 3 ): 2.38 (s, 3H), 6.54 (d, 1H), 7.70 (d,
1H), 8.50 (s, 1H), 8.62 (s, 1H), 10.51 (s, 1H).
22
80
m.p. 121-123° C. δ (CDCl 3 ): 2.02 (s, 3H), 2.40 (s, 3H), 6.53 (d,
1H), 7.10 (d, 1H), 7.27 (s, 1H), 8.74 (s, 1H), 9.03 (s, 1H).
22
86
oil. δ (DMSO): 2.33 (s, 3H), 6.92 (d, 1H), 7.26 (s, 1H), 7.78 (d,
1H), 8.63 (s, 1H), 9.54 (s, 1H).
22
88
m.p. 204-205° C. δ (CDCl 3 ): 2.31 (s, 3H), 6.48 (d, 1H), 7.43 (d,
1H), 8.26 (s, 1H), 8.54 (s, 1H), 10.36 (s, 1H).
22
89
m.p. 185-186° C. δ (CDCl 3 ): 2.41 (s, 3H), 6.56 (d, 1H), 8.31 (d,
1H), 8.52 (s, 1H), 9.23 (s, 1H), 10.59 (s, 1H).
22
93
m.p. 148-150° C. δ (CDCl 3 ): 2.12 (s, 3H), 7.04 (d, 2H), 8.70 (s,
1H), 8.87 (s, 1H).
22
94
m.p. 154-156° C. δ (CDCl 3 ): 2.21 (s, 3H), 7.20 (m, 1H), 7.80 (m,
1H), 8.59 (s, 1H), 9.94 (s, 1H).
22
95
m.p. 140-142° C. δ (CDCl 3 ): 2.17 (s, 3H), 7.19 (d, 2H), 8.71 (s,
1H), 8.94 (s, 1H).
22
97
m.p. 142-143° C. δ (CDCl 3 ): 2.20 (s, 3H), 6.59 (s, 1H), 7.58 (s,
1H), 8.67 (s, 1H), 8.80 (s, 1H).
22
98
m.p. 160-162° C. δ (CDCl 3 ): 1.95 (s, 3H), 7.41 (s, 2H), 8.72 (s,
1H), 9.19 (s, 1H).
22
104
m.p. 180-182° C. δ (CDCl 3 ): 1.99 (s, 3H), 7.69 (s, 2H), 8.67 (s,
1H), 9.00 (s, 1H).
22
106
m.p. 169-171° C. δ (CDCl 3 ): 2.32 (s, 3H), 6.42 (s, 1H), 8.20 (s,
1H), 8.60 (s, 1H), 8.62 (s, 1H).
22
107
m.p. 132-134° C. δ (CDCl 3 ): 1.95 (s, 3H), 3.96 (s, 3H), 8.05 (s,
2H), 8.70 (s, 1H), 9.13 (s, 1H).
22
116
m.p. 216-219° C. δ (CDCl 3 ): 2.30 (s, 3H), 7.88 (s, 2H), 8.48 (s,
1H), 8.85 (s, 1H).
22
118
m.p. 169-171° C. δ (CDCl 3 ): 2.26 (s, 3H), 8.50 (d, 2H), 8.99 (s,
1H), 10.14 (s, 1H).
22
119
m.p. 160-161° C. δ (CDCl 3 ): 2.13 (s, 3H), 2.54 (s, 3H), 6.40 (d,
1H), 7.19 (d, 1H), 8.68 (s, 1H), 8.96 (s, 1H).
22
122
m.p. 135-137° C. δ (CDCl 3 ): 2.16 (s, 3H), 7.95 (dd, 1H), 8.26 (t,
1H), 8.63 (s, 1H), 8.82 (s, 1H).
22
123
m.p. 151-153° C. δ (CDCl 3 ): 1.99 (s, 3H), 8.31 (d, 1H), 8.47 (d,
1H), 8.66 (s, 1H), 9.00 (s, 1H).
22
124
m.p. 96-97° C. δ (CDCl 3 ): 2.21 (s, 3H), 5.08 (m, 1H), 6.59 (s, 1H),
7.49 (s, 1H), 8.66 (s, 1H), 8.78 (s, 1H).
22
125
m.p. 192-194° C. δ (CDCl 3 ): 2.20 (s, 3H), 7.05 (s, 2H), 8.04 (s,
1H), 8.22 (s, 1H), 9.07 (s, 1H), 9.43 (s, 1H).
22
126
m.p. 125-127° C. δ (CDCl 3 ): 1.94 (s, 3H), 7.53 (s, 2H), 8.75 (s,
1H), 9.29 (s, 1H).
22
129
m.p. 151-154° C. δ (CDCl 3 ): 1.97 (s, 3H), 8.49 (s, 2H), 8.68 (s,
1H), 9.03 (s, 1H).
22
130
m.p. 172-175° C. δ (DMSO): 2.32 (s, 3H), 8.49 (s, 1H), 8.68 (s,
2H), 9.50 (s, 1H).
22
133
m.p. 131-132° C. δ (CDCl 3 ): 2.10 (s, 3H), 6.99 (t, 2H), 7.17 (m,
1H), 8.72 (s, 1H), 8.98 (s, 1H).
22
139
m.p. 158-161° C. δ (CDCl 3 ): 2.16 (s, 3H), 2.61 (s, 3H), 6.47 (d,
1H), 7.67 (d, 1H), 8.69 (s, 1H), 8.85 (s, 1H).
22
140
m.p. 137-139° C. δ (CDCl 3 ): 1.91 (s, 3H), 2.31 (s, 3H), 8.10 (s,
1H), 8.21 (s, 1H), 8.73 (s, 1H), 9.20 (s, 1H).
22
152
m.p. 160-162° C. δ (CDCl 3 ): 2.18 (s, 3H), 7.88 (d, 1H), 8.32 (d,
1H), 8.55 (s, 1H), 9.97 (s, 1H).
22
163
m.p. 241-243° C. δ (CDCl 3 ): 1.97 (s, 3H), 7.83 (s, 2H), 8.69 (s,
1H), 9.11 (s, 1H).
22
164
δ (CDCl 3 ): 1.94 (s, 3H), 3.03 (d, 3H), 7.78 (s, 2H), 8.70 (s, 1H),
9.14 (s, 1H).
22
169
m.p. 187-190° C. δ (CDCl 3 ): 2.18 (s, 3H), 8.23 (s, 2H), 8.57 (s,
1H), 10.39 (s, 1H).
22
170
oil. δ (CDCl 3 ): 2.27 (s, 3H), 8.52 (s, 1H), 9.09 (s, 2H), 10.93 (s,
1H).
22
171
m.p. 93-95° C. δ (CDCl 3 ): 2.19 (s, 3H), 8.14 (s, 2H), 8.56 (s, 1H),
10.42 (s, 1H).
22
172
m.p. 204-206° C. δ (DMSO): 2.32 (s, 3H), 7.03 (s, 1H), 8.73 (s,
1H), 8.86 (s, 1H), 10.40 (s, 1H).
22
180
m.p. 127-129° C. δ (CDCl 3 ): 2.36 (s, 3H), 6.55 (s, 1H), 8.40 (s,
1H), 8.54 (s, 1H), 10.31 (s, 1H).
22
207
m.p. 159-162° C. δ (CDCl 3 ): 2.16 (s, 3H), 8.23 (s, 1H), 8.63 (s,
1H), 8.91 (s, 1H).
22
208
m.p. 133-135° C. δ (CDCl 3 ): 2.07 (s, 3H), 7.70 (s, 1H), 8.69 (s,
1H), 9.22 (s, 1H).
23
22
m.p. 136-138° C. δ (CDCl 3 ): 2.22 (s, 3H), 6.70 (d, 2H), 7.41 (d,
1H), 8.00 (d, 1H), 8.16 (d, 2H), 8.22 (s, 1H).
23
23
m.p. 146-148° C. δ (CDCl 3 ): 2.19 (s, 3H), 6.70 (d, 2H), 7.36 (d,
1H), 7.53 (d, 2H), 7.96 (d, 1H), 8.20 (s, 1H).
23
24
m.p. 72-74° C. δ (CDCl 3 ): 2.12 (s, 3H), 6.75 (d, 2H), 7.12 (d, 2H),
7.25 (d, 1H), 7.98 (d, 1H), 8.46 (s, 1H).
23
63
m.p. 158-160° C. δ (CDCl 3 ): 2.30 (s, 3H), 6.47 (d, 1H), 7.59 (m,
2H), 7.94 (d, 1H), 8.60 (s, 1H), 10.21 (s, 1H).
23
77
m.p. 136-138° C. δ (CDCl 3 ): 2.22 (s, 3H), 6.75 (d, 1H), 7.03(s,
1H), 7.45 (d, 1H), 7.67 (d, 1H), 7.99 (d, 1H), 8.16 (s, 1H).
23
80
oil. δ (CDCl 3 ): 2.02 (s, 3H), 2.38 (s, 3H), 6.34 (d, 1H), 7.00 (d,
1H), 7.18 (m, 2H), 7.98 (d, 1H), 8.30 (s, 1H).
23
97
m.p. 112-114° C. δ (CDCl 3 ): 2.18 (s, 3H), 6.38 (s, 1H), 7.38 (d,
1H), 7.50 (s, 1H), 7.97 (d, 1H), 8.11 (s, 1H).
23
101
oil. δ (CDCl 3 ): 1.92 (s, 3H), 7.22 (d, 1H), 7.58 (s, 2H), 7.93 (d,
1H), 8.39 (s, 1H).
24
47
m.p. 138-140° C. δ (CDCl 3 ): 2.58 (s, 3H), 3.37 (s, 3H), 7.23 (d,
1H), 7.48 (s, 1H), 7.57 (d, 1H), 8.08 (s, 1H).
24
170
m.p. 140-142° C. δ (CDCl 3 ): 2.58 (s, 3H), 3.30 (s, 3H), 8.38 (s,
1H), 8.57 (s, 2H).
25
105
m.p. 134-136° C. δ (CDCl 3 ): 1.79 (s, 3H), 3.96 (s, 3H), 8.29 (s,
2H), 8.74 (s, 1H), 9.18 (s, 1H).
26
105
m.p. 132-134° C. δ (CDCl 3 ): 2.11 (s, 3H), 2.39 (s, 3H), 8.29 (s,
2H), 8.47 (s, 1H), 8.95 (s, 1H).
27
164
m.p. 216-218° C. δ (CDCl 3 ): 1.56 (s, 3H), 3.04 (m, 6H), 7.80 (s,
2H), 8.18 (s, 1H), 9.13 (s, 1H), 9.58 (s, 1H).
28
105
m.p. 178-180° C. δ (CDCl 3 ): 1.71 (s, 3H), 2.86 (s, 6H), 8.29 (s,
2H), 8.66 (s, 1H), 9.45 (s, 1H).
30
101
m.p. 155-157° C. δ (CDCl 3 ): 1.90 (s, 3H), 7.66 (s, 2H), 8.21 (s,
1H), 8.98 (s, 1H), 9.19 (s, 1H).
30
104
m.p. 183-185° C. δ (CDCl 3 ): 1.93 (s, 3H), 7.68 (s, 2H), 8.23 (d,
1H), 8.94 (d, 1H), 9.03 (s, 1H).
30
120
m.p. 175-177° C. δ (CDCl 3 ): 2.00 (s, 3H), 7.54 (d, 1H), 7.71 (d,
1H), 8.28 (d, 1H), 8.96 (d, 1H), 9.02 (s, 1H).
30
122
m.p. 108-110° C. δ (CDCl 3 ): 2.11 (s, 3H), 7.95 (dd, 1H), 8.26 (d,
1H), 8.31 (d, 1H), 8.79 (s, 1H), 8.92 (d, 1H).
Cell Viability Assay
Example 22
In Vitro Cell Inhibition Assay (MTT Method)
The human cancer cell lines used for this assay were lung cancer A549 and leukemia HL-60.
The concentrations of compounds used for this assay were 0.01, 0.1, 1, 10, 100 μM. Based on in vitro cell culture, we use the MTT assay to detect the inhibitory rate of each compound.
The A549 or HL-60 cells were picked up from cell incubator, after washed for twice using PBS, cells were digested by 0.25% trypsin, and then add medium to terminate the digestion. After cells were collected using centrifuge and re-suspended, count cells under inverted microscope and add medium to make a density was 5×10 4 cells/mL. After 100 μL aliquots were added to each well of 96-well microtiter plates, cells were cultured in 5% incubator for overnight at 37° C., then the different concentration compounds were added to each well. After incubation for 48 h, MTT solution was added to each well and plates were then incubated for 4 h. The MTT tetrazolium was reduced to formazan by living cells. Then the formazan crystals were dissolved though adding DMSO to each well. The absorbance was read at 570 nm with a microplate reader.
Part of the test results are as follows:
TABLE 31
Proliferation inhibitory effect of the compounds on A549 cell
(% of Control)
Compounds
Concentration (μM)
No.
100
10
1
0.1
0.01
6-1
19.8
20.4
16.9
12.1
13.1
6-23
93.8
93.7
2.5
−1.8
−0.8
6-35
92.7
58.6
1.0
−0.8
0.5
6-39
92.6
24.9
19.6
18.8
18.3
6-41
92.0
84.0
13.1
0.7
3.8
6-93
98.2
80.3
74.8
39.4
12.1
6-98
93.2
90.1
11.7
−0.7
−2.5
6-99
86.3
83.6
55.0
0
0
6-113
93.7
75.6
2.6
2.9
9.2
6-114
94.9
82.1
11.5
2.8
10.1
22-33
90.3
78.7
61.3
−1.1
−1.6
22-93
91.4
73.7
−0.2
−1.8
−2.2
22-101
97.5
66.4
19.1
21.4
13.7
22-105
89.8
80.6
49.9
8.8
16
22-120
92.1
86.8
9.8
0
0.8
22-121
89.5
51.2
9.9
12.4
6.2
22-153
85.2
60.6
14.7
0
3.7
22-208
91.3
83.2
2.4
−1.2
−1.0
25-105
93.7
78.0
0.9
2.2
3.1
28-105
89.6
54.9
2.7
5.3
4.1
29-105
91.9
94.2
72.7
−0.5
−0.2
30-104
91.8
78.4
−0.1
1.1
2.4
30-120
92.0
84.0
−0.7
−0.9
−1.5
TABLE 32
Proliferation inhibitory effect of the compounds on HL-60 cells
(% of Control)
Compounds
Concentration (μM)
No.
100
10
1
0.1
0.01
6-1
61.9
63.9
18.8
10.4
11.5
6-3
94.5
72.2
−2.1
−6.3
−7.1
6-10
77.1
78.5
9.8
16.1
21.8
6-23
90.6
93.2
23.1
10.8
2.3
6-35
89.9
72.3
−1.8
−5.0
−8.3
6-39
80.8
78.5
31.0
14.7
11.9
6-41
87.9
86.5
7.8
3.9
6.5
6-93
74.8
72.3
70.7
51.8
0
6-98
95.1
91.7
30.0
10.1
−2.5
6-99
54.8
56.5
60.2
34.2
8.6
6-109
94.4
52.4
2.9
2.2
0.1
6-113
93.1
85.4
9.3
8.8
−3.8
6-114
93.2
87.5
20.7
10.0
−0.4
6-205
91.9
59.5
5.8
12.6
−3.4
22-24
94.3
82.4
−9.3
−16.7
−22.4
22-33
81.2
66.2
54.3
−1.8
−4.9
22-61
89.8
85.7
11.0
7.8
5.2
22-88
94.1
79.1
−24.6
−32.9
−35.2
22-93
95.4
70.4
6.8
−7.1
−3.6
22-95
95.4
76.0
32.6
−4.0
0.3
22-98
91.0
77.7
9.5
1.3
−7.3
22-101
64.7
73.4
48.6
5.5
8.3
22-104
94.0
60.5
−2.1
−7.3
4.1
22-105
53.8
70.4
71.1
31.7
27.2
22-107
94.4
65.4
−7.0
−9.3
2.8
22-120
61.0
63.1
19.7
20.5
9.6
22-121
61.2
73.6
47.6
12.5
13
22-122
94.6
57.2
11.7
−1.9
6.3
22-153
65.8
73.4
59.6
7.3
12.9
22-207
90.5
61.9
0.4
−3.6
7.3
22-208
91.2
91.2
28.9
−14.0
−8.0
25-105
88.0
80.2
20.0
4.4
3.1
26-105
88.0
80.2
20.0
4.4
3.1
28-105
77.2
88.4
13.3
−3.7
4.9
29-105
91.5
95.1
94.7
70.2
11.2
30-101
80.7
57.3
−0.3
−14.2
−6.4
30-104
93.3
88.0
65.3
31.6
21.8
30-105
89.0
85.6
80.6
43.6
−6.8
30-120
95.7
95.9
70.6
39.2
23.6
30-122
82.4
61.3
18.0
7.4
10.7
Example 23
In Vitro Cell Inhibition Assay Using the Cell Counting Kit-8(CCK-8) Method
The human cancer cell lines used for this assay were: non-small cell lung cancer A549, NCI-H1650 and NCI-H358, leukemia HL-60, CCRF-CEM and MOLT-4, colon cancer HT-29 and COLO-205, pancreatic cancer BXPC-3, hepatocarcinoma SK-HEP-1, cervical cancer Hela, bladder cancer T24, prostate cancer DU-145 and PC-3, osteosarcoma MG-63, breast cancer MDA-MB-231, intracranial malignant melanoma A375, glioma U251, nasopharyngeal carcinoma CNE.
The concentrations of compounds used for this assay were 0.01, 0.1, 1, 10, 100 μM. Based on in vitro cell culture, we use the CCK-8 assay to detect the inhibitory rate of each compound.
The non-small cell lung cancer A549, NCI-H1650 and NCI-H358, colon cancer HT-29 and COLO-205, pancreatic cancer BXPC-3, hepatocarcinoma SK-HEP-1, cervical cancer Hela, bladder cancer T24, prostate cancer DU-145 and PC-3, osteosarcoma MG-63, breast cancer MDA-MB-231, intracranial malignant melanoma A375, glioma U251, nasopharyngeal carcinoma CNE were picked up from cell incubator. After the cell culture flasks gently shaking, culture fluid was discarded in clean bench. Then washed cells for twice using PBS, and add 0.25% trypsin to digest, when the cells were turning round, add medium to terminate digestion. Cells were collected and transferred to centrifuge tube. For the non-adherent cells HL-60, CCRF-CEM and MOLT-4, cell flasks were picked up from incubator and then transferred to the centrifuge tubes directly. After cells were collected using centrifuge at 1000 rpm/min for 5 min, the fluid was discarded. Then cells were washed for one time by PBS, discard fluid. Then add some medium, count cells under inverted microscope using blood cell counting plate, according the counting number to making the density of adherent cell was 1×10 5 cells/mL, the non-adherent cell was 2×10 5 cells/mL (the volumes of HL-60, CCRF-CEM, MOLT-4 are smaller than non-adherent cells, these cells added to each well was much more higher). Add 50 μL aliquots to each well of 96-well plates (the density of adherent cells was 5000 cells/well, non-adherent cells was 10000 cells/well). Blank control, Negative control, blank control with compounds and positive control wells were grouped, and three replicate wells were used for each data point in the experiments. Then the cells were cultured in 5% incubator for overnight at 37° C., Then the different concentration compounds were added to each well. After incubation for 48 h, according to the manufacturer's instructions, CCK-8 reagent (10 μl) was added and incubation was continued for a further 2-4 h. The absorbance (A) of each well was read at 450 nm using a plate reader.
TABLE 33
Proliferation inhibitory effect of the compounds on A549 cells
(% of Control)
Compounds
Concentration (μM)
No.
100
10
1
0.1
0.01
6-24
87.36
60.31
31.44
24.27
22.06
6-25
81.32
55.87
17.11
18.59
15.66
6-47
99.91
55.57
53.58
49.86
42.56
6-93
98.18
87.64
70.04
19.35
14.77
6-95
98.69
97.88
78.63
56.27
39.65
6-100
89.94
57.45
52.15
50.53
43.98
6-111
99.83
80.03
53.14
29.42
23.15
6-112
99.26
89.34
76.90
47.20
46.52
6-201
83.86
60.23
26.90
19.63
14.31
TABLE 34
Proliferation inhibitory effect of the compounds on HL-60 cells
(% of Control)
Compounds
Concentration (μM)
No.
100
10
1
0.1
0.01
6-24
95.11
56.72
48.39
17.55
0.00
6-25
84.30
92.02
84.06
42.54
11.52
6-43
78.53
73.80
38.45
31.60
23.65
6-45
80.30
52.09
39.89
27.78
0.00
6-47
98.51
83.33
41.47
34.70
7.02
6-93
93.71
87.80
82.05
44.96
30.19
6-95
96.40
94.99
94.76
43.28
0.00
6-100
97.42
49.85
39.47
26.90
14.24
6-111
99.28
95.16
79.31
41.52
13.70
6-112
96.45
97.63
91.55
59.46
48.31
6-201
98.14
86.76
75.70
48.61
40.59
TABLE 35
The half maximal inhibitory concentration (IC50) of the compounds
Compound6-
Tumor cells
Cell culture
93
Gefitinib
Taxol
Non-small-cell
A549
0.715
33.688
83.528
carcinoma
NCI-H1650
1.366
16.260
0.420
NCI-H358
0.443
1.166
0.278
leukemia
HL-60
0.085
34.445
<0.01
CCRF-CEM
<0.01
12.691
<0.01
MOLT-4
0.167
25.839
<0.01
Colorectal Cancer
HT-29
0.224
18.310
>100
COLO-205
0.125
6.973
<0.01
Prostate cancer
DU-145
0.646
3.371
17.428
PC-3
1.356
77.363
69.019
cervical cancer
Hela
1.509
35.442
<0.01
bladder cancer
T24
0.603
31.346
3.535
nasopharyngeal
CNE
6.078
43.682
>100
glioma
U251
1.616
26.801
>100
pancreatic cancer
BXPC-3
0.331
24.011
<0.01
hepatocarcinoma
SK-HEP-1
0.489
9.074
0.047
breast cancer
MDA-MB-231
0.175
>100
2.018
melanoma
A375
0.160
35.463
55.345
osteosarcoma
MG-63
0.196
33.706
<0.01 | The invention relates to substituted diphenylamine compounds using as antitumor agents. The structure of the compounds is represented as the general formula (I):
The groups are as defined as specification.
The compound represented by formula (I) showed potent antitumor activity, especially to cure or alleviate the cancer causing by cancer cells of human tissue or organ. The preferred cancers are: colon cancer, liver cancer, lymph cancer, lung cancer, esophageal cancer, breast cancer, central nervous system cancer, melanoma, ovarian cancer, cervical cancer, renal cancer, leukemia, prostatic cancer, pancreatic cancer, bladder cancer, rectal cancer, osteosarcoma, nasopharynx cancer or stomach cancer. | 2 |
BACKGROUND OF THE INVENTION
This invention is related to an apparatus and method for controlling the direction of a vehicle travelling through a fluid medium.
More particularly this invention constitutes a unique method and apparatus for actuating the aft control surfaces of a submarine with X-shaped empennage.
Most modern military submarines have a hull form that at least approximates an axisymmetric body of revolution. Most of these have four control surfaces at the stern for steering the vessel, that is, for making it turn left or right—the rudder—or rise or dive—diving plane—or a combination of both. In turn, in most modern submarines these control surfaces are in cruciform. That is, the rise-dive surfaces are generally in the same plane as the horizontal plane through the centerline of the vessel, and the turning surfaces are in the same plane as the vertical plane through the centerline. Thus, the control surfaces are generally in the form of a Greek cross.
In most cases the two rudder planes are yoked together, and the two diving planes are yoked together. Because of this yoking, each pair of control surfaces is operated by a single actuating rod. Thus, one rod turns the ship, and the other rod causes the ship to rise or dive.
It is known that arranging the control surfaces or planes of a submarine in an X configuration has certain advantages. In this form, the control surfaces are in the form of an X. Unlike cruciform designs, X-stern designs utilize all four planes as part of any maneuver. Therefore, an X-stern design enjoys more maneuvering force per unit of control surface area than cruciform designs. X-stern ships can be designed with smaller control surfaces while maintaining maneuvering envelopes comparable to cruciform ships with larger control surfaces. Smaller control surfaces obviously have less drag, but may also be quieter—a very important factor today for a submarine.
The submarine USS ALBACORE had an X-stern configuration where the opposite control surfaces were yoked together. Australian submarines of the recent COLLINS class have X-stern configurations, but the control surfaces are not yoked together and each of the four surfaces has its own actuator. These are two examples of the current known methods of actuating X-sterns. In both cases, the control system for the operating rods is more complicated than that aboard a cruciform ship. In a cruciform ship, if the helmsman wants to turn the ship, the control system commands the rudder operating rod to extend or retract. If a change in depth is required, the control system commands the diving operating rod to extend or retract. In both X-stern designs, the control system commands every operating rod to move in one direction or the other, for any maneuver. Controlling these coordinated operating rod movements is a complex task that can be accomplished with a computer. However, manual coordination of the operating rods, in the event of a computer casualty, is difficult.
Usually the turning axes of the control surfaces are perpendicular to the ship's centerline at the stern. In this configuration, yoking of the two planes on opposite sides of the ship is an option. Some X-stern configurations require that the turning axes of the control surfaces be tilted such that they are not perpendicular to the ship's centerline. In this case, the control surfaces cannot be yoked, since no two turning axes are collinear. For these designs, the only current method of actuation is to use four separate operating rods.
U.S. Pat. No. 3,757,720 gives some idea of the stern arrangement of a submarine. FIG. 2 of the patent shows the mechanism in the stern necessary to actuate the diving planes, including an additional mechanism to actuate a smaller control surface as part of the main surface. Another mechanism of the same type would be required to do the same for the rudder surfaces.
U.S. Pat. No. 2,654,334 shows a torpedo with four control surfaces. However, they are in cruciform and have actuating rods 29 and 32 and a control rod 26 .
U.S. Pat. No. 5,186,117 shows an altogether different steering system for a submarine mounted at the bow; this patent is assigned to the assignee of the present invention.
An X-stern control surface actuation mechanism that requires only two and not four operating rods whether the planes on control surfaces are yoked or not is not known in the prior art but offers the following benefits:
a. The space in the stern of most submarines is filled with propulsion shafting and bearings, other equipment and piping, as well as for the control surface actuating mechanisms. Minimizing the number of control rods penetrating this space is highly desirable.
b. The operating rods would operate as they would be in a cruciform design. In other words, one rod would cause the ship to turn and the other rod would cause the ship to rise or dive. This would simplify the control system for the operating rods, and make manual operation of the operating rods as simple as it is in a cruciform design.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view partly broken away showing the X-tail configuration of the planes along with the diving operating rod and steering operating rod as well as the inner and outer gimbal rings.
FIG. 2 is a perspective view of the X-tail configuration taken aft and looking forward and showing the aft side of the inner and outer rings and the position of the planes in an X-tail configuration.
FIG. 3 is a perspective view very similar to that of FIG. 2 but on a larger scale showing in greater detail the spherical connections of the stock connecting rods and the diving and steering operating rods to the outer gimbal ring and the inner gimbal ring.
FIG. 4 is a perspective view showing only one pair of planes and their position during a dive of the vessel and also showing the positioning of the movement control assembly formed by the inner and outer gimbal rings.
FIG. 5 is a perspective view of all four planes positioned for a turn of the vessel and illustrating particularly the movement of the inner ring relative to the outer ring.
FIG. 6 is a perspective view showing each of the four planes in a position for the vessel to take a diving turn and illustrating the position of the outer ring and the inner ring as they have been moved by the diving operating rod and the steering operating rod respectively.
FIG. 7 is a schematic view partly broken away illustrating the position of the stock and plane relative to the pedestal and the ship's hull. Also illustrated in phantom lines is an alternate embodiment wherein the stock is angled relative to the main axis of the ship at an angle less than 90 ° but is substantially perpendicular to the contoured surface of the ship.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the essential elements of the invention positioned as they would be in the stern of a vessel such as a submarine, shown at 10 . The parts of the submarine not directly pertinent to an understanding of the invention are omitted.
Planes or control surfaces 12 , 14 on the right (starboard) side and 11 , 13 on the left (port) side of the longitudinal centerline of the submarine are located outside the submarine at the stern for contact with the sea. These planes are of conventional shape and design but it is their manipulation and the apparatus for controlling the direction of the submarine that are the novel features of the present invention.
The planes 12 , 14 , 11 & 13 move by virtue of the rotation of their solid cylindrical stocks 15 , 19 , 16 , and 18 respectively to which they are secured. The rotation of the stocks and their planes through a limited arc of motion produces turning moments that cause the submarine to move up or down, right or left, or a combination thereof as in rising or diving turns of the submarine. The stocks are rotatably secured at ends 15 a , 19 a , 16 a , and 18 a , respectively to the submarine internal structure by means of suitable bearings and seals, not shown. Also at the locations 15 b , 16 b , 18 b , and 19 b , as shown in FIG. 1, these stocks are rotatably secured at their respective locations through the ship's hull H as shown for one instance at 16 c in FIG. 7 . Similar securings would be accorded stocks 15 , 18 and 19 all using conventional through the hull bearings and seals.
Stocks 15 , 19 and 16 , 18 are rotated about their longitudinal axis by the action of stock rods 22 , 26 , 23 and 25 connected at their forward ends to their respective stocks 15 , 19 , 16 and 18 by being pivotally connected to protruding lever arms 20 a , 20 b , 20 c , and 20 d respectively. Each of these lever arms 20 a - 20 d is secured at its inboard ends to its respective stocks and pivotally receive its respective stock rods in a manner such that substantially longitudinal movement of the stock rods produces rotational movements of the individual stocks and therefore the planes 12 , 14 , 11 , and 13 respectively.
As best shown in FIGS. 1, 2 , and 3 , these stock rods 22 , 26 , 23 and 25 are connected at their rearward ends to a movement control assembly or gimbal ring assembly shown generally at 30 . The gimbal ring assembly 30 is composed of an outer gimbal ring 34 and inner gimbal ring 38 . The gimbal ring assembly also includes a pair of radially opposed trunnions 34 a and 34 b secured to the outer periphery 34 c of the outer gimbal ring. These trunnions 34 a and 34 b mount the gimbal ring assembly 30 in a pivotal arrangement, not shown, within the interior of the submarine, all in a conventional manner. Pivotally secured to the internal surface 35 of outer gimbal ring is inner gimbal ring 38 . Inner gimbal ring has a cutout center shown at 38 a of FIG. 3 and is also provided with a pair of radially opposed trunnions 38 b and 38 c that are generally positioned along an axis that is transverse to the generally horizontal axis of the trunnions 34 a and 34 b of the outer gimbal ring. It should be understood that, as shown, the gimbal rings are arranged such that the axes of the mounting trunnions 34 a , 34 b , 38 b and 38 c are orthogonally positioned relative to each other, however, there is no reason why other angular arrangements relative to each other or to the longitudinal axis (C/L) of the submarine could not be used to achieve the same or similar purpose or function in the present invention.
As shown in FIG. 1 and particularly in FIG. 3, the stock rods 22 , 26 , 23 and 25 are pivotally secured to the inner gimbal ring by spherical rod ending bearings 22 a , 26 a , 23 a and 25 a respectively or by any other conventional arrangement that permits the degree of movement necessary. Accordingly, stock rods 22 , 26 , 23 and 25 are moved substantially longitudinally by the combined or independent movements of outer gimbal ring 34 and inner gimbal ring 38 . Inner gimbal ring 38 pivots about trunnions 38 a and 38 b on an axis that, for example, is essentially vertical, as shown, with respect to the centerline C/L of the submarine. As stated, outer gimbal ring 34 is secured to the submarine structure by means of the trunnions or outer ring bearings 34 a and 34 b but pivots on an axis essentially horizontal with respect to the centerline C/L of the submarine. But, as previously stated, these angular arrangements are not critical and can be changed to achieve the same or similar purpose or function.
Diving operating rod 28 and steering operating rod 29 are connected to the gimbal ring assembly 30 to independently or together rotate the respective gimbal rings about their respective axis. As shown, diving operating rod 28 is a cylindrical linear activator and includes connecting rod 28 a that is extensible in any conventional manner from diving operating rod 28 . At the rearward end of the connecting rod 28 a is pivot connector 28 b that pivotally receives elongated diving operating rod extension 28 c for pivotal movement within pivot mount 28 d . The pivotal connection between the diving operating rod extension 28 c and the pivot mount 28 d is conventional allowing the diving operating rod extension 28 c to pivot about axis 28 e.
In a similar manner, steering operating rod 29 is shown also to be a cylindrical linear activator and includes connecting rod 29 a , pivot connector 29 b and steering operating rod extension 29 c for connection at the spherical rod end bearing 29 d . The spherical rod end bearing 29 d is similar to the spherical bearing arrangements of 22 a , 23 a , 25 a and 26 a , all of which are secured to the inner gimbal ring 38 . Again, it is to be understood that the functions and the respective connections of the outer and inner gimbal rings 34 and 38 may be reversed from that shown and described without departing from the scope of the present invention.
It is also within the purview of the present invention for the gimbal ring 30 to be activated from the rear or the side rather than from a forward position. Also, conventional rotary activators may be substituted for each of the cylindrical linear activator operating rods 28 and 29 .
Referring to FIG. 7, there is shown one of the control surfaces or planes 12 that is rotatable by its stock 15 that is shown to be perpendicular to the C/L of the submarine as it passes through the hull H and the pedestal P that protrudes out of the hull H. The pedestal P has a upper surface 40 that is coextensive and substantially congruent with the lower surface 42 of the plane 12 to produce therebetween a gap G. The magnitude of the gap G is important, as well as the alignment of the gap for the performance of the submarine. For instance, it is desirable to have the plane of the gap G substantially parallel to the flow lines of the hull H, generally as shown in FIG. 7 . This minimizes the magnitude of the spacing that forms the gap G, which means lower flow noise and less drag as the submarine traverses the water.
If the stock 15 is perpendicular to the main axis or C/L as shown in the position depicted at 15 . 1 in FIG. 7, the gap G must be larger in order to accommodate the transverse movement of the plane 12 as it rotates about an axis that is not perpendicular to the plane of the gap G. It should be apparent that the gap has to be larger if the position of the stock is as shown at 15 . 1 because the movable plane 12 has a finite thickness. As it rotates with respect to the pedestal P, the outer edges of the plane would foul the pedestal if the gap G between the plane 12 and the pedestal P were not large enough. Accordingly, it is preferred that the angle of each of these stocks, such as the example shown in FIG. 7, be lessened with respect to the C/L of the submarine so that the stock is perpendicular to the plane of the gap G, as shown at 44 and therefore at an acute angle with the C/L of the submarine. The magnitude of the acute angle is variable depending upon the magnitude of the gap G and also is variable depending upon the degree of plane rotation. Thus in sum, it may be stated that the stocks of the planes are preferably substantially perpendicular to the flow lines of the hull H at the point that they protrude from the hull H so that they are also substantially parallel to the plane of the gap G to achieve the purpose of the present invention.
FIG. 7 along with the foregoing description, illustrate one of the novel benefits of the present invention in that now only two operating rods, rather than the four operating rods of the prior art discussed above, may be utilized to operate the control surfaces or planes having their turning axes tilted from perpendicular to the ship's C/L.
For an understanding of the operation of the submarine and the mechanism that controls the movement of the X-tail arrangement, the following description is set forth. FIGS. 1 and 3 depict the positioning of the planes 11 , 12 , 13 , and 14 in a neutral position for straight ahead (cruising) direction of the submarine. In such a position, the gimbal ring assembly 30 and particularly outer gimbal ring 34 and inner ring 38 are in a common plane and that plane is essentially perpendicular to the C/L of the submarine as is apparent in the view from the rear of the submarine. FIG. 3 shows this common plane arrangement of both the outer gimbal ring 34 and the inner gimbal ring 38 .
In order to steer the submarine, steering operating rod 29 extends steering connector rod 29 a pivot connector 29 b and steering operating rod extension 29 c rearwardly to the spherical rod end bearing 29 d as it is connected to the inner gimbal 38 . Such extension rotates the inner gimbal ring 38 clockwise about its vertical axis extending through opposed trunnions 38 b and 38 c as shown in FIG. 5 . In this turning maneuver, it should be noted that outer gimbal ring 34 remains stationary and essentially in a vertical plane again as shown in FIG. 5 . The movement of the steering operating rod 29 not only moves the inner gimbal ring 38 but also pushes stock rods 23 and 25 in a forward direction and simultaneously pulls stock rods 22 and 26 in a rearward direction. This movement of the inner gimbal ring 38 and the movement of the stock rods rotates the four stocks 15 , 19 and 16 , 18 through their respective protruding lever arms 20 a through 20 d respectively and ultimately rotates the planes 12 , 14 and 11 , 13 respectively into the position shown clearly in FIG. 5 to produce turning moments on the stern of the submarine. It is obvious, in a reverse manner, to steer the submarine in the opposite direction, steering operating rod 29 is retracted to rotate the inner gimbal ring 38 in a counter clockwise direction about its vertical axis so as to reverse the previously described movement and move the planes 12 , 14 , 11 , and 13 in the opposite direction.
When it is desired to dive the submarine, the position of the diving mechanism is illustrated in FIG. 4 . The diving operating rod 28 extends diving connecting rod 28 a rearwardly along with pivot connector 28 b and diving operating rod extension 28 c to achieve the pivotal movement about pivot mount 28 d and therefore rotate outer gimbal ring 34 about its horizontal axis formed by outer ring bearings 34 a and 34 b of which only outer ring bearing 34 a is shown in FIG. 4 . This action and pivotal movement of the outer gimbal ring 34 pulls upper stock rods 22 and 23 rearwardly. In this view from the right side of the submarine, only planes 12 and 14 are illustrated along with their accompanying manipulating elements. Stock rod 22 thus rotates stock 15 through protruding lever arm 20 a and at the same time stock rods 26 and 25 similarly are moved forwardly to rotate their respective planes. For clarity, only plane 14 and its respective stock 19 is shown. With the rotation of all four stocks and their respective planes, a powerful diving moment is placed upon the stern of the submarine for it to dive. Obviously, the opposite movement of the diving operating rod 28 will cause the submarine to rise. Here it is to be noted that during the diving maneuvers inner gimbal ring 38 remains within the plane of the outer gimbal ring 34 so that no steering motions are created.
Should, however, it be desirable to produce both diving and turning of the submarine, FIG. 6 illustrates the positioning of the gimbal ring assembly 30 with its outer gimbal ring 34 and the inner gimbal ring 38 along with each of the planes 12 , 14 , 11 and 13 to create a diving turn of the submarine. To effect such a diving turn, the diving operating rod 28 operates in a manner as described for FIG. 4 to tilt or rotate the outer gimbal ring 34 about its horizontal axis, however, at the same time, steering operating rod 29 is retracted forwardly to produce a rotation of the inner gimbal ring 38 in a counter clockwise direction relative to its axis within the outer gimbal ring. This plural action produces movement of the stocks and their respective planes to the position shown in FIG. 6 . It should be noted that the steering movement illustrated in FIG. 6 is the opposite of that represented by the turn illustrated in FIG. 5 . This should be apparent from the relative positions of the end of the steering operating rod 29 when viewed in each of the FIGS. 5 and 6.
It should be understood that the diving operating rod 28 and the steering operating rod 29 could be actuated by ordinary double acting hydraulic cylinders, one for each operating rod or by any other means conventional in the art.
It is important to understand that a feature of this invention is that all four planes or controlled surfaces 12 , 14 , 11 and 13 produce both steering and rise or dive moments simultaneously. The four planes are not activated independently but act together. In a military vessel such as a submarine, it is significant that all the controlled surfaces or planes are connected by the mechanism described above so that it is much less likely that any single plane, through equipment malfunction or damage could produce moments that would unpredictably negate or reinforce those of the other surfaces. It is also to be noted that the control system described for this invention is simpler and less complex than in a submarine using separate control rods for each plane or controlled surface.
It is important to understand that the scope of the invention described above is only to be limited by the scope of the following claims. | A direction control assembly for a vehicle, particularly a submarine, travelling through and below the surface of a fluid medium such as the sea. The vehicle has a body formed with a main axis running fore and aft, a contoured outer surface forming flow lines with the fluid medium and a plurality of planes movably secured relative to and extending out from said surface for contact with the fluid medium to permit and produce rising, diving or turning procedures. A movement control assembly including inner and outer gimbal rings are mounted within the body for selective mutual as well as independent movement. A first operating rod is connected to the outer ring for controlling the mutual movement of both the rings and a second operating rod is connected to the inner ring for moving the inner ring independently of the outer ring. Individual connectors or stock rods are positioned between a selected ring such as the inner ring 38 and each of the planes for moving the planes according to the movement of the selected ring whereby selected movements of either or both of the rings move the planes for directing the travel of the vehicle. | 5 |
FIELD OF THE INVENTION
The present invention relates to semiconductor optical amplifiers (SOAs) and in particular to linear optical amplifiers of the type formed by integrating an amplifier and a vertical cavity surface emitting laser (VCSEL).
BACKGROUND TO THE INVENTION
Linear optical amplifiers of the type formed by integrating an amplifier and a VCSEL have been developed by Genoa Corporation and are described in their paper “A single-chip linear optical amplifier” by D. A. Francis, S. P. DiJaili and J. D. Walker (Optical Fibre Communications Conference, 17-22 March 2001, Anaheim, Calif., USA, paper PD13) which is incorporated herein by reference. The present invention builds on and extends the work described in that paper.
Optical communications networks use optical amplifiers as is well known in the art to increase the power of optical signals. As optical communications networks develop, increasing demands are required of such optical amplifiers in order that they can operate with increased data rates, in multi-wavelength environments, are smaller and can be easily integrated with other optical equipment and devices.
Existing optical amplifiers are problematic in many of these respects. For example erbium doped fibre amplifiers (EDFAs) are relatively expensive to manufacture, control and test because they contain many active and passive components. They also have a relatively large footprint. Semiconductor optical amplifiers avoid some of these problems, being smaller in size and less expensive to manufacture. However, they are non-liner and as a result cross-talk between channels occurs which is undesirable. Genoa Corporation address this problem of non-linearity by integrating a VCSEL into an SOA on an Indium Phosphide (InP) substrate. This is described in more detail below in the section headed SOA with Integrated VCSEL. However, the device proposed by Genoa Corporation is not suited for operation at speeds above 10 Gbps such as at speeds of 40 Gbps. In addition the saturation output power of the Genoa device is at around 8 dbm. However, for many applications, higher output powers of around 12 to 14 dbm and above are required.
OBJECT OF THE INVENTION
An object of the present invention is to provide a semiconductor optical amplifier with integrated VCSEL that addresses or at least mitigates one or more of the problems noted above.
Further benefits and advantages of the 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.
SUMMARY OF THE INVENTION
Semiconductor optical amplifiers (SOAs) are cheaper to manufacture, control and test than other types of optical amplifier such as erbium doped fibre amplifiers (EDFAs). However, SOAs are non-linear in the respect that the gain of an SOA is not constant for different input or output signal powers. This is a significant problem because cross-talk between channels occurs as a result. It is known that the gain of SOAs can be clamped by integrating a vertical cavity surface emitting lasr (VCSEL) with the SOA such that their active regions are shared. The present invention enables the physical length of such devices to be increased in such a manner that the saturation output power is increased whilst retaining the gain clamping effect. This is achieved by using two or more contact points on the device at which different drive currents are applied.
According to a first aspect of the present invention there is provided a semiconductor optical amplifier comprising:
a vertical cavity surface emitting laser (VCSEL) integrated with the semiconductor optical amplifier such that the active regions of those devices are shared;
two or more electrical contacts provided on the semiconductor optical amplifier and arranged such that an electrical current may be applied to those contacts in use such that power is applied to the VCSEL.
This provides the advantage that the range of input or output signal powers for which the gain of the SOA remains constant is increased. By using two or more contacts to add drive current to the VCSEL this is achieved. In addition the saturation output power of the SOA is increased. Preferably the amount of drive current applied at a particular one of the contacts is related to the position of the contact along the semiconductor optical amplifier. That is, larger drive currents are applied to contacts further along the length of the SOA in the direction of propagation of an optical signal through the SOA in use.
Preferably the semiconductor optical amplifier further comprises an electrically conducting layer which is separated into two or more regions by one or more electrically insulating areas and wherein each of said electrical contacts is provided on a different one of said regions. For example the electrically conducting layer can be a metallic layer applied to the surface of the SOA and into which a groove is etched between the two contacts in order to separate/isolate them from each other. This provides a simple and cost effective way in which the device can be manufactured.
Preferably the semiconductor optical amplifier has a length greater than about 1 mm. This provides the advantage that devices suitable for operation at high signal speeds are created.
Advantageously, the semiconductor optical amplifier is suitable for operation at signal speeds of greater than 10 Gbps and to have a signal output power of greater than 12 dbm.
According to another aspect of the present invention there is provided a method of amplifying an optical signal comprising the steps of:
passing the signal through a waveguide in a semiconductor optical amplifier with an integrated vertical cavity surface emitting laser (VCSEL); and
applying a current at two or more points along the semiconductor optical amplifier such that said current provides power to the VCSEL.
The preferred features may be combined as appropriate, as would be apparent to a skilled person, and may be combined with any of the aspects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to show how the invention may be carried into effect, embodiments of the invention are now described below by way of example only and with reference to the accompanying figures in which:
FIG. 1 is a schematic diagram of a semiconductor optical amplifier with integrated VCSEL according to the prior art;
FIG. 2 is a schematic plan view of the device of FIG. 1 showing laser light emitted from the optical amplifier.
FIG. 3 is a schematic diagram of a semiconductor optical amplifier with integrated VCSEL according to an embodiment of the present invention;
FIG. 4 a is a schematic graph of gain against output power for an SOA with no integrated VCSEL;
FIG. 4 b is a schematic graph of gain against output power for the devices of FIGS. 1 and 3 .
DETAILED DESCRIPTION OF INVENTION
Embodiments of the present invention are described below by way of example only. These examples represent the best ways of putting the invention into practice that are currently known to the Applicant although they are not the only ways in which this could be achieved.
SOA with Integrated VCSEL
As mentioned above SOAs are non-linear. That is, the gain provided by the SOA is not constant for different signal powers. This is illustrated in FIG. 4 a where it can be seen that the gain of the SOA drops as the signal input or output power increases. Genoa Corporation address this problem by integrating a VCSEL with the SOA. That is, the VCSEL and the amplifier are arranged to share the same active region such that the VCSEL acts along the whole length of the amplifier. The VCSEL has high reflectivity mirrors positioned above and below the active region and is arranged to provide lasing action perpendicular to the direction of travel of the light signal. This is illustrated in FIG. 1 which shows a device 10 comprising an SOA with integrated VCSEL. An input signal 11 comprising for example a series of light pulses, enters the device 10 via an input fibre. The input signal is amplified as it travels along the device 10 as a result of the action of the SOA. In addition the VCSEL acts on the signal with a lasing action in a direction perpendicular to the direction of travel of the signal. As a result of this lasing action light is emitted from the device as indicated by arrows 12 in FIG. 1 . The VCSEL acts to clamp the gain produced by the SOA such that the gain remains substantially constant for a range of input or output signal power levels. The amplified output signal 14 exits the device 10 via an output fibre as indicated in FIG. 1 .
The SOA is a travelling wave optical amplifier that acts to amplify the signal during a single pass as is known in the art. In addition, the lasing action of the VCSEL enables photons to be added to the signal as it travels along the device 10 and this produces the gain clamping effect. That is, some of the radiation emitted by the VCSEL in the direction perpendicular to the signal, is taken into the signal and acts as a ballast to ensure that the gain is clamped. This process is explained in more detail in the paper “A single-chip linear optical amplifier” mentioned above, in which Genoa Corporation describe achieving a constant gain of 17 dB for a signal output power from −8 to 12 dBm. This was found for a device of size 1 mm×0.5 mm×0.5 mm, with a VCSEL threshold current of about 100 mA and an operating current of around 200 to 300 mA. The amplifier operated across the C-band (1530-1565 nm) and the device was formed using a standard manufacturing process. Signals at 10 Gbps were used.
FIG. 2 is a schematic plan view of the device 10 of FIG. 1 in use. It shows light 20 emitted from the top of the device 10 as a result of the lasing action of the VCSEL. The present invention recognises that the intensity of this emitted light becomes weaker in the direction indicated by the arrow A which is the propagation axis of the SOA.
The present invention recognises that this light emitted by the VCSEL becomes weaker along the propagation axis because photons from the lasing action of the VCSEL are converted into the signal propagating in the amplifler. This affects the lasing condition of the VCSEL and eventually the clamping action of the VCSEL on the gain of the device is lost. As more and more of the photons from the VCSEL action are converted into the signal the VCSEL eventually stops lasing and effectively switches off. The gain experienced by the signal is then destabilised.
For these reasons the device proposed by Genoa Corporation in their paper mentioned above is not suited for operation at speeds significantly greater than 10 Gbps because longer devices are required for operation at higher speeds. The longer the device 10 of FIG. 1 becomes the greater the propagation distance for the signal in the device and the more likely that the VCSEL action will be lost for the reasons described above. In addition the saturation output power of the device described in Genoa's paper is only around 8 to 12 dBm.
The present Invention addresses these problems by providing additional power/drive current to the VCSEL at two or more contact points along the length of the device. These contact points are preferably created by etching one or more grooves in a metallic contact region on the surface of the device. However this is not essential, any suitable means by which two or more contacts are provided can be used.
This is illustrated schematically in FIG. 3 which shows a device 30 comprising an SOA with integrated VCSEL similar to the device 10 of FIG. 1 but with two contacts 31 , 32 . The device 30 is supported on a substrate which is at ground potential and an input signal 33 is shown entering the device. The signal propagates along the active region of the semiconductor material 34 forming the device and is amplified by the action of the SOA. The VCSEL also acts on the signal as described above and VCSEL emissions 35 occur in a direction perpendicular to the signal as indicated. A metallic layer 36 is provided on the upper surface of the device 30 running along the length of the device and covering at least part of the surface of the device. A groove 37 is etched in this metallic surface such that two regions of the metallic layer are formed. A first contact 31 is made on one of these regions and an electric current applied using a suitable power source as is known in the art. This acts to produce more carriers in the active region and makes more photons available enabling the gain to be clamped effectively by the VCSEL. The same is done using a second contact 32 in the second region of the metallic layer. By using two or more contacts in this way the length of the device 30 can be extended such that the device is suitable for operation at high speeds. Preferably a larger current is applied at the second contact 32 than at the first contact 31 . That is, larger drive currents are applied at contacts located further along propagation axis of the SOA. Better clamping of the SOA gain of the device is achieved and the range of output powers for which the gain of the device is constant is increased. The saturation output power being the highest output power at which the constant gain is mentioned. This is illustrated in FIG. 4 b.
FIG. 4 b is a schematic graph of gain against output power for the devices of FIG. 1 (see line 40 of FIG. 4 b ) and FIG. 3 (see line 41 of FIG. 4 b ). It can be seen that the range of output powers for which constant gain is achieved is greater for the device of FIG. 3 (see R 1 ) than for the device of FIG. 1 (R 2 ). In addition the saturation output power (see points A and A′) is higher for the device of FIG. 3 (point A′) than it is for the device of FIG. 1 (point A).
This is explained further with reference to the rate equation below: I ( s ) z = Γ A ( s ) τ J / ed + ( τ A ( p ) / hv ) N a ( p ) I ( p ) - N a ( s ) 1 + I ( s ) / I o ( s ) I ( s ) ( 1 )
Where Γ is the confinement factor, A (s),(p) are the differential gain coefficients for the signal and the pump lights, N a (s),(p) are the carrier densities at transparent for signal and pump lights, J is the injection current, d is the wave-guide thickness, I (s),(p) are the light intensities for signal and pump lights, and τ is the gain recovery time given by: 1 τ = 1 τ c + A ( p ) I ( p ) hv ( 2 )
where τ c is the carrier lifetime.
The term pump light is used to refer to light emitted from the VCSEL. The injection current J refers to the drive current input at one of the contacts ( 31 or 32 ).
From the equations above it can be seen that the saturation output power I (s) is inversely proportional to the gain recovery time τ of the amplifier. The present invention enables the gain recovery time to be reduced by injecting more photon density into the amplifier. This then leads to an increase in the saturation output power.
The multiple contacts offer the flexibility of applying an extra amount of drive current at the sections of the SOA where the VCSEL emission (pump light) has been reduced. The extra current results in an increase of the VCSEL emitted light, hence an increase of the saturation output power of the SOA according to the equation 1 and stabilizes the SOA gain for longer lengths along the device.
The term “light” is used herein to refer to electromagnetic radiation which may or may not be in the range of the electromagnetic spectrum which is visible to humans.
Any range or device value given herein may be extended or altered without losing the effect sought, as will be apparent to the skilled person for an understanding of the teachings herein. | Semiconductor optical amplifiers (SOAs) are cheaper to manufacture, control and test than other types of optical amplifier such as erbium doped fiber amplifiers (EDFAs). However, SOAs are non-linear in the respect that the gain of an SOA is not constant for different input or output signal powers. This is a significant problem because cross-talk between channels occurs as a result. It is known that the gain of SOAs can be clamped by integrating a vertical cavity surface emitting laser (VCSEL) with the SOA such that their active regions are shared. The present invention enables the physical length of such devices to be increased in such a manner that the saturation output power is increased whist retaining the gain clamping effect. This is achieved by using two or more contact points on the device at which different drive currents are applied. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a method for impregnating porous abrasive elements with a reactive solution for use in distressing fabrics and, in particular, to be utilized in a tumbling environment with denim fabric.
In recent years, the fashion industry has seized upon the use of cotton denim fabrics as fashionable materials. While the history of blue denim fabrics has coincided, to a degree, with that of the rural areas of this country, the popularity of garments made from this fabric has extended throughout the country. Since these fabrics have been traditionally stiff, pretreatment of fabricated garments to achieve a softening as well as a prefading indicative of long term use have been found to be commercially beneficial to the marketer of the garment. In addition, a substantial market has been created for intentionally distressed, prefaded and softened denim garments. In order to pretreat or precondition these garments to an acceptable distressed look in what are otherwise new garments, the industry has sought to develop low cost and reliable preconditioning processes.
Initial interest in the industry was directed to what is called a prewashing process, which preshrinks the garment and is conducted in water, to utilize the well-known tendency of cotton fabrics to change dimension. The next step in the preconditioning sequence has been the introduction of stone-washing utilizing rocks in a tumbling apparatus to, in effect, prewear the garment in a random or unpredictable pattern. This process utilized a soft stone, typically a volcanic such as pumice. Since the fashion industry is never static, attempts were made to introduce additional processing steps which would further distinguish garments so treated from those in vogue during the prior season. As a result, the industry has recently introduced denim fabric garments which have been subjected to a rifling process. This process combines the abrasive action of the stone-washing process, along with the introduction of a reactive solution such as a bleach. Typically, conventional chlorine bleaches, wellknown in the industry, have been utilized.
At present, a substantial portion of the pretreated denim fabrics are subjected to a rifling process utilizing a porous volcanic with abrasive characteristics and which has been sprayed, coated or otherwise provided with a surface-region infusion of chlorine bleach. The operating lifetime of the volcanic rock is limited since it is subjected to continuous tumbling until it disintegrates sufficiently so that the fines in the tumbling machinery detract from the abrasive action of the solids and the mass of rocks decreases so as to cease abrading the fabric. In addition, the amount of bleach provided with each of the porous rocks is limited to the surface or near surface environment so that as erosion of the volcanic rock takes place, the amount of chlorine available to contact the fabric has greatly diminished and the desired result is not achieved. As a result, the operating cycle for the present processes is unduly limited.
Accordingly, it is a primary object of the present invention to provide an improved porous abrasive element for use in the preconditioning of fabrics. Also, the invention is directed to the increase of the amount of bleaching agent or conditioning material contained in the abrasive elements so as to increase the time interval between replacement thereof. Another objective of the invention is to utilize conditioning materials which are more effective than the conventional chlorine bleaches so that the resultant distressing is more visually noticeable in the treated garment. The present invention is further concerned with a process for providing abrasive elements of increased effectiveness and longer operating lifetime by utilizing an operating process which is easy to operate, low in cost and possesses a high capacity for treatment.
SUMMARY OF THE INVENTION
This invention relating to a method for impregnating porous abrasive elements for use in the intentional distressing of fabric comprises a sequence of steps including the placement of a quantity of the porous abrasive elements in a vacuum vessel. The pressure in the vessel is then reduced to a first pressure which is less than ambient atmospheric pressure and this pressure is maintained while a reactive solution is introduced into the vessel to a level sufficient to cover the porous elements.
The reactive solution is preferably a potassium or sodium permanganate solution which is a strong bleaching agent. If desired, a suitable dying solution can be utilized in its place. The first pressure is maintained for at least as long as the time required to introduce the reactive solution in the vessel and cover the porous elements. The low pressure in combination with the introduction of the solution from near the base of the vessel has been found to result in substantially the entire pore volume of the elements being impregnated. To further promote impregnation, the low first pressure can be maintained for an interval after the introduction of the active solution.
When the solution has been introduced into the vessel, the pressure therein is restored to approximately ambient level and the impregnated elements are removed therefrom. In practice, the impregnated elements are surface dried to facilitate handling and are then transported to the tumbling equipment wherein the fabric to be distressed is located.
The tumbling process is normally conducted with an initially damp fabric to promote the chemical reaction with the reactive solution and no other liquids are added during the distressing process. Conventional techniques and equipment are utilized in the tumbling process and thereafter. These may typically include a following wash with a reducing agent or neutralizer such as sodium meta bisulfite.
The present process has been found to result in the preparation of porous elements wherein the pores are essentially filled with liquid throughout the entire volume. As a result, the tumbling or processing lifetime of the elements is substantially greater than present processes which result in the porous elements containing reactive solutions only in the regions proximate to the surface thereof. Further features and advantages of the present invention will become more readily apparent from the following detailed description thereof when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of one embodiment of apparatus suitable for use in performing the present invention.
FIG. 2 is a side view of the embodiment of FIG. 1.
FIG. 3 is a partial cross-section of the vacuum vessel shown in FIGS. 1 and 2.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention comprises a sequence of steps directed to the making of porous abrasive elements containing a reactive solution throughout the pore volume thereof to be used in the treatment of fabric and is practiced in apparatus of the type shown in the drawings. The resultant product is normally utilized in tumbling apparatus of conventional design to abrade, bleach and otherwise distress the fabric therein in a random pattern.
In FIG. 1, a vacuum vessel 11 containing an outer wall 12 which is preferably part of a double wall vessel with a removable cover 14 is shown connected to multiple sources or reservoirs of reactive solution 15, 17. In addition, the cover 14 is provided with a port 10 suitably coupled through valves to a vacuum pump 18 and compressor 16. Thus, the pressure within the vessel 11 is controlled by the actuation of the individual valves connecting vacuum pump 18 and compressor 16 to the vessel via port 10. The cover is fittedly received beneath inwardly extending segments 20 and is provided with an outline that corresponds to the size and spacing of the segments 20 affixed to outer wall 12 of the vessel. The cover 14 is provided with corresponding segments 22 which allow removal of the cover 14 from the vessel when segments 20 and 22 and spaces therebetween are in adjacent registration as shown in FIG. 1. In order to secure the cover 14 to the vessel, the handle 29 is grasped by the operator to move the cover above the opening in the vessel followed by rotation about retaining pin 28 to provide a locking feature with the double wall vessel.
Support arm 26 is affixed to cover 14 at pin 28 and imparts vertical movement thereto upon the actuation of an external hydraulic cylinder having its ram 24 attached to the outwardly extending portion of arm 26. In addition, the combination of arm 26 and ram 24 are rotatable within the hydraulic system in the direction of the arrows so as to permit the cover to be rotated thereby permitting access to the inside of the vessel. This movement can be effected by the operator utilizing handle 29 since the weight of the cover lid 14 is borne by arm 26.
A T-shaped coupling member 32 with flexible hoses 30 and 31 extending outwardly therefrom includes a vertical stem 33 connected to a passageway 34 in cover lid 14. Hose 30 is coupled via a valve 51 to air tank 36 and thence to compressor 16 linked to motor 37. The flexible hose 31 oppositely coupled to member 32 is coupled via valve 50 to an air tank 34 which in turn is coupled to vacuum pump 18 driven by motor 35. The sequence of actuation of the vacuum pump 18 and compressor 16 control the pressure within the vessel 11 during operation.
The constructional features of the handle 29 and the T-shaped coupling member 32 with associated flexible hoses 30, 31 are shown in further detail in the side view of FIG. 2 wherein the peripheral location of segments 22 of cover lid 14 are shown. The elevation of the handle and cover occurs from the movement of ram 24 in its hydraulic cylinder which also provides the axis for rotation of the cover lid 14 when it is to be directed out of the way and the vessel 11 is to be loaded or unloaded with porous elements. The handle 29 is shown in section containing the vertical portion 33 of coupling member 32 extending therethrough. A partial cutaway portion of vessel 11 is shown in FIG. 2 highlighting the location of the segments 20 in wall 12 and the double wall construction. The foregoing vacuum vessel is representative of apparatus which may be utilized in the practice of the present invention.
The reactive solution to be utilized in the present process is shown in FIGS. 1 and 2 as being contained in reservoir or holding tank 15. A mixing tank 17 is connected through valving to the same pump 19 as holding tank 15. It is to be recognized that as one tank is emptied, the other of the tanks becomes the holding tank for purged fluid, if desired. The fluids in the tank utilized in the process at the moment are supplied into the vessel 11 at input port 21 located proximate to the bottom of the tank. Valve 23 controls the flow of fluid into vessel 11 and is electrically coupled to level sensor 27 inserted in a pressure tight fitting in the walls of vessel 11. Thus, the height of fluid in the vessel is directly controlled from within the vessel itself. The valve at the holding and mixing tanks are manually operated based on the operator's assessment of which tank is to supply the vessel during a particular operation.
The porous elements, typically volcanic rock or pumice, to be loaded into the vessel are contained in a wire basket 40, shown in part in FIG. 3, which is top loaded, typically by an overhead loading assembly, directly under the control of the operator. The basket is loaded and unloaded at locations remote from the vessel 11. A stand 41 dimensioned to fit within the vessel 11 and containing a central mesh area to permit the passage of fluid therethrough is shown in plan view in FIG. 4. The mesh 42 supports the mesh basket 40 containing the porous elements therein and stand 41 elevates the basket above the bottom member of vessel 11. The input port 21 formed in sidewall 12 is shown in FIG. 3 positioned beneath the level of the mesh 42 of stand 41 so that fluid entering the vessel moves upwardly through the supported porous rocks until such time as it reaches the level sufficient to cause sensor 27 to close valve 23 and cease the filling operation.
In operation, the present process is conducted by having the cover 14 rotated away from the wall 12 to permit access to the interior of vessel 11. The basket 40 is filled with the porous elements to be treated and transported to a position overlying the vessel and lowered to rest upon stand 41. The operator detaches the hoist assembly and causes it to be moved out of the way. Next, the cover lid 14 is rotated about the axis of ram 24 to overlie the opening in vessel 11 with the segments 20 and 22 in appropriate adjacently registered position. The hydraulic mechanism is then actuated so that the cover lid 14 moves vertically downward into position as part of the vessel with the operator then grasping the handle 29 to provide a degree of rotation causing the segments to lock one below the other and provide a pressuretight fit between cover lid 14 and wall 12.
In preparation for the practicing of the present invention, an aqueous solution of a permanganate, either potassium or sodium, is prepared and stored in one or both of tanks 15, 17. This reactive solution is normally mixed within the tank and appropriate agitation means can be incorporated in the tank if desired. In practice, the percent of permanganate added is within the range of 1-5% by weight of solution. Since the effect to be produced on the fabric treated with the porous rocks treated in accordance with the present invention varies based on the dictates of fashion, the strength and composition of the reactive solution can be altered in accordance with the result desired. The permanganate aqueous solution is readily prepared at ambient temperature although a heated solution could be utilized if other components were added to produce different visual effects on the fabric so treated. The porous, abrasive elements which are to be impregnated with the reactive solution are loaded in the mesh basket at a site and the basket is elevated and placed within the vessel 11 so as to rest upon stand 41. The cover lid 14 is then rotated and lowered into position and locked to provide a pressure-tight vessel. At this time the pressure within the vessel is equal to the atmospheric pressure.
To initiate the operation, the operator activates motor 35 and vacuum pump 18 to lower the pressure in air tank 34. As shown, the air tank is coupled through a valve 50 which is open to reduce the pressure in vessel 11 to a level below that of the ambient pressure. This pressure drop is within the range of 12-14 pounds per square inch below atmospheric pressure and upon reaching this reduced pressure level, valve 23 is opened and pump 19 actuated to supply the reactive solution to vessel 11. The vacuum pump 18 maintains the desired pressure level in tank 34 so that the evacuation through port 10 in cover 14 continues during the introduction of the reactive solution. This permits the reduced pressure to be maintained during filling of the vessel 11. Filling continues until the reactive solution level reaches the level sensor 27 which then closes valve 23 connected in the feed line through input port 21 to vessel 11. The wire basket 40 is filled with porous elements to a level that does not exceed the liquid level established by sensor 27. As a result, the entire volume of porous elements is covered in vessel 11 by the reactive solution. During this step, the vacuum pump 18 continues to maintain the desired low pressure level in tank 34 so that the pressure within the vessel 11 remains at the reduced level. While it is then possible to deactivate the compressor and begin restoring pressure within the vessel to approximately the ambient level, it is preferred to maintain the reduced pressure for a short period, typically less than 15 minutes. The porous elements have had their pore volumes evacuated by the reduced pressure in vessel 11 so that the reactive solution rising from the bottom of the vessel can then occupy the pore volume. The maintenance of a reduced pressure of 12.25 psi below atmospheric pressure for a limited period after filling the vessel to its desired level has been found to materially aid the impregnation process of the porous elements.
After this low pressure interval, pump 19 is reversed to begin the removal of the reactive solution from vessel 11. At the same time, valve 50 has been closed and valve 51 is opened to permit the flow of air from tank 36 into vessel 11. The reservoir tank 36 is coupled to compressor 16 which maintains a pressure therein at a level slightly above ambient pressure. The introduction of air at this elevated pressure assists in the removal of the reactive solution from vessel 11 through the bottom port 21 and also is believed to enhance the impregnation of the porous elements with the reactive solution. In practice, the process has utilized a 10-15 pounds per square inch above ambient pressure to provide the desired results. Upon the purging of the reactive solution from vessel 11, the compressor 16 is deactivated to permit the pressure in air tank 36 to reach ambient level which thus causes the pressure in vessel 11 to also reach ambient or atmospheric level. Next, the locking process of cover lid 14 is reversed and the arm 26 used to swing the cover to one side. Since the flexible hoses 30 and 31 are attached to the cover, the hoses permit the movement of the cover without interfering with the removal of wire basket 40 containing the impregnated porous elements.
The treated and impregnated porous elements are carried in the basket to an appropriate area which permits them to be spread over a larger area to ensure that surface drying occurs prior to handling. The surface drying can be promoted by air movement apparatus if desired. The surface drying has been found to enhance the mechanical stability of the porous rock, which is typically a pumice, and also to permit handling of the rock without undue disturbance of the surface-located solution. The conditioned porous rock is then available for use in the rifling or stone-washing conditioning processes utilized with denim fabric. Typically this includes the addition of rocks to a tumbler containing dampened denim clothing. The reactive solution utilized in the process as described is a permanganate solution but it is to be noted that other solutions reactive with the fabric to be treated can be utilized if desired. The strength and composition of the reactive solution are dictated by the desired effect on the fabric being treated. As describe, the process using the permanganate requires the fabric to be subjected to a further wash containing a reducing agent or neutralizer. While the foregoing description has referred to a specific embodiment of the invention, it is recognized that variations and modification may be made therein without departing from the scope of the invention as claimed. | A method of preparing porous abrasive rock for use in distressing fabric, including the steps of impregnating rocks placed in a vacuum vessel with a bleaching solution under reduced pressure, maintaining the reduced pressure for a first interval while injecting the solution beneath the rocks and then increasing the vessel pressure above ambient for a second interval prior to removal. | 3 |
This is a continuation, of application Ser. No. 664,473, filed on Oct. 24, 1984, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a process for the production of a matrix of electronic components. It applies to any matrix-type arrangement of electronic components and particularly a matrix of elements used for controlling a liquid crystal or electroluminescent display screen, or optical detectors.
In a matrix of electronic components having m rows and n columns of components which are electrically interconnected, the excitation of a component ij located at the intersection of the row i, i being an integer such that 1≦i≦m, and column j, j being an integer such that 1≦j≦n, is carried out by simultaneously exciting (applying a voltage) row i and column j of components.
The selective control of this electronic component is only possible if the components have a sufficiently non-linear characteristic permitting multiplexing.
In the case of a liquid crystal matrix display, this characteristic is represented by the ratio of the voltage applied to the optical contrast on the screen.
Multiplexing in a matrix display is facilitated by the addition of a non-linear, electronic element (diode, transistor), arranged in series with the electrode of the elementary display point of the liquid crystal. The non-linear element makes it possible to introduce a threshold on the electrooptical characteristic of the effect used.
FIG. 1a diagrammatically shows in simplified manner, the organisation of a prior art, non-redundant, matrix display. The screen 1 of the display is formed by m rows and n columns of elementary display points 2 forming a matrix.
The video signal 3 is stored in capacitive samplers 4 1 . . . 4 n , which store one image row. The samplers are controlled by a shift register 5 j in which circulates a pulse controlling the successive sampling operation. The video information contained in the sampler is transferred into the row of the corresponding matrix, where the control transistors of the elementary display points are in the conductive state. These transistors are controlled by the row control registers 6 1 . . . 6 n . The shift registers 5 1 . . . 5 n and the row control registers 6 1 . . . 6 m are controlled by clock rows 7 and 8 respectively.
A row-by-row scanning is performed in order to reproduce the video signal of the display, in accordance with a conventional method used in television equipment.
FIG. 1b shows an elementary display point of a liquid crystal display.
Electrode 9 is located on the face of the display in contact with the liquid crystal. A transparent electrode covering the complete screen is located on the front face of the liquid crystal. This electrode is kept at a constant potential and can e.g. be connected to earth 11. The two electrodes form a capacitance 10, the liquid crystal being located between the two electrodes.
A transistor 12 is connected in series with electrode 9, its drain being connected to the interconnection line 14 of a column, its grid being connected to an interconnection line 13 of a row of display points. Transistor 12 is the non-linear element authorizing the multiplexing of the electrodes 9 forming the matrix.
In such a matrix of components, such as a matrix display, the presence of defects with respect to the electronic components, the interconnection lines between the components or in the circuits controlling the rows and columns of the matrix leads to overall operational disturbances.
The most harmful defects in a matrix are interruptions of the interconnection lines between the electronic components and short-circuits between the rows and columns. For example, these defects are due to over or underetching of the interconnection lines during the matrix production process, or to the presence of grains of dust on a mask during the photolithography stage during the production of the matrix.
It is also possible for short-circuits to occur at the control transistors in the electronic components. Defects solely relating to a single elementary display point in a matrix display can be accepted, if the point is sufficiently small to be invisible to the naked eye.
An interruption of an interconnection line between the electronic components of the matrix or a short-circuit, however, makes the row or the row and the column respectively inoperative. Thus, complete defective rows make the matrix unusable.
Hitherto, most of the matrix displays produced were too small for most applications, but too large for the matrix of electronic components to be produced with a good production efficiency.
The efficiency of a matrix is dependent on the number and type of defects which can be accepted. For example, in a matrix of (240) 2 components and accepting defective rows, columns and elementary display points, the efficiency is approximately 50%, but such a circuit cannot be used. If only the defective elementary display points are accepted, the production efficiency decreases to 10%. The matrix is usable if the points are sufficiently small.
Without any defect, the efficiency can drop to 1% and can vary as a function of the technology used, but overall the results remain inadequate.
In order to obviate such problems and increase the production efficiency of these matrixes, it is possible to introduce a redundancy on several matrix levels.
Thus, it is possible to provide interconnection lines between the redundant electronic components, or there is a redundancy for each component, i.e. the number of components is increased.
Consequently, if one interconnection line is defective, it can be replaced by another formed by a redundant line, or in the second case it is possible to replace a defective component by another adjacent component.
The production of a matrix of redundant electronic components in accordance with the prior art consists of producing the components and the interconnections, then testing the continuity of the interconnection lines, bringing about a reconfiguration of the matrix by disconnecting the defective elements and reconnecting the satisfactory elements to one another and connecting the thus obtained matrix of electronic components to associated control circuits, which are located in the periphery of the matrix.
In order to be able to carry out the matrix operating test, all the redundant functions must be individually accessible during the test. The latter requires a large number of access hubs in the matrix.
This leads to an increase in the overall dimensions within the matrix, which is prejudicial to certain applications, e.g. in the case of a liquid crystal display. Moreover, it is necessary to mechanically displace the test points, which makes the testing process long and difficult.
According to the prior art, following the testing of the matrix, the satisfactory rows and columns are connected to the associated control circuits, which do not have any redundancy. Thus, it is not possible to test both the satisfactory operation of the complete control circuitry and the matrix. These post-test connections can lead to a deterioration of the functions recognised as satisfactory during the test.
SUMMARY OF THE INVENTION
The object of the present invention is to propose a process for the production of a matrix of electronic components making it possible to obviate these disadvantages. In particular, it makes it possible to produce a smaller redundant matix, carry out the test more easily and rapidly by including the testing of the control circuitry, as well as increasing the matrix output rate.
More specifically, the present invention relates to a process for the production of a matrix of electronic components having m rows and n columns of electronic components and control circuits located at the periphery of the matrix, associated with each row and each column of components, wherein it comprises realising the matrix and the associated control circuits in redundant form, the redundant elements being subassemblies each constituted by a certain number of electronic components associated with their control circuits, each subassembly being realised in such a way that it can be tested at the matrix periphery; performing the test of each subassembly by means of an optical addressing consisting of transmitting light rays onto photodiodes located at the matrix periphery and connected to each subassembly, certain of these photodiodes being used for selecting the subassemblies to be tested and the other photodiodes being used to produce test signals by means of light rays in the same subassembly; said test being used to check, in each redundant subassembly, the continuity of the interconnection lines between the electronic components and the operation of the associated control circuit; reconstituting the matrix, as a function of the test result, by disconnecting within the redundant subassemblies the defective electronic components and reconnecting the satisfactory electronic components.
According to another feature, for each row of electronic components of the matrix, the interconnection lines of electronic components of said row of electronic components are produced in redundant form, together with the corresponding control circuits, each redundant subassembly thus being formed from the said row of components and its control circuits.
According to another feature, for each column of electronic components of the matrix, the interconnection lines of the electronic components of said column of electronic components and the corresponding control circuits are produced in redundant, each redundant subassembly then being formed by the said column of components and its control circuits.
According to another feature, when m is equal to 2p and n is equal to 2q, p and q corresponding to the minimum number of rows and columns necessary for the intended use of the matrix of electronic components and when a row or column of the matrix is detected as being defective, the reconstitution of the matrix of electronic components is carried out by connecting the electronic components of the defective row or column to the corresponding electronic components of the respectively adJacent rows or columns.
According to another feature, the operation of each electronic component is tested by means of optical addressing, which consists of transmitting light rays onto a photodiode associated with each electronic component.
According to another feature, the reconstitution of the matrix takes place by means of active components included in the control circuit.
According to another feature, the reconstitution of the matrix at the control circuit takes place by means of passive reconnections, following the destruction of the undesirable connections.
According to another feature, the matrix of electronic components is a matrix of transistors making it possible to control a matrix display.
According to another feature, the control circuits comprising registers are produced in such a way that the registers can be addressed during the test by light means using addressing photodiodes connected to the register points and during the test, by illuminating the said photodiode, the register point is switched to 1, which connects the interconnection line between the corresponding electronic components to a test output.
According to another feature, a second photodiode is provided at the other end of the interconnected line and a light ray is applied to said other photodiode, which produces a current in the interconnection line, which is observed on the test output if the line is not broken or interrupted.
According to another feature, as a function of the test result on the lines, the interconnection of the connections between the registers recognised as defective of each subassembly is interrupted by means of switches, the inputs of said unused registers being kept at zero, the satisfactory registers of each subassembly being connected to the satisfactory registers of the following subassembly.
According to another feature, the state of the switches associated with each interconnection is determined by interrupting or not interrupting the connection between a selection line and the switches of one subassembly, which makes it possible for the switches to return to a position imposed by a polarization.
According to another feature, the reconstitution of the matrix at the redundant registers is carried out by means of passive interconnections between the registers of each subassembly and the corresponding registers in the following subassemblies and wherein as a function of the test result, the defective registers are disconnected and the satisfactory redundant registers of each subassembly are connected to the satisfactory registers of the following subassembly, if this has not already been done, by means of connections between them.
According to another feature, the redundancy of the different elements of the subassembly is a redundancy of 2.
According to another feature, the redundancy of the different elements of the subassembly is a redundancy exceeding 2.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:
FIG. 1a, already described, diagrammatically and in simplified form the organisation of a matrix display.
FIG. 1b, already described, diagrammatically an electrode of a liquid crystal display with its control transistor, connected to the corresponding column and row of the matrix.
FIGS. 2a-2e diagrammatically, several embodiments of the redundancies at the elementary display points, pixels and their control transistors.
FIG. 3a diagrammatically, an example of a redundant matrix, where the interconnection lines between the pixels and their control circuits are in redundancy with the test arrangements, incorporating photodiodes.
FIG. 3b diagrammatically, an electrode of a liquid crystal matrix display, the control transistor being individually testable by means of a photodiode included in the pixel.
FIGS. 4a to 4c diagrammatically, the various stages of producing passive connections between the satisfactory register points.
FIG. 4d diagrammatically and in perspective form, an example of a connection obtained.
FIG. 5 diagrammatically, a circuit of active components making it possible to choose during the test the connection between the satisfactory register points.
FIG. 6 diagrammatically, the organisation of a matrix of a liquid crystal display and the arrangement of its control circuits at the periphery.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 2a to 2e, diagrammatically show several embodiments of the redundancies and at the pixels and their control transistors.
FIG. 2a shows an electrode 19 of a pixel, controlled by two control transistors 21, 22. In this case, the redundancy takes place at the rows of pixels of the display.
The sources of each transistor 21 and 22 are connected to electrode 19, the drains are connected to the common interconnection line 20 forming the connection between all the pixels of a matrix column and the grids of each transistor are in each connected to an interconnection line 23, 24 respectively between the rows of pixels of the matrix. The redundancy in this case is realised by two interconnection lines 23, 24 between the pixels of a matrix row and by the two control transistors 21, 22 for each pixel.
If one of the interconnection lines 23 or 24 between the rows of pixels of the matrix is defective, i.e. is for example broken, use is made of the other redundant interconnection line. The probability that both interconnection lines 23 and 24 will be defective is proportional to the square of the probability of one of these two lines being defective.
In an illustrative manner, if the probability of a defect or fault in an interconnection line 23 or 24 is equal to 0.1, the probability that both redundant interconnection lines will be defective drops to 0.01%. The reliability of this interconnection is therefore considerably increased due to the redundancy.
FIG. 2b shows a second variant of the redundancy at the control transistors of each pixel. In this case, the redundancy is at the columns of pixels of the display. The grids of the two transistors controlling an electrode of a pixel are connected to a common interconnection line 23 connecting the pixels of one row of the matrix. The drains of each transistor 21, 22 are in each case connected to separate interconnection lines 25, 26 interconnecting the pixels of one matrix column.
The redundancy at the interconnection lines between the rows of pixels and between the columns of pixels of the matrix can be combined, as is shown in FIG. 2c. In this case, one pixel electrode is controlled by four transistors 27, 28, 29, 30.
In another variant, shown in FIG. 2d, the redundancy is at each pixel. As is shown, instead of 4 transistors controlling a pixel, it is also possible to subdivide the electrode into 4 separate electrodes, each being controlled by a transistor. In this case, the dimensions of these 4 electrodes are chosen in such a way that they occupy the same space in the matrix as one electrode in the preceding cases.
Thus, the number of matrix pixels is quadrupled. The number of registers for controlling the video sampling and rows or lines is increased in an adequate manner, the resolution of the image reproduced on the matrix consequently being increased.
Accepting that the resolution is improved by a factor of 2, on the complete screen, i.e. twice as good as necessary for achieving the initial objective, the fact that one row or column in the matrix is defective does not cause disturbing problems, provided that the pixels of a defective column or row are connected to the corresponding pixels on a respectively adjacent column or row.
The latter condition is necessary, because the failure of a row or column leads to a white or black row or column on the screen, which remains visible, even if the naked eye cannot resolve each elementary display point. By connecting the pixels of the defective row or column to the corresponding pixels of the preceding row or column and the following row and column in an alternate manner, resolution is locally brought to a definition twice less good than on the remainder of the matrix, but no defective row or column is visible on the display screen.
In this case, it is obviously possible to introduce a redundancy at the interconnection lines in a manner described hereinbefore. For example, FIG. 2e shows the combination of the redundancy at the electrodes of pixels with a redundancy of 2 at the interconnection lines between each row of pixels.
The interconnection lines between the rows and columns of pixels are connected to their control circuits at the periphery of the matrix, i.e. to the register points, power supply, clock, etc.
According to the invention, these control circuits are also in redundancy. Thus, for two redundant interconnection lines, there are also two register points, connected to each of the interconnection lines. The redundant functions, i.e. the interconnection lines between the rows or columns of the pixels and their associated control circuits must be individually accessible for an operational test without introducing a large number of access hubs, preference being given to a common series output.
For testing purposes, it is necessary to subdivide the matrix into redundant subassemblies and test each subassembly separately. If the subassemblies are too large, the efficiency becomes too low despite the redundancy, whilst if the subassemblies are too small, the overall improvement is reduced by the reconfiguration. By choosing rows and columns of redundant pixels having a complexity of approximately 500 to 1000 control transistors with their control circuits in the form of subassemblies, the optimum is approximately reached. The thus obtained subassemblies have the advantage of being accessible at the matrix periphery, which facilitates testing and reconfiguration.
FIG. 3a shows two redundant subassemblies. Each subassembly 30 is constituted by a row of pixels 31, their interconnection lines 32, 34 in a redundancy of 2, as well as by register points 33, 35, each associated with the corresponding interconnection lines 32, 34 respectively.
Each register point 33, 35 respectively comprises a photodiode 36, 37 which permits, by optical addressing by means of a light beam, to switch to one the register point 33 or 35, whilst all the other points of the matrix registers are kept at zero. The 1 in register 33, 35 respectively connects the corresponding line 32, 34 to the test output 40 by means of a switch 38, 39 respectively.
A second photodiode functioning as a photovoltaic cell 41, 42 respectively is placed at the end of each interconnection line 32, 34. During the test, said photodiode receives a light beam and consequently produces a current in the interconnection line, which will be observed on the test output if said interconnection line is not interrupted or broken. It is advantageous to use a pulsed optical signal in order to be able to separate the background noise from the electrical signal produced in this way in the interconnection lines and observed at the test output. In other words, the pulsed light beam creates a distinctive electrical signal that may be easily separated from background noise. The interconnection lines of the columns are kept at earth during the test.
This test procedure utilizing optical addressing makes it possible to test the different subassemblies of the matrix, without a defective element prejudicing the testing of the other subassemblies.
Thus, testing takes place of the retention or maintenance of one or 0 in the register points, the continuity of the interconnection lines and the absence of short-circuits on the interconnection lines.
By transferring the 1 from a register point 33, 35 of a subassembly to a register 43, 44 of the following subassembly, it is possible to test the connections between the register points forming future reconnections, which consequently benefit from the redundancy and clock or timing lines and the switches controlled by them.
In the case when it is wished to have a fault-free matrix, it is necessary to test each pixel individually and correct it if necessary. For this purpose, it is necessary to introduce a photodiode into each pixel. It must be relatively large in order to be able to receive a light beam during the test by means of optical addressing.
FIG. 3b shows a pixel comprising a photodiode 50, which is connected between earth and the pixel control electrode.
The interconnection line 51 between the pixels of a row of the matrix being connected to earth, so that the test signal produced by the illuminated photodiode 50 exits via the interconnection line 52 between the pixels of a matrix pixel column. This column 52 is connected to a corresponding register point. An optical addressing on the photodiode 50 on this register point connects line 52 to the test output. As a function of the test result, the defective pixels are reconnected either to the same redundant interconnection line, or to the adjacent line if there is no line redundancy.
The reconstitution of the matrix as a function of the results of the tests carried out on the subassemblies or on the pixels individually, can be directly carried out during or after the test. In the latter case, the test results are stored and reconfiguration takes place in a separate process.
In the following text, a description is given of the reconfiguration process of a subassembly constituted by a row of pixels, whose interconnection lines and associated control circuits are produced with a redundancy of 2, as shown in FIG. 3a.
If, for example, the test of interconnection line 34 has shown that it is defective, all the control transistors of all the pixels of the row connected to interconnection line 34 are disconnected. The disconnections can be also carried out according to conventional etching procedures in CMOS technology. Thus, it is possible to ensure that a possibly defective control transistor cannot bring about disturbances at the columns. This is followed by the disconnection of register point 35 associated with said interconnection line 34 from the registers of the preceding and following pixel rows.
According to the invention, at the connections between the register points, two fundamentally different interconnection circuits 45 can be envisaged. The connections can already be produced between the register points of each row of pixels arranged in superimposed manner, i.e. the register points 35 and 44 are connected, as well as register points 33 and 43 and so on, which gives two parallel registers.
As a function of the test result, if a register point or a corresponding interconnection line between the pixels is defective, the connections between this register and the preceding and succeeding registers are interrupted and a modified connection is produced by replacing said defective register point by the redundant register point associated with the same row of pixels and by reforming the connection between the preceding and succeeding register points.
This reconnection by means of so-called passive reconnection circuits is shown in FIGS. 4a to 4d.
FIG. 4a shows that the register points 33, 43 and register points 35, 44 are interconnected by means of aluminium connections, e.g. 60, 61 respectively. If during the test, register point 43 is found to be defective, firstly two holes 62, 63 are made in the oxide layer 67 covering the aluminium lines, as shown in FIG. 4b. Thus, these regions of the aluminium connections have been bared.
An aluminium hub 66 is then deposited on these two contact holes in insulant 67, in order to produce the contact between register points 33, 43 and simultaneously interrupt the connections 60, 61, so that a portion 64, 65 of said connections is left and can be connected to the parts of the aluminium lines which are to form the future connection. Instead of interrupting line 61 connecting the satisfactory register points 35, 44, it is possible to leave them connected. In this case, use is also made of the redundancy after the test, i.e. during the permanent use of the matrix. This has certain advantages. In particular, it reduces the number of modification operations relative to the connections between successive register points. If there is no fault in a subassembly, all the associated register points are kept in operation.
In a final stage, the input of the unused defective register point 43 is connected to earth, in order to define its potential. The process of providing this connection to earth takes place in the same way as described hereinbefore. FIG. 4d shows in perspective the thus obtained connection.
As a result of the process described hereinbefore, it is then possible to interrupt or produce a connection between successive register points. In this case, the reconfiguration circuit of the connections between the registers can have a very small surface area (size of one contact), but it is not possible to test different function associations during the test.
In an active reconfiguration, an electronic circuit controlled from the outside produces various connections between the functions during the test. The electronic reconfiguration circuit is tested in the same way as the other functions and consequently benefits from the redundancy. FIG. 5 shows an example of an active reconnection.
In FIG. 5, a reconfiguration circuit between four register points 33, 35, 43, 44 comprises four switches 72, 73, 74, 75. The switches can be produced by means of CMOS transistors. The output of register point 33 is connected to the input of register point 43 by means of a line 70 having two switches 74, 75. In the same way, the output of register point 75 is connected to the input of register point 44 by means of a line 71 having two switches 72, 73. The two lines 70 and 71 are interconnected by means of an aluminium line, their contact points being located between the two switches of each line 70, 71.
Two switches 74, 72 or 75, 73, such as transistors, each on a line 70 or 71 are controlled by complementary signals from selection lines 76, 77. For example, selection line 77 is directly connected to switch 74 and via an inverter 78 to switch 72. A pulling resistor 82 makes it possible to define the so-called standard state of the two associated switches e.g. 74, 72, i.e. the opening or closing of switch 74 and conversely the opening or closing of switch 72. This standard state can be inverted by a signal opposite to that of the pulling signal on selection line 77. For example, in earth pulling, a voltage produced in selection line 77 closes switch 74 and opens switch 72. If there is no voltage on the selection line, the signal from the pulling resistor 82 reverses the states of switches 74, 72, i.e. switch 74 is open and switch 72 closed.
Switches 75 and 73 are connected in an identical manner to selection line 76. The associated pulling resistor is 83 and the associated inverter 79. With the four possible combinations of signals in the selection lines, i.e. signal on line 76, signal on line 77 or signal on line 76, no signal on line 77 or no signal on line 76, signal on line 77 or no signal on line 76, no signal on line 77, it is possible to test the four possible connections between the successive register points. In order to definitively choose the electrical path between the successive register points, it is possible to interrupt or not interrupt the connections between the selection lines 76 or 77 respectively and switches 74, 72 or 75, 73 respectively. If the said connection is interrupted at a predetermined location 80, 81, the switches are solely controlled by the pulling resistors.
Hitherto, a description has been given of the production process of a matrix of electronic components with a redundancy of 2 at the interconnection lines, as well as the associated control circuits, together with the case of a redundancy of 2 at the electronic components.
It is also possible to increase the redundancy in both these cases by providing at least three interconnection lines between the components or by choosing a resolution at least three times higher than necessary, in order to achieve even greater reliability. However, an increase in the redundancy implies an increase in the overall dimensions of the matrix, as well as an increase in the number of testing and reconfiguration stages, which can lead to a drop in efficiency. Nevertheless, redundancies exceeding 2 can be envisaged.
The overall dimensions of the control circuits comprising resister points, memories, clocks, etc. already causes certain problems in the case of a redundancy of 2.
According to the invention, the control circuits of the columns of pixels 92 are located in alternating manner above and below the matrix of pixels. In the same way, the control circuits of the rows of pixels 93 are arranged in an alternating manner to the right and left of the matrix.
FIG. 6 diagrammatically shows the organisation of a matrix 90 of pixels of a liquid crystal display and the arrangement of these control circuits 92, 93 on the periphery. The circuits located on the same side of the matrix are interconnected. The sampling of the video signal 94 and the clocks are adapted to this configuration by means of switches 95. | Process for the production of a matrix of electronic components.
The matrix and the associated control circuits are produced in redundant form. The redundant elements can be interconnection lines between the electronic components of a matrix row or column and the associated control circuits or the actual electronic component. A row or column of electronic components represents a subassembly, which is tested by means of optical addressing, consisting of transmitting light rays onto photodiodes located at the periphery of the matrix and connected to each subassembly. As a function of the test result, the matrix is reconstituted by disconnecting the defective electronic components in the redundant subassemblies and then reconnecting the satisfactory subassemblies to one another. This process is more particularly applicable to a matrix of elements used for the control of a matrix display. | 6 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of Ser. No. 09/784,848, filed Feb. 16, 2001 under the title “AUTOCLAVED AERATED CONCRETE PANELS AND METHODS OF MANUFACTURING, AND CONSTRUCTION USING AUTOCLAVED AERATED CONCRETE PANELS”, and Ser. No. 09/741,787, filed Dec. 21, 2000 under the title “METHODS OF MANUFACTURING AND CONSTRUCTING A HABITABLE, CEMENTITIOUS STRUCTURE”, by the inventor hereof, where the contents thereof are incorporated herein in their entirety.
FIELD OF THE INVENTION
[0002] This invention is directed to the field of manufacturing and building structures, such as dwellings, and more particularly to a system for manufacturing structures of cementitious materials of an autoclaved aerated cementitious concrete.
BACKGROUND OF THE INVENTION
[0003] This invention relates to a system for manufacturing structures of cementitious materials, and to unique techniques for finishing various features of the structures. The construction industry is basically unchanged in materials and processes for hundreds of years, while during this same time most other industries have been revolutionized. The consequence is that there is vast room, and need, for improvement in the construction industry, for the lack of improvement has resulted in escalating costs and a compounding of negative impact on the environment.
[0004] The construction industry has sought alternative building The construction industry has sought alternative building materials and techniques in order to limit the traditional expenses of construction. The costs include the high energy costs of manufacturing, increasing scarcity of quality materials and the rising cost of available materials, and increasingly expensive construction labor. Regrettably, the majority of solutions employed so far have only resulted in an increasingly inferior quality to finished product. Consumers desire to lessen the negative environmental impact (i.e.: deforestation, mining and pollution from manufacturing) and negative health effects (i.e.: fluorocarbons and other harmful gases, mold from decay) of some building materials. These factors have forced home builders in particular to consider new construction materials. These new materials must be versatile, easy to use, durable, and energy efficient.
[0005] An alternative to the conventional building materials is what may be called Autoclaved Aerated Concrete, hereinafter referred to as “AAC”. AAC is superior to current building materials and is extremely environmentally friendly. That is, the teachings hereof will substantially reduce global warming by preserving forests. While this invention applies to any cementitious material which can employ the teachings of this invention, AAC is a preferred material and the further description will be so limited.
[0006] AAC was invented in the early 1900's and consists of a mixture of cement, aluminum powder, lime, water and finely ground sand. This mixture expands dramatically, and this “foamed” concrete is allowed to harden in a mold, followed by curing of the hardened mixture in a pressurized steam chamber, or autoclave. Commercial production of AAC began in the 1930's, and presently more than 31 million cubic meters have been produced worldwide.
[0007] Compared to wood, steel and standard concrete, AAC is a clearly superior material as it is fire proof, termite proof, self insulating, sound insulating, non decaying and does not rust. Compared to concrete, AAC weighs 30% less than traditional concrete masonry units. Additionally, AAC is well known as an environmentally friendly construction material with certain manufacturing plants receiving recognition as being “Green Factories.” Compared to the energy consumed in production of many other basic building materials, only a fraction is required to produce AAC. Raw materials consumption is very low for the amount of finished product produced. In the manufacturing process, no pollutants or toxic by-products are produced. AAC is also completely recyclable.
[0008] AAC is an inorganic material that contains no toxic substances. It does not slowly decompose nor emit a gas. Since AAC is both a structural and insulation material it allows the elimination of other materials that can contribute to poor indoor air quality. Due to its inorganic structure, AAC also eliminates the food source condition required to be present for microbial growth to occur. Thus, AAC is resistant to water penetration and decay. As it is a solid cementitious building material, insect (roaches, ants) and rodent (rats, mice) infestation is impossible within walls and floors as there are no cavities as now occurs in standard frame construction.
[0009] Further, AAC is non-combustible, so in the case of fire it can help prevent the fire from spreading to other rooms. During a fire, no toxic gases or vapors are ever emitted from inorganic AAC. As building methods using AAC include using solid blocks and panels with very simple connection details, the ease of construction helps to ensure a monolithic, highly fire-resistant wall.
[0010] AAC buildings, as described by this invention, can be very energy efficient. This efficiency is due to a combination of high R-value, thermal mass and air-tightness. AAC is the only product currently available that meets Germany's stringent energy codes without added insulation. It is well documented that the R-value of a mass product need not be as high as that of light frame construction, to perform thermally efficiently.
[0011] AAC products are unfinished. Depending on the building use or the aesthetic requirements, AAC may be coated with an exterior surface finish of approved stucco, stone, brick-veneer, wood siding with furring, or a combination thereof. On the interior AAC usually has sheetrock installed over furring strips due to utilities and numerous joints of blocks.
[0012] While the construction industry recognized certain advantages in the use of AAC components for building, no system exists to effectively take advantage of the superior qualities of AAC in a cost effective manner. In fact, even though AAC is itself considered a vastly superior construction material than current construction industry standard wood, steel and/or concrete, the prior methodologies employed in AAC construction cause ACC to be so much more labor intensive and costlier than current standard construction materials, that the negatives of prior methodologies of AAC construction basically outweigh AAC's inherit advantages and so prohibit AAC from being considered as a viable alternative. The teachings of this invention not only eliminate these prohibitive negatives, they so facilitate the construction of AAC habitats that AAC habitats now can be built in less time and for less end use cost than conventional materials, with the underlying theme being the construction industry's prerequisite “simpler, better, cheaper” motto.
DESCRIPTION OF PRIOR ART
[0013] Despite the early development of AAC as a potential building material, there is little in the patent prior art. There is a recent patent, U.S. Pat. No. 5,286,427, Koumal, Feb. 15, 1994, which relates to only a manufacturing process using a modified composition for AAC. While it is helpful in finding a beneficial use for what is now a waste product, it in no way addresses any of previously mentioned problems prohibiting AAC's market acceptance. So while it is helpful in finding a beneficial use for what is now a waste product, it fails in that AAC still has no way of being successful in construction industry, so it is dependent upon this invention for its success.
[0014] The present invention is a synergistic whole, completed structure as a precast concrete system and may appear similar to U.S. Pat. No. 5,761,862 to Hendershot et al., Jun. 9, 1998, but that is due only to also emulating a residential structure, as the very nature of material used and processes employed are incompatible. Of the searched Prior Art, it is the closest, yet upon closer inspection it is vastly different in every respect. Hendershot uses a very complex steel reinforcing and joint system, bonding system requiring flared coil loops and sheebolts, structural bearing system requires complex precast steel mechanism, and a hip roof cannot be constructed as even simple dormers are reduced to nothing more than exterior architectural accents placed over constructed roof All prior art requires great quantities of steel reinforcing, steel brackets, mechanisms and/or laborious, precise manufacturing processes facilitating site construction.
[0015] Wall process: U.S. Pat. No. 6,098,357 Franklin et.al., Aug. 8, 2000, cites well the problems of all prior art's various block wall systems. Yet, itself requires additional materials for architectural finish, its process of uniquely formed and dimensional blocks greatly exceed the minimal three block vertical height of current art, requires additional steel anchor system, does not even address the problem of utility locations in walls and it is composed of inferior material lacking all the innate attributes of AAC. Referring again to U.S. Pat. No. 5,286,427, Koumal, Feb. 15, 1994, fails in its design in FIG. 5 and description to be so unfeasible that they are only intended as an example of product and no way intended as representative of a construction system. The present invention's processes and articles of manufacture allow for the temperature transfer system which heats/cools the wall for specific purpose of countering exterior environment's temperature effects on wall material. Most prior art is concerned with radiant heating of interior and not stabilizing the insulate properties of the wall's material, therefore their design and processes are either inadequate or unfeasible.
[0016] In this invention's support beam system for roof, etc., the prior art of U.S. Pat. No. 4,285,179, Goidinger, employs a lightweight cementitious material in panel form that has longitudinal cavities that are filled with heavy standard type concrete and optionally reinforcing steel which makes vertical wall panels load bearing. The roof beam system hereof with optional reinforcing channel, is novel for following reasons: 1) Goidinger is specifically vertical walls, 2) due to incompatible uses are structurally and dimensionally dissimilar, 3) while Goidinger has internal cavities formed by sandwiching formed wide panel halves together, the solid rectangular beams hereof have much thicker exterior AAC for distinct purpose of receiving “R” screws or similar fasteners and can be shaped in angles to equal roof panel's pitch, 4) beams can have corrugated shaped channel system adding strength and additionally preventing added cement from adhering too quickly to dry sides preventing added cement from adhering too quickly to dry sides and clogging cavity and therefore preventing it from being completely filled, which can be a serious failure problem of Goidinger, and lastly 5) has a utility channel. It is unobvious as no other prior art has specific use of: 1) weaker material used for a structural purpose of receiving fasteners, 2) used solely for structural, load bearing beams spanning space, as without the present invention screws and interlocking beam ends it was almost impossible to engineer such a system for practical application. In regards to beam's interlocking ends, there is no prior art in cementitious material, but U.S. Pat. No. 4,409,763, Rydeem, Oct. 18, 1983 uses a great wood system of one vertically oriented dowel to secure a plurality of intersecting beam ends onto a post, but has no method for a suspended, self supporting, load bearing beam system spanning space. Again, all other prior art in cementitious materials employ complex, heavy-duty steel brackets, support/reinforcing, etc., and still cannot accomplish process of invention.
[0017] Presently, there is great waste in conventional roof construction to accomplish the desired architectural look of multiple hips, ridges and valleys. In U.S. Pat. No. 5,794,386, to Klein, Aug. 18, 1998, there is taught a roofing system. More specifically, the patent is directed to a roof panel for sloped roofs and includes a self-supporting reinforced plate of cementitious materials, wherein the reinforcement above the plate has bars running along the slope of the roof. Compared to the present invention it is a very complicated, costly combination of cement and steel reinforcing.
[0018] Another aspect of this invention's roof system is its gravity induced internalized gutter system. All prior art with internalized gutter systems for pre-cast concrete panels (Meyers, U.S. Pat. No. 723,175; Novoa, U.S. Pat. No. 3,603,052; Rook, U.S. Pat. No. 6,006,480) rely on force from additional moisture to push accumulated previous moisture out of a level, straight gutter system, and the results are problems of residual moisture and accumulated debris causing damage to gutter system and structure. U.S. Pat. No. 929,684, Mills & Taylor, Aug. 3, 1909, is an example of common design deficiency allowing moisture to run down the face so that debris residue leaves streaks and moisture angle water deflection system.
[0019] No prior art addresses either processes or compositions of matter of this invention's roofs water proofing system. Only U.S. Pat. No. 5,981,030 Haupt et al, Nov. 9, 1999 has a figure similar in appearance, but by closer inspection thereof, and by reading the detailed description, the following incompatibilities, physical differences and new unrelated processes become clear: 1) is not used for waterproofing but rather water retention which defeats process of facilitating removal of vapor from AAC roof panels, 2) its process is a solid mass for water retention and not air cavities for venting, 3) the materials used are completely different and incompatible, 4) while absorber ( 4 ) is held in place by fleece ( 1 ) and joined to base material ( 5 ) by a laminate ( 2 ), there is no continuity as absorption is confined to small areas ( 6 ), the laminate does not coat entire product but on specific areas ( 6 ), the fleece has no structural purpose other than to hold absorber ( 4 ), 4 ) quilted absorber areas are of various sizes and perforated coating film contradict teaching of this invention. There is no prior art, nor proven commercial product for matter of composition which will be a satisfactory alternative roof water proofing system. Heretofore AAC roofs were forced to use conventional roofing materials that are labor intensive, costly, add tremendous weight to roof system, and are for the most part environmentally harmful.
[0020] While there are pre-cast roof panel systems in the prior art, none could emulate the ridges and valleys of contemporary rooflines. Current methods of wood construction use nominal 4′×8′ sheets of processed wood, i.e. plywood, which results in large amounts of waste.
[0021] When an existing wood structure requires roofing replacement, prior art systems had no satisfactory way to permanently fasten AAC panels to the wood rafters, nor was there a roofing product light enough for wood structure to support both the AAC panels followed by the heavy roofing material.
[0022] In areas requiring sound control, such as near airports, etc., there was no cost effective way to sound proof the roof of a house while simultaneously making it energy efficient and environmentally friendly.
[0023] For multi-story buildings, Prior Art U.S. Pat. No. 723,175, Meyers, Mar. 17, 1903 is only prior art of a remote reference to ring/bond beam floor panel and corbel ring/bond beam as the patent shows a wall with floor and roof being incorporated into a single monolithic unit without a separate ring/bond beam. The processes it employs of a mold into which concrete is poured is incompatible with this invention which uses pre-cast pieces.
[0024] U.S. Pat. No. 5,143,498, Whitman, Sep. 1, 1992 has a screw with a chamber with laterally disposed openings that are to disperse liquid sealant. The Whitman screw has a single chamber for dispersing sealant which attaches to rubber material as material presses against openings and exterior wall of screw's shaft, which may work for it as it has a screw head which remains exposed outside material and a tight configuration of threads ideal for rubber. U.S. Pat. No. 5,249,899, Wilson, Oct. 5, 1993 employs a shaft for dispersing an adhesive through openings located in a recessed thread which works for it since it is used for pre drilled, machined metals, but would be useless in cementitious product as dust would clog. U.S. Pat. No. 5,516,248, DeHaitre, May 14, 1996 has a plurality of outwardly projecting serrations which burr into the work piece for self locking, but the design is limited to that sole use and design is counter productive in a cementitious material. Standard rebar requires drilling a hole, inserting rebar and then mortar, and in method cannot hold inclined pieces in place.
[0025] While there are many references to prior art for tools of routing and reciprocating saws with plunging process, U.S. Pat. No. 5,682,934, Rybski, Nov. 4, 1997; U.S. Pat. No. 5,240,052, Davison, Aug., 31, 1993 references are closest related to this invention, yet they are more complex, confined to independent actions performed on individual pieces at a work station requiring pieces to be later combined with other pieces at site, and are restricted by complexity of guide or design's dimensional limitations as systems lose feasibility when enlarged so cannot create and finish large openings and/or architecturally finish large surfaces of permanent placed, vertically positioned structural material.
[0026] U.S. Pat. No. 721178, E. P. Golden, Feb. 24, 1903 does not apply to joint finishing tool as it is for process of removing a prescribed depth of material surface and not just cleaning off an excess of a different material from surface, the patent shows it has two wheels to each side of blade vs. one elongated wheel which serves additional function of smoothing out and imprinting residual material, FIG. 4 shows pressure is exerted on rear positioned blade vs. on rear rolling pin like wheel which drives neutral front positioned blade.
[0027] U.S. patent to Planchon, Mar. 22, 1995 shows a reciprocating saw blade with unique tip for starting a hole and cutting, but not a good method for holding tool in position while blade starts hole as one of problems will be maintaining blade in starting hole without opening template guide and tool guide arms.
[0028] It is now understood that all prior art and standard industry methodologies employ complex, expensive and labor-intensive combinations of concrete with heavy-duty steel reinforcing and structural support systems/beams that employ complex steel fastening systems.
SUMMARY OF THE INVENTION
[0029] Present invention was forced to develop new processes, machines, articles of manufacture and compositions of matter for the effective use of cementitious AAC panels, blocks and shapes for the construction of environmentally friendly habitats. Upon review of Introductory Figures of Prior Art/Current Methodology, it will be noticed that there is not one component that is not either completely unique or modified in such a manner that the resultant process is completely new. Entire structural habitat can be constructed of cementitious product without use of steel support beams, interlocking steel brackets, bolts or other common steel parts (only rebar as building code requires), gutters, down spouts, wood trim, casing, and /or molding, nor conventional roofing materials, yet has the same degree of functionality as a conventional dwelling with these features.
[0030] It was discovered that large, precisely dimensioned elements of AAC allow for rapid construction as compared to conventional brick and CMU (concrete block). Their greater dimensional accuracy requires less on site adjustment. The combination of large size and dimensional accuracy allows greatly increased productivity. Due to the light-weight of AAC, reduced equipment demands are realized.
[0031] The walls employ processes of minimizing vertical blocks. There are two wall block sizes: mini-wall and wall block. Their differing contributions to wall process will be detailed later. But each wall block has invention's utility channel and is coordinated with other blocks of invention's processes. Each block serves a specific function in the wall itself as well as replacing as many as four separate items required in current construction.
[0032] Invention's process of constructing walls of cementitious blocks, such as AAC, is superior in minimal quantity of two vertical components (wall block and top block—with casing block for openings) and three vertical components (base block, mini-wall block and top block—with casing block for openings), structural pieces are pre-finished and simply installed as specified (base, casing, top, crown), are constructed so utilities are inside walls which have finished surface including architectural effects ready for painting.
[0033] Openings for windows and doors use present art's casing block with utility chase system and are dimensionally located with components of this invention's process on one foot centers so entire dwelling is an unified dimensional process thereby a standard 8′ high wall uses three components vertically and horizontally can have virtually no waste. Invention's alternative process of wall block system allows for all advantages of vertical three block system with less labor as requires only invention's utility channel slot at base which coordinates with utility channel in other articles of manufacture such as casing blocks, etc. To fully appreciate wall block system, to be cost effective in manufacturing and field requires adding 6″ of length to AAC industry's standard 20′ slurry mold so three full lengths of 82″ wall blocks and matching casing blocks can be produced without waste.
[0034] Returning to the current manufacturing capabilities, casing blocks, etc. are horizontally dimensional for 1′ and 2′ center construction. Single wall block is not called a panel as steel reinforcing is not required which is substantial savings. Casing blocks can be omitted and architectural effect added into wall blocks and Top Block using invention's tools.
[0035] One example of an advantage of this invention over prior methodology of AAC construction and prior art of CMU block, by using the traditional solid blocks and/or panels there was no good means to provide a finished interior wall without first using wood furring strips and externally positioning electrical utility boxes and wiring which further meant that wood studs and sheetrock or dry wall panels were required; consequently basically requiring two wall systems, or, alternatively routing and then inserting conduit and then having to repair walls. All this added substantial extra labor and material costs to the construction using AAC panels and blocks. Current art's internal “utility channel” system allows all utilities to be placed inside wall during construction and with special “fishing curve” and “multi conduit” inserts allow utilities to be placed within wall even after construction. The current art's utility channel system, inserts and architectural finish provide a structurally superior finished wall with surface simply requiring paint and/or wallpaper as a normal finished sheetrock wall. Current art eliminates all labor and/or forest materials of constructing an additional wall system. Current art even eliminates need for finished wood trim by architecturally finished blocks and invention's tools that are designed to finish vertical, and even upside down, surfaces. Current art's unique wall block system has not only saved labor and materials as compared to conventional AAC construction, it has actually made AAC less expensive and labor intensive than standard construction materials and methodologies.
[0036] The top course of a wall is constructed using top block/beam that is dimensionally sized at +/−16″. It can be manufactured as a block or a continuous beam, as it can be reinforced and even house invention's air duct system. An industry standard 2′ wide panel can be substituted for top block, as wall block's unique shape is critical for process.
[0037] A common design problem is resultant gap between the top of a wall where it meets a sloped roof. The crown block with sloped top fits perfectly into this space and allows for architectural continuity. The crown block allows for sloped roofs and, if left with a level top, even additional floor systems to rest on architecturally finished structural components.
[0038] As previously noted, AAC buildings can be very energy efficient. A recent study in the U.S. shows that an 8″ AAC wall performs better than a conventional 2″×6″ wood stud wall system with R-30 Insulation. AAC is ideal for variable temperatures so that the outside temperature is dissipated by change before it can permeate block and effect interior. The only disadvantage to AAC's thermal insulate value is in a location where there are continuous days of below freezing temperatures as occurs during winters in northern United States and Canada, the cold eventually permeates the AAC block. A test in Pennsylvania not using current art for AAC, showed when AAC is exposed to a constant temperature, such as freezing, over a period of time, it was found that a winter's heating expense was the same as a standard 2×4 wood frame home. This is one reason why AAC plants are presently located only in Southern areas, an ideal climate of moderate, fluctuating temperatures. Current art solves this problem through its temperature transferring system manufactured in blocks and panels and is available for climates requiring it. Warm or cool air is simply circulated through holes in exterior half area of blocks. The manufacturing of transfer channels is unique in that the tubes inserted into the pan mold are two conical tubes with threaded ends, one male and one female, which after curing are separated by tool which is inserted into larger end and engages indentations and is twisted to unscrew tubes. The purpose for conical shape is ability to ease withdrawing longer sections of pipe from cementitious material thereby enabling even 20′ lengths to be more easily removed.
[0039] The utility chase and block wall systems are only a few of the numerous other embodiments and claims of this application which each individually and combined, address specific areas of improvement in AAC construction.
[0040] The structural beam system is placed on walls and is unique in being constructed of reinforced AAC or alternatively can be comprised of two cementitious materials, having a center fiber and steel reinforced concrete and outer casing of AAC which accepts the screws hereof, flange bar and/or hollow bar, which are used to fasten roof panels to beams.
[0041] The beams can have reinforcing center formed by two halves with longitudinal slots joined and filled, even HVAC duct and a utility channel can be placed inside so trades simply pierce AAC where desired openings are to be located.
[0042] Currently the AAC industry does not use AAC for its roof systems in residential application because the required structural steel support beams, etc., rendered it impractical, so industry methodology is to attach a conventional wood and asphalt shingle roof on top of AAC walls. Current art is able to feasibly employ an entire AAC roof system with no steel I beams, support columns, brackets, braces, bolts, etc. The structural beam system allows for all conventional roof designs to be possible, which was previously thought unfeasible with cementitious products due to weight, fastening systems and difficulty of working with product.
[0043] Invention's roofing system maximizes AAC's innate attributes by combining structure, insulation, gutter, water deflection, and waterproofing all in one. One of the more important ideas of invention is the AAC roof panel's waterproofing system. The AAC roof panels employ current art's cost effective waterproofing systems, both systems are environmentally friendly products to manufacture, and the consumer use of either invention will relieve landfills of 100,000 of tons of current industry asphalt shingle refuse currently being dumped every year. The current art is designed to never have to be replaced, only re-coated every 10+ years. Roof repairs are easily discovered and can be repaired by an unskilled homeowner. Professional roofers will appreciate ease of application. Both systems not only waterproof, but also remedy problem of AAC's requirement for vapor permeability (to be able to “breathe”) so moisture build up does not occur inside habitat. These are only systems known to be able to be applied directly to roof surface and still facilitate vapor permeability.
[0044] The indivisible internalized gutter system is similar in that it eliminates costly additional gutter systems that must be maintained and replaced. The water deflection system not only adds aesthetic enhancement but provides process through its unique reverse (upward) angles to cause water to separate from face preventing unsightly runs as well as help dissipate negative effect of water runoff. The gutter down spout box eliminates need for unsightly down spouts and add architectural accent. Because of new roof system interior space is greatly increased by volumes as attic insulation is not required. insulation is not required.
[0045] The new beam and panel roof system of this invention greatly increases interior space by creating habitable areas in roof vaults that previously were inhospitable, namely wasted attic space.
[0046] The waste-free system taught herein allows for flexible custom application of AAC roof panels so contemporary roof lines are realized. The waste-free roof system can be implemented for hips as well as valleys.
[0047] When teachings of this invention are applied to install AAC panels over existing roof structures, they overcome weight, fastening and aesthetic concerns. An unanticipated use may be for sound proofing by removing existing asphalt shingles, etc., and screwing AAC panels directly over wood decking into rafters. The unique screw for installing AAC panels into wood have wide flanges in the area to cover the AAC material. The wood threads on the tip are used to permanently secure the panel into the wood. The threads actually help to control the depth of penetration of the screw, followed by a light weight, environmentally friendly coating.
[0048] When constructing multiple stories, invention's ring/bond beam floor panel eliminates several time and material consuming steps. The floor panel has unique modification of top row if reinforcing stopping 1′ short of panel end (same as for roof panel for gutter system). This allows invention's ring/bond beam slot to be manufactured. Construction is simply placing beam on top of wall with panel end flush to exterior wall face, inserting required rebar into slot, installing the screws hereof through slot into wall below, which screws engage other reinforcing in panel. The heads of screws can be left protruding into slot and rebar tied to them, then add mortar and immediately next course of block, and continue on with next wall. This eliminates all the following current methodology: 1) place panel end short of face of exterior wall, 2) mortar a block flush to face of exterior wall leaving a gap between panel end and block, 3) place rebar into gap and add lots of mortar, 4) wait day for ring/bond beam to set and then continue construction.
[0049] An alternative improvement in time and costs for multiple story construction is method of constructing walls without laying floors or roof until all walls are constructed. This method saves cost trips which can add up to thousands of dollars, as well as additional costs of down labor time for wall crews waiting for crane to finish, The method is for a crown block to be used that protrudes into interior area and forms a ledge for supporting floor system. When all walls are constructed crane simply sets all floor panels into interior area and roof panels onto crown block ledge, all in same day by use of invention screws. The crown blocks serve as ledge as well as architectural finish.
[0050] Corbel ring/bond beam is similar, as wall face is routed, using invention's routing system, to receive a pre-cast, reinforced AAC beam. Simply mortar and fasten into place using the screws hereof and then floor or roof can be set on corbel ring/bond beam. This process using unique articles of manufacture allow for quick, strong permanent placements of floor and roof panels where before an entire wall assembly system was required.
[0051] Stairs providing access between floors are now able to be cost effectively constructed of cementitious material that immediately gives fire protection. Stairs will not creak and have benefit of muffling a lot of the noise transmitted by standard wood stairs. Current methodology for constructing stairs, especially curved and suspended stairways, require a very skilled craftsman, but now unskilled labor can construct a superior stairway in less time.
[0052] The invention screw is an indispensable article of manufacturing which facilitates many of invention's processes. The auger type invention screw now makes it possible in one motion to set steel reinforcing into cementitious product without pre-drilling a hole and having to wait for mortar to set. An example of one advantage, a roof panel set on a {fraction (12/12)} pitch can be set in place with invention screws into wall and invention's beam support system and left with no other support. The invention screw locks all pieces together with threads and counter sunk head. An entire roof system can be installed, then the worker comes back and fills all invention screws with mortar at end of day for them to set up overnight. Next day roof is waterproofed.
[0053] A few nuances of the invention screw are advantage of invention's flanges on screw head are to gouge out AAC so head can counter sink and simultaneously help lock in place. Unlike any other screw, the invention screw has the ability to be drilled very close to surface without breaking AAC apart because of its auger process alleviating pressure that a standard solid shaft creates. The chambers' unique design actually allows mortar and screw process to make one monolithic piece of separate pieces in one step.
[0054] Invention's alternative, the flange bar, is a modified rebar with most of the advantages of the invention bar except it requires pre-drilled holes. Invention's flange bar allows direct bonding and reinforcing as code requires with superior results of centering rebar in hole, allowing mortar to fill hole around rebar, secure rebar directly to cementitious material, hold cementitious pieces in place by flanges imbedded in walls of hole preventing shifting movements, flanges greatly increase holding power. The “R” screw has advantage of one step process while flange bar has less expensive manufacturing costs and can be cut at any length at a point removed from a flange so that a hammer drill can be placed over shaft and the shaft used as a bit.
[0055] A hybrid of both the invention screw and flange bar is hollow bar which combines best attributes of both inventions into one unit. It uses invention's cutting device that in cutting uses a crimping action that results in serrations which through bar's twisting action grind AAC into dust and force into hollow core. It has a helix-action with auger flanges which leaves slots for special epoxy (not regular mortar) to be inserted around bar.
[0056] By use of the invention's nail screw, the result is synergism in that now one item replaces two previously separate processes with the benefits of both and modifications eliminating detriments. A problem with fastening items into a cementitious product is that the cement is not like wood which holds by a constant expansion pressure upon inserted object, cement holds by a gripping and/or binding to concrete. Therefore when object is removed it can rarely be reinserted into same hole with effective holding power. The invention screw overcomes this problem by gathering dust in its tip which binds, by prongs near head which pierce and hold, torque more pressure via screw head and by ability to reinsert finish nail in hollow shaft and re-explode tip. While prior art, such as Helifix, has advantages of piercing and twisting to hold in AAC, it requires long sections of shaft to work effectively and still wiggles and can work free without mortar. The screw hereof has variable degrees of hold, and via nail exploding tip, has unique process of being permanently set and still retain ability to be removed without damage to AAC or fastener and then even reused in same hole.
[0057] Door slabs can be composed of AAC giving great fire safety and sound insulation to rooms. As AAC is non-combustible, current art even has an AAC door that is unique in allowing a four-hour fire rated wall having a specially designed opening.
[0058] Tools biggest advantages are ability to be used on vertical plane surface and enabling unskilled workers to make finished openings and other modifications in thick walls, as well as finished trim designs. Most of the tools combine steps so that what required two or more tools and several processes in prior art can now be done with invention's machines, articles of manufacture and processes with one tool and in one step.
[0059] Invention's air duct system uses AAC insulate characteristic and duct's structural reinforcing for unexpected result of a manufactured structural component: 1) an internal duct system that is installed during construction of habitat as it is an integral, structural part of habitat, 2) is an insulated forced air duct system which reinforces cementitious material, 3) reduces volume weight of top beam, 4) requires no additional framing, etc., to hide it, and 5) uses process of varying opening sizes custom installed at site to regulate required air supply. Blocks and beams can also be used with a standard sized hole becoming the air duct with no other duct work required.
[0060] An advantage of the present invention is its ability to emulate the aesthetic appeal of industry's standard habitats while being composed of a completely different, unique cementitious material. It is the invention's synergy that allows it to overcome problems preventing AAC's acceptance by construction industry. Each of the present embodiments is crucial to whole as it is synergistic, i.e. without support beam system, roof panel system would not feasible, and without invention screws and light-weight roof waterproof coating system the support beam system would not be feasible. AAC systems are environmentally friendly. In contrast, conventional wood structures create a problem of waste, while this system reduces waste to almost nothing. What waste there is can be dealt with by the teachings hereof. It was discovered that the waste hereof is to grind the AAC into powder and then, by optionally adding proper nutrients and fertilizers, turn the mixture into a yard enhancer so that no waste has to be removed from the building site.
[0061] The manner by which the system hereof applies the processes, machines, articles of manufacture and compositions of matter will become apparent in the description which follows, particularly when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0062] [0062]FIG. 1 is an exploded perspective view of a partial, two a story cementitious dwelling constructed in accordance with the teachings of this invention, showing specifically a first floor construction, with portions removed, a second floor with a partial roof to override the first floor, and a partial roof section to override the remainder of the first floor.
[0063] [0063]FIG. 2A is a partial perspective view of a wall, with a door and a window opening, using in section, a base block and mini-wall block combination, top block/beam and optional curved block wall, showing architecturally finished coordinated seam system that enables thin coatings previously considered insufficient.
[0064] [0064]FIG. 2B is a continuing partial perspective view of a wall, with a door and a window opening, omitting base block and mini-wall block and substituting them with a wall block and big base block showing architecturally finished coordinated seam system revealing a sloped and architecturally finished crown block on top.
[0065] [0065]FIG. 2C is a continuing partial perspective view of a wall, using a second story on floor panels, with a door and a window opening, substituting top block with top beam over openings and omitting wall block and substituting full wall blocks, with architectural features added after installment.
[0066] FIGS. 2 BB- 1 & 2 are two partial perspective views of wall blocks that are routed with a vertical chase and shaped edges, where FIG. 2BB- 1 is an example of architectural design routed on face by tools of invention.
[0067] [0067]FIG. 2CC is a partial perspective view of an elongated, vertically oriented casing block, showing incorporated utility chase and a curved insert to facilitate pulling/fishing electrical wiring or cable through the blocks. It is adjoining a finished wall block.
[0068] [0068]FIG. 2D is a partial perspective view of a top block which dimensionally compliments wall block to allow precise height dimension for doors and window openings, showing the invention's casing and utility channel as well as industry standard slot for reinforcing.
[0069] [0069]FIG. 2DD is top block beam that combines functions of a header for openings and a bond beam for wall and can house utility channel and invention's enclosed, insulated duct system.
[0070] [0070]FIG. 2E is a partial perspective crown block, having crown molding, showing a tapered top wall with a longitudinal slot and crown block used as floor support system.
[0071] [0071]FIG. 2F are two views, perspective and plan, showing a special molded plastic insert to convert a utility chase into a multi-chamber chase.
[0072] [0072]FIGS. 2G and 2H are several views illustrating curved AAC blocks and manufacturing procedures, along with exemplary shapes for said curved blocks.
[0073] [0073]FIGS. 2I and 2J are a series of views showing a preferred manner of providing temperature transfer within an AAC dwelling.
[0074] [0074]FIG. 2K is a view of inserts to form a temperature transfer system.
[0075] [0075]FIGS. 3A through 3I are different views illustrating various aspects of a roofing beam support system according to this invention.
[0076] [0076]FIGS. 4A through 4D are different views illustrating various aspects of this invention's water proofing system, and gutter/down spout system, as applied to roof and invention's moisture removal system.
[0077] [0077]FIGS. 4F through 4H are views illustrating the waste-free roof panel system according to the present invention.
[0078] [0078]FIGS. 5A and 5B are two views showing further this invention's panel bond beam system. invention's panel bond beam system.
[0079] [0079]FIG. 5C is a cross sectional view of a wall detail showing invention's panel bond beam in conjunction with invention's wall block and top beam with duct system, routed with casing block design for spanning opening.
[0080] [0080]FIG. 6 is a partial side view illustrating invention's corbel bond beam system which allows floor and roof panels to be secured directly to a cured cementitious mid wall sections.
[0081] [0081]FIGS. 7A through 7D are different views illustrating a preferred auger screw, “R” screw for securing AAC materials according to this invention.
[0082] [0082]FIG. 7AA is an exploded perspective view illustrating a preferred hollow bar, a hybrid of a unique screw and flange bar which replaces standard rebar, and selected tools used to cut, crimp and create serrated ends in hollow bar.
[0083] FIGS. 7 AAA through 7 CCC are different views illustrating a preferred flange bar, showing a modified rebar as used in fastening and holding pieces in position until grout can be added.
[0084] [0084]FIGS. 7E and 7F illustrate fastening devices for installing panels onto wood and steel roofs supports.
[0085] [0085]FIGS. 8A through 8D are various views illustrating a dual functioning screw for attaching items to AAC materials.
[0086] [0086]FIGS. 9A through 9C are selected views of an AAC stair case assembly.
[0087] [0087]FIG. 10 is a top view of an improved firewall with opening and door.
[0088] [0088]FIGS. 11A through 11D are various views of routing tools, such as a hand held utility chase cutting tool.
[0089] [0089]FIGS. 12A through 12C are various views of a tool for inserting wires into utility channel and fastening in place.
[0090] [0090]FIGS. 13A through 13C are various views of a duct system for manufacturing structures according to the invention hereof, including architecturally finished seam system.
[0091] [0091]FIG. 14 is a perspective view of a pair of AAC crushing rollers members for converting and transforming the AAC waste into a suitable fertilizing base for trees, soil conditioner, and the like.
[0092] [0092]FIG. 15 is a side view of a joint cleaner for removing and smoothing excess grout from a seam.
[0093] [0093]FIG. 15A is a perspective view of the joint cleaner of FIG. 15.
[0094] [0094]FIG. 16 is a partial side view of a double edge cutting blade for creating openings in AAC walls.
[0095] [0095]FIG. 16A is a perspective of a portable cutting tool using the double cutting blade of FIG. 16.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0096] The present invention relates to a system for manufacturing structures and habitats of cementitious materials, more particularly by the use of an autoclaved aerated concrete. The invention will now be described with regard to the several Figures, where like reference numerals represent like components or features throughout the various views. Though the invention has applicability to a variety of cementitious materials, the further description, for convenience, will be restricted to the use of autoclaved aerated cementitious (AAC) materials. Turning now to the several Figures, FIG. 1 is a perspective view of an AAC constructed structure 10 according to the techniques of this invention, while FIGS. 2A to 2 C illustrate sections of structure wall blocks 200 A and 200 B.
[0097] AAC blocks are typically formed by first preparing a slurry of the AAC mixture and placing same into current industry standard, large mold measuring approximately 4′ wide by 24″ deep and 20′ long. After the slurry sets, the form may be lifted out of the tray and cut into the desired sizes. Industry standard panels are always steel reinforced and sized 2′ wide by +/−8″ thick and when used for walls are +8′ long (for vertical height). Most blocks are usually 8″ wide by 8″ tall×24″ long with only one USA plant manufacturing a jumbo block of 2′×4′×8″.
[0098] The system hereof shows manufacturing modifications of 8″×16″ for top block, which is coordinated with wall block of industry standard 2′×4′ but new dimensional length of 82″ which requires modifying mold length by additional 6″, from the prior art, so three lengths of 82″ wall block as well as coordinated casing block can be manufactured without waste. Accordingly, one preferred size is wall block 200 B having an elongated dimension of standard pre-hung doors with only jambs to slip flush into invention's casing block system so that no additional wood trim is required or customizing blocks at site. Further, through the use of the large blocks 241 , and the unique and precise manufacturing techniques, it is now possible to construct a habitat with the architecturally finished structural components. That is, the blocks 12 have specifically located architectural finish along the edges of faces that will be abutting at joints of the blocks and hides the seams and surface deflection. This eliminates the need for extra surface finish, wood molding, other material or labor. The finish need only be a paint or a superficial layer of smooth stucco, as known in the art.
[0099] As illustrated in FIGS. 1 and 2A, the system hereof is amenable to the use of curved wall sections 205 . FIGS. 2G and 2H illustrate techniques for manufacturing the curved wall sections 205 . That is, alternative curved blocks 205 are manufactured by wires, as known in the industry, but modified by being connected to a computerized, mechanical arm which cuts AAC as pattern and arrows as illustrated. There are presently no curved blocks being manufactured anywhere in the world to the knowledge of Applicant.
[0100] For more frigid climate construction applications, reference is made to FIGS. 2I and 2J, showing the invention's temperature transfer system. The manufacturing of transfer channels 54 is unique in that the tubes 251 inserted into the pan mold 250 are two conical tubes with threaded ends 255 , one male and one female, which after curing are separated by tool 253 which is inserted into larger end and engages indentations 252 and is twisted to unscrew tubes. Optional flange 254 on female conical tube holds it stationary while male tube is first unscrewed and withdrawn. The purpose for tool and conical shape is ability to ease withdrawing longer sections of pipe from cementitious material, as tool employs fulcrum to initially break tube free and then conical shape allows for no resistance as withdrawn. This now allows for extremely long voids/channels to be easily created. Also ends the need for coring of individual blocks as is currently done since blocks cut with void suffice.
[0101] The temperature transfer system of this invention allows for excess heat, usually wasted and/or lost, to be realized and circulated 58 via air channels 54 throughout exterior walls 200 A and panels 40 of habitat. System can employ a geothermal 56 and solar 55 storage tank 52 .
[0102] After the cementitious materials are prepared, construction can begin. Initially a superior concrete foundation, or footer with slab is poured, as known in the art, to present a base for receiving the AAC blocks. The blue prints, as known in the art, are measured and laid out on floor by a qualified individual. Correct designations are marked on floor for openings, block type, location of outlets, etc. From this point a small crews of four unskilled workers using a level, trowel and drill can construct a quality habitat in half the time of a comparable “stick built.”
[0103] A first step in constructing invention is the wall system, FIGS. 2A through 2C. The process comprises selecting a discontinuous first course of elongated AAC base blocks (FIG. 2A) for placement on a pre-built foundation. A base block 201 is one solid structural finished component that is load bearing, utility receiving, architecturally finished and uniquely dimensionally processed. The respective +/−10″ tall×+/−9″ wide blocks are oriented with a longitudinal slot, called a utility channel 202 , see also FIG. 2I, exposed along the upper surfaces or/and along the vertical face thereof, into which utilities 217 , 216 , 123 , 124 are inserted and later covered by subsequent course and/or preformed, dimensional type of cementitious board 229 which fits perfectly between notch 225 at the base and start of architectural finish 208 so that there is no seam and it becomes integral part of design.
[0104] Alternatively, the base block 201 may be omitted and the mini-wall blocks 200 A substituted with wall blocks 200 B, see FIG. 2B. Wall blocks have a custom notch design near base 202 (FIG. 5B) that is covered by flooring and/or optional baseboard. Another alternative (FIG. 2C) may be the omission of casing blocks and instead, wall blocks 200 B are architecturally routed, including utility chase. All blocks work with the present invention's utility channel system.
[0105] Whatever block process is used, the blocks are cemented into place and leveled, except where door openings 212 are located. Initial leveling is critical as all subsequent courses of blocks can be laid directly on the base course without further delay as subsequent leveling since AAC blocks are dimensionally accurate.
[0106] Continuing description using base block 201 , as apparent, the purpose of the slot, as best seen in FIG. 5A, is to receive utilities, i.e. electrical wiring. After utilities and all inserts, etc. are placed in the utility channel 202 , then a thin cover composed of plastic or paper may be placed over utility channel 202 opening to prevent special AAC mortar 19 from falling into utility channel 202 when constructing subsequent blocks and panels, as mortar would obstruct future installments of utilities which can be pulled/fished. Additional utilities can be placed on top of the base block 202 which are accepted into the utility channel 202 in base of second course 200 . The base blocks 201 are +/−10″ high and +/−1″ wider than mini-wall blocks 200 A and have architectural base board finish 208 which recesses and reduces base block to width of subsequent mini-wall block 200 A. The base block 201 also has optional variably sized recessed notch 225 at base for overlapping the flooring. Reference numerals 208 & 225 create the invention's unique attribute of being architecturally and functionally equivalent to a baseboard; so even while housing utilities, it is structural and functional as well as having ornamental finish.
[0107] Outlets 216 may be located into the base block 201 by cutting opening using special rotor plunging tool and template guide. Outlet boxes, etc., fit exactly into opening formed by template guide and are fastened into place, preferably using a proprietary nail screw as illustrated in FIGS. 8A through 8D.
[0108] Thereafter, a method of vertically orienting and cementing comparably designed, plural mini-wall blocks 200 A onto at least certain of the first course of blocks, where the height of each block is a multiple of a nominal dimension of “X”, where a typical miniwall block is 6′, and “X” equals 2′. Mini-wall blocks 200 A are preferably 72″ high, do not require wire reinforcing as does standard wall panels that have manufacturing difficulties and additional costs, but have advantages of panels in quick installation and can be routed, see FIGS. 2 BB- 1 & 2 BB- 2 . Mini-wall blocks 200 A can have utility chase system 202 integrated into ends and sides to form horizontal and vertical utility channels.
[0109] Alternatively to mini-wall blocks mounted on base blocks is a method of employing wall blocks 200 B, FIGS. 2A & B. Wall blocks are +/−6′-10″ tall so top equals height of standard door with frame. Wall blocks which have hidden utility channel machined into bottom, FIG. 5C. Additionally, specially designed tools are able to architecturally finish wall blocks 200 B with casing design and utility channel allowing for omission of casing blocks.
[0110] In any case, thereafter, plural elongated casing blocks 203 , FIG. 2CC, preferably the height of wall blocks, are vertically oriented around the first horizontal course where openings 212 for doors and windows are to be placed. Invention's casing blocks 203 , FIG. 2CC, are used for window and door openings and are structural, integral components of wall which have architectural finish 208 and can have a utility channel 202 . Electrical switch boxes 216 can be located in casing blocks 203 at door openings and are constructed similarly to outlet boxes 203 in base blocks. The slots for the utility channel are of such a width that when windows and doors are installed their frames conceal slots and only caulk or shoe mold is required to finish. The top beam has casing block's architectural finish where openings are located.
[0111] Casing blocks have vertical and horizontal “X” factors. Vertically, the same dimensional vertical “X” equals wall blocks 200 A & 200 B, so their top heights are level. This level height is optimized at +/−6′-10″ to match rough opening for doors and windows. Horizontally, casing blocks are “X” equals 2′ or 1′, so that either 17+/−″ wide for full size openings (ex: 36″ (3′-0″ door)+ 2 +/−″ (¾″+¾″ frames & gap), +34″+/−(two 17″ Casing Blocks)=1′ center), or 14″ for half size openings (ex: 30″ (2′-6″ door)+2+/−″ (¾″+¾″ frames & gap), +28″+/− (two 14″ Casing Blocks)=1′ center). The walls are constructed on 1′ centers with minimal waste. By disciplining design using matching units a wall can be constructed without having to cut 2′ wide wall blocks. Doors and windows with ¾″ jambs can slide under subsequent course and into opening, requiring nothing else to flush finish other than trim or caulk, as the architectural finish 208 on blocks blend into door and window frames and become one architectural unit when painted. Conventional finishes have architectural finish added onto wall and so protrude away from wall, while present invention has finish recessing into structural walls as walls are thick enough to use the invention's time and material saving process.
[0112] A simplified wall process is for the tools, see FIGS. 11A through 11D, hereof to architecturally finish 243 wall blocks FIG. 2C, at openings and create utility channel 202 so that a casing block is not required, as wall block has features of casing block machined into it. The width of opening is flexible so that only top block/beam 206 acting as header spans or big base block 241 , see FIG. 2B, used under window are cut to fit. Big base blocks 241 are basically wall blocks turned horizontally so all window openings can have standard height from floor of 24″ and variable width. This is preferred method of all options.
[0113] Where the utility channel 202 intersects with other blocks or changes angles, in a preferred embodiment, a curved insert 214 , FIG. 2A, sized to be slidably placed into the longitudinal slots 202 , may be placed into perpendicularly converging utility slots to provide a continuous curved path for easy wiring of the erected structure in future after direct access is closed off. By this arrangement, and with pre-positioned openings extending to the inside from the longitudinal slots, the entire structure may be suitably wired with recessed utility boxes to present a wall surface suitable for finishing.
[0114] Where architectural finishes 208 for casing blocks 203 and top block/beam 206 B meet, an architectural insert 213 is placed to cover incompatible intersection, see FIG. 2B.
[0115] Top block beams 206 , FIG. 2D, are placed as a horizontally oriented course of comparably designed AAC blocks, where the longitudinal slots 202 over the openings, such as doors and window openings, and casing finish 208 are exposed downwardly toward the opening. An optional architectural finish 208 can give a crown molding appearance to top block where floor panel 59 , FIG. 5A, will rest on top block 206 . Top block are preferably manufactured as beams and have enclosed air duct system and reinforcing channel that coordinates with roofs beam system.
[0116] Thereafter, the top most course of wall, comprised of invention's +/−16″ top block beam 206 , is placed on wall blocks 200 A, 200 B, not 200 C, and/or casing blocks 203 . Top block can have variation of architectural finish 208 as casing blocks for windows and doors, as well as continuous design to equal crown molding, which allows for one structural component, top block, to replace four standard pieces: header, filler, casing and crown. Additionally, top block is of specific dimension so that base block, mini-wall block and top block form a minimum 8′ high wall. A unique feature of this invention is the provision of an effective method to construct a dwelling using primarily precut and sized blocks of cementitious material. By the use of such cementitious blocks containing specific dimensions unique to this invention process and not in prior art, an 8′ high wall can be constructed using only two blocks (or three if using base block) which blocks have specific, unique design and functions beyond just dimensional advantage. Blocks are additionally modified with predetermined slots and openings termed utility chase system for utilities, i.e. electrical wiring, plumbing, etc., facilitating construction of habitat.
[0117] Further, also employing tools for finished architectural routing for either the base block, casing, features for openings, and/or crown block, smooth finished walls are transformed into architectural finished walls with no additional materials.
[0118] For rounded walls and/or corners, if desired, one may employ arch shaped rounded blocks 205 , where the rounded shapes of such blocks may be accomplished by inserting rounded mold (FIG. 2G) into an industry standard AAC pan. Alternatively, a computerized mechanical arm may run wires through cementitious material (FIGS. 2H) in a unique pattern producing curved blocks with very little waste, and which waste is able to be recycled as it is still in green stage before autoclaving. This finishes wall construction processes.
[0119] The corbel bond beam system (FIG. 6A) is the system's approach to attach floor and roof panels directly into the mid wall section surface instead of on top of walls that requires a great deal more construction effort and material. The corbel slot is formed at manufacturing or on-site field routed using the proprietary tools according to this invention, see FIG. 11A, with different bit. The corbel bond beam 60 , which is reinforced with rebar 35 , is set into the slot with mortar and fastened with the proprietary screw 70 , note FIGS. 7 A through 7 AAA, or the invention's alternatives, which engage rebar reinforcing.
[0120] When there are multiple floors, floor panels can be placed directly on top of first level wall top block/beam (FIG. 5A) with panel end flush to exterior wall. Floor panels, according to this invention, may use invention's bond beam slot 50 and proprietary auger screws 70 to effectively replace several steps of prior methodology. In prior art systems, a bond beam was to first drill vertical holes into top of wall, then short sections of rebar were mortared into holes, and thereafter a long, horizontal rebar was tied off to vertical rebar. This necessitated a space between end of floor panel and a block placed flush to exterior face of wall. The bond beam was formed in the gap between panel end and wall block using rebar and mortar. This method required additional material, labor and days of curing time before subsequent floors could be constructed. The present invention eliminates several steps and materials and allows construction to continue uninterrupted.
[0121] Floor panels 59 , see FIG. 5B, hereof have unique bond beam slot 50 achieved by manufacturing AAC similarly to roof panels for a proprietary gutter system, see FIGS. 4A through 4D, where upper course(s) of steel reinforcing 52 stops short of panel end than other layers so slot can be routed and bit not hit reinforcing steel. Rebar 35 is horizontally laid in bond beam slot 50 and tied to screws 70 and then bond beam slot is filled with mortar 19 as base block 201 , which is the first course of next wall, is laid.
[0122] An alternative floor support system is illustrated in FIG. 5B for a crown block 207 B to be placed into wall during construction to support floor system. This invention's method allows for wall construction to continue until all walls are constructed before floors and roof panels are installed. When floor panels are installed, the gap between end of floor panel and wall is filled halfway with rebar 35 and mortar 19 and becomes bond beam. The upper half of gap is left a void and becomes a utility channel 202 for wires 217 and other utilities to be inserted. Outlets 216 are placed in floor panel using invention's method in area void of reinforcing. Finish floor covers uniquely located utility channel or small gap that can be filled with additional mortar.
[0123] Where stairs are employed to travel between floors, the invention's stair system is employed as shown in FIGS. 9A through 9C which are partial views of stairs made entirely of AAC. There is no prior art of cementitious stairs being supported only at ends and reinforced by adjoining steps. All prior art uses either steel reinforcing throughout or supports in middle of stair, which extends to ground along total run of stairs.
[0124] The invention's stair system uses cementitious blocks 90 which have an angled slot 91 that corresponds to the desired pitch of the stairs. The angle support brackets 92 are secured to the wall at the desired pitch of stairs, which pitch corresponds to slot 91 in cementitious block. Blocks are simply slipped onto support bracket at top of stairs in gap, see FIG. 9B, reference numeral 93 , between brace and floor and then slid down and mortar 19 to secure onto top of previous block. Optionally, a screw 70 can be used for additional fastening. The angle iron 92 with special slot 91 makes a permanent structural unit. Mortar placed on ends of stairs additionally bonds stairs to AAC walls. Face of cementitious AAC blocks can be routed to have a tread 94 and/or other architectural advantages. The advantages allow for additional safety of fire proof stairs cases which are devoid of squeaking.
[0125] Thereafter, if there is not to be an additional floor, on the top most course of wall comprised of top block, a crown block 207 , FIG. 2A, featuring a sloped top wall 228 is cemented to the top course. The slope is comparable to the roof slope so that the roof panels may be supported thereon and secured by suitable fastening means. FIG. 4B further shows a tapered crown block 207 secured to the top of the wall for mounting a roof panel ( 40 ) and roof support members. The crown block has a slope equal to the roof panel pitch and is manufactured by taking a standard base block width and cutting in half so that mirror sides equal slope pitch of roof. The interior face is routed to resemble crown molding. The result of this inventive technique is a single structural piece of cementitious material that has architectural attributes of finished wood trim and is used to bond pitched roof panels to flat walls. Crown blocks with a level top, instead of angled to the roof pitch, can also be used to add height and design features to any wall.
[0126] The roof is constructed by first securing AAC roof panels 40 to the roof support beam system, beams 30 , 31 , 32 , where a typical roof has a plurality of beams arranged in specific load and stress managing pattern.
[0127] The construction method may be continued by positioning the invention's support beam system, see FIGS. 3 A- 3 F, on walls. The cementitious beams are comprised solely of cementitious material with steel reinforcing, and optionally can have invention's reinforcing channel 36 , see FIG. 3F. Support beams require only mortar and fasteners as unique interlocking design, FIGS. 3C & 3D, eliminates need for interlocking brackets, bolts, or other mechanisms. All types of roof pitches and designs, including hip and valley, FIG. 3A, are now possible for a purely cementitious roof and support system.
[0128] The supporting beam system with reinforcing channel 36 is constructed by placing rebar into channel (and utilities), tying all rebar together, which can include rebar coming from foundation/slab, then drilling holes into beam and pouring mortar into beams 38 , FIG. 3F, so that incredibly strong support beams result. The invention allows for AAC surrounding hard concrete reinforcing channels to receive fasteners 70 and so secure roof panels to supporting beam system. Invention's roof system requires no brackets, braces, bolts, etc., as does all prior art. At most what may be required are tension tie rods for certain hip roof designs to give walls extra support.
[0129] The construction process is continued by placing roof panels 40 , see FIGS. 3E and 3F, on supporting beam system. When a roof is resting on standard 8 ′ wall instead of a second floor FIG. 4B, then a fourth level of blocks comprised of crown block 207 can be used. As best seen in FIG. 4B, a series of crown blocks 207 , preferably eight (8) inches in height, are cemented to the planar surface 229 , where the crown block 207 features a slanted upper surface 228 for receiving an angled roof panel 40 . The panel 40 may be secured to the crown block 207 by invention screws 70 , as shown in FIG. 7A, and mortar 19 as known in the art, on planner surface. Crown blocks, FIG. 2E, can also be structural for openings with cavity 227 being filled with rebar and cement.
[0130] The beam system utilizes the invention's optional reinforcing channels 36 , FIG. 3F, which can be used in addition to standard reinforcing to facilitate easy construction and provides even stronger support due to internal bond beam/utility channel tying together the entire habitat. Beams can have a squared edge corrugated pipe 36 inserted into the AAC mold during manufacturing. The AAC fits between the square corrugation in pipe and holds fast and is strong enough to remain intact during initial construction. The hollow corrugated pipe ( 36 ) at site has rebar 35 placed inside, as well as any utility conduits 26 desired, which conduits can be accessed for lights, etc.
[0131] Roof beams are erected and fastened so that the hollow core formed by corrugated pipe, which is termed reinforcing channel 36 , align each other at intersection/joint of beams. After beams are joined together and set with proprietary screws 70 , the AAC mortar is pumped throughout the reinforcing channel system 36 resulting in an incredibly strong beam system that ties the entire structure together. This reinforcing channel system also allows invention screws to fasten roof panels into the softer AAC portion of the beam. Optionally, FIG. 3H, a standard concrete beam 19 can be constructed and then an AAC beam 30 adhered with mortar to top of concrete beam so result is a dual material beam which has softer cement for fasteners on top and harder, reinforced concrete on bottom. The concrete beams can be constructed and poured at site with foundations.
[0132] While any type of pipe can make reinforcing channel, the reasons for using optional corrugated pipe or corrugated, helical conical mold insert 255 (FIG. 2K) which unscrews from mold, are: 1) the corrugation gives extra surface strength and adds additional strength to reinforcing channel when filled with concrete as two cementitious materials bind against each other; 2) the corrugation prevents AAC outside and cement inside from separating from pipe during stress flexing; and 3) the corrugated pipe allows mortar to flow throughout entire system as AAC is known to absorb moisture so quickly that if system had only exposed AAC the mortar may quickly adhere to channel walls, possibly clogging channel and thus prevent mortar from reinforcing certain areas.
[0133] The roof panel system is then fastened to the beam system. The teaching of the present invention's waste-free system is illustrated, in part, in FIG. 4E. This simplifies construction by manufacturing a standard length precast cementitious panel for the entire roof system. Once the length is determined, the parts (A), (B), (C), and (D) are simply cut off site and delivered and installed in a manner which emulates contemporary roof lines without waste. The cut angles of 30° and 60° (FIG. 4G) are turned to meet each other, i.e. (A) to (A) through (D) to (D). When laid at a 45° angle incline, FIG. 4H, or as known in the art “{fraction (12/12)}” pitch, and installed on the invention's teachings of the beam system, FIG. 3A, it creates a perfectly mirrored hip or valley, FIG. 14F. The roof layout, FIG. 4E, becomes simplified and cost effective with zero-waste. Also, what is lost as just uninhabitable attic space under typical roof constructions becomes finished living area, FIG. 4H, by the teachings of this invention.
[0134] The roof panel system is then fastened to the beam system and roof panels waterproofed. The roof design is identical for both sections A and B of invention's roof waterproofing system (FIG. 4A). Section A is a perspective of a finished stage using a different water proofing material 47 than Section B's segment which is shown at an initial stage in its construction using the technology hereof. It is important to note that the invention's water proofing system for roof panels is of four distinct processes/features, namely: 1) water proof coating 47 &/or 41 ; 2) the facia water deflection system 45 ; 3) integrated gutter system 44 ; and, 4) gutter box 48 which replaces down spouts. The gutter box 48 comprises a generally rectangular housing portion 61 , see FIG. 4D, having at least one wall opening 62 for receiving water overflow from the angled gutter slot 63 , a tapered lower wall 64 , and a pair of outer walls 65 that feature water outflow slots 66 at the bottom of said outer walls 65 , note the water flow arrows. The roofs water proofing system is constructed as follows:
[0135] [0135]FIG. 4A, section A, 47 is a composition of matter for a roofing material, having the following characteristics: waterproof, climate durable, chemical resistant, vapor permeable (“breathes”,) high modulus of elasticity (stretchable), durable (10+ year use expectancy), can be continuously re-coated so no waste material has to go to landfills, can be tinted for various colors, and bonds well to AAC. It is simply applied by spray or roller.
[0136] [0136]FIG. 4A, section B, as a preferred system, incorporates a polyester/nylon mesh 42 , having alternate sections of a tight mesh 43 and a loose mesh, and is placed over the AAC panels in the direction of the ridge down to the eaves. Next, an elastomeric composition 41 is applied to the mesh, and, as a result of the porosity of the loose mesh, the elastomeric composition goes through the loose mesh and adheres to the AAC panels. However, the elastomeric material will not go through the tight mesh 43 such that an air channel 47 is created between the tight mesh 43 and the AAC panels 40 . Further, another coat of the elastomeric material 41 may be applied for extra wear resistance. The respective air channels 47 allow moisture in the AAC panels to escape, i.e. breathe. Additionally, the air channels 47 also function as air is drawn up through the channels from the eaves end of roof to the top ridge vent 48 by use of naturally occurring temperature and wind where it may be vented 48 to the atmosphere.
[0137] The integrated gutter system of this invention uses industry standard AAC roof panels with a modification in steel reinforcing. Since gutters (FIGS. 4A and 4B) 44 , may be routed out of the roof panel 40 , the top rows of embedded reinforcing rods 52 , see FIG. 4B, extend short of the edge similar to bond beam panels (FIG. 5B). There is no need for all the structural reinforcing at the gutter location as AAC is strong enough by itself An angled routed groove 44 may be added to the AAC panels to transmit moisture out of the roof assembly and act as an integrated gutter system to gutter box 46 hereof. No prior art of cementitious materials with integrated gutter systems employ a gravity driven water removal method. All prior art relies on inferior water pressure method as subsequent water forces previous water toward down spout box and off the roof. The prior art's use of water pressure has negative results of residual moisture remaining in trough which eventually causes water damage due to debris build up and/or freezing. Invention's down spout box 46 , FIG. 4D, disperses moisture out and away from habitat by curved wall and wide slot at base. The interior ridges and various platform heights of curved wall near slot break up the mass of water into smaller droplets so as it is propelled out of box large volumes of water do not overburden any one area too much.
[0138] Finally, the facia water deflection system 45 is one and the same material as the roofing and is one continuous niece of roofing material, specifically shaped to have reversing angles with a series of sharp angles so it is impossible for water coming off the roof to run down its face, but rather gravity pulls water off its face at several different places, which not only deflects water away from house but also breaks water down into smaller droplets so it does not damage landscaping beneath. Therefore, facia design is not just a cosmetic architectural feature, it is an unique functioning aspect of the roofs waterproofing and moisture removal system much different than existing plumb facia boards and molding which recess with angles but not reversing angles. An integral functioning process advantage of the finished ends of the roof panels lies in its water deflection that is multifaceted. The reversed angle routed end makes it impossible for excess moisture from the roof to run down face of the panel end/roof facia. This overcomes two failures of the prior art, namely: 1) moisture carrying naturally occurring debris running down vertical facia causes unsightly streaks; and 2) moisture running down facia is easily blown back toward habitat. By means of the instant invention, the need for additional labor and material of drip edge is avoided, while adding unique architectural enhancement to the habitat.
[0139] Therefore, the present invention's roof panel design and process of moisture removal system is comprised of a single cementitious material identical to the roof and is actually roof material itself and thus an indivisible component of roof consisting of two distinct components: 1) a downwardly angled trough 44 which feeds moisture to a down spout or the down spout box of this invention; and 2) a facia 45 with square edges and upward, reverse angle pitches having a multi faced formed edge of cementitious roof. This roof system is then coated with either of the two water-proofing materials 47 , or 41 . Both moisture removal attributes are part of the present invention's roofing system and work in conjunction with each other as one moisture removal system.
[0140] Doors are possible with AAC, as seen in FIG. 10, so that even four hour rated fire wall 204 may be possible with an operating door 100 which is composed of AAC. The door face can have all types of architectural or decorative effects as a standard wood door. The wall is composed of standard wall blocks 200 A, 200 B but uses casing blocks 203 having custom fire thwarting design and latch system 101 . The door can be held in place by special heat resistant piano type hinge 103 or the internal hinge 104 hereof, which has special sliding hinge pin so all mechanical parts are protected within fire proof AAC.
[0141] Now that the individual embodiments of materials and structure of habitat are understood, what needs to be explained is the preferred fasteners and tools of this inventive system. The auger screw (FIGS. 7 - 7 C) is a preferred method of securing, not just to fasten, but to actually bond AAC together. The screw 70 acts as an auger screw and gets its name from the fact it provides more structural advantages than standard rebar but does so with the ease of a screw, especially as screw engages any steel reinforcing in the panels and elsewhere. As noted above, a fastener 70 can be used to secure a roof beam 30 and/or panel 40 to the crown block 207 .
[0142] One difficulty is that prior art fasteners, such as the Helifix, can work free over time without mortar holding pieces fast, consequently if mortar in joints ever failed then system is in jeopardy. Also, the Helifix is inadequate in size to secure large, heavy pieces of cementitious material, and due to need for cement to assist bonding, simply increasing size does not solve its design inadequacies. To improve the fastening capabilities of AAC materials, such as the roof beam to the crown block, a new and unique fastener had to be developed.
[0143] Though different, U.S. Pat. No. 5,143,498, to Wiftman, and granted Sep. 1, 1992, teaches a rubber roofing material fastening device that includes an optional liquid sealer to facilitate the process of affixing roof items to the upper surface of a roof The fastening device has a longitudinally extending centrally located chamber that is coaxially aligned with the longitudinal central axis of the fastening device. The chamber has a plurality of laterally disposed openings that extend from the chamber to the outer surface of the fastening device. The chamber is adapted to receive a liquid sealant at an opening in the upper surface and disperse same through such lateral openings. The exterior surface of the screw shaft is formed with screw threads having a dual set of helically wound, threaded members. The external, most radially outer portions of the threads are grooved with serrated teeth to enhance the holding power of the fastening device.
[0144] The screw fastener member 70 , FIGS. 7 - 7 C, of this invention is comprised of a solid core 71 , preferably “hour glass” in shape, within an annular wall 72 to define three elongated cavities, one passing through the center to each side, and two opposite each other on outer sides separated by the center cavity. The three elongated cavities create two functioning processes with the two cavities opposite each other performing the same process, namely, the center cavity is a mortar chamber 73 and the side cavities are dust chambers 74 . Along the annular wall there are provided plural openings 75 in communication with the mortar chambers. Additionally, there are provided plural openings on the annular wall and in pointed end 78 in communication with the dust chambers with at least one cut-out window having a scraper blade 76 , which is a portion of the cut-out of the wall extending tangentially from the annular wall 72 . In operation, the dust chambers 74 captures AAC dust created by scraper 76 , as well as through opening in pointed end 78 . The scrapers 76 serve two functions: 1) to enlarge hole area around shaft 72 so that an air space is created between the AAC and shaft 72 , which space will be filled with mortar flowing out of mortar chamber 73 via opening 75 ; and, 2) remove from the enlarged hole all lose AAC dust so that mortar flowing out of mortar chamber 73 has a good surface for bonding. The head portion 77 removably receiving a square head power screw driver as an air ratchet, which square opening is an opening through to the mortar chamber and through which mortar is poured into cavity after driver bit has placed screw member 70 .
[0145] Additionally, at head 77 is the termination of helical thread arrangement 79 at an open slot 77 A so that the entire screw can be counter sunk into AAC. Finally, exterior of the shank 72 , from the head portion 77 to the opening, is pointed at one end 78 , and includes said large angled helical screw arrangement 79 with wide threads. It will be seen that this is in sharp contrast to the very shallow angle and narrowness of the helical threads of a conventional screw. The design of thread of this invention is unique to its application for maximum hold with least negative torque influence thereon, and damage to the AAC. The result of the invention is a screw which has all the advantages, and more, of rebar but can be installed in one easy step directly through numerous pieces of AAC and secures in place each piece of AAC, regardless of where AAC is located, i.e., slope, angle, etc. which before this invention was not possible.
[0146] Alternative fastening inventions are the hollow bar (FIG. 7AA) and flange bar (FIG. 7AAA). The hollow bar has a dust chamber 74 within annular wall 72 with advantage of provided plural cut-out windows having a scraper blade 76 , which is a portion of the cut-out of the wall extending tangentially from the annular wall 72 . In operation, the dust chambers 74 captures AAC dust created by scraper 76 , as well as through opening in pointed end 78 . The scrapers 76 serve two functions: 1) to enlarge hole area around shaft 72 so that an air space is created between the AAC and shaft 72 , which space will be filled with mortar being poured into gap around exterior of shaft at entrance to hole; and, 2) remove from the enlarged hole all lose AAC dust so that mortar has a good surface for bonding. The design of thread of this invention is unique to its application for maximum hold with least negative torque influence thereon, and damage to the AAC and the gaps 705 in thread are for purpose of allowing mortar poured into opening created by flanges to flow continuously down between screw wall and AAC and around threads sections. The result of the invention is a screw which has all the advantages, and more, of “R” screw, but can be manufactured for less cost and be custom cut at site to variable lengths as thread gap 705 and opening pattern repeats itself.
[0147] The crimping tool for cutting and forming hollow bar has multiple blades which form functions of: 1) crimping tube which helps hollow bar enter AAC and grind it, 2) cut it, and 3) form teeth out of cut end for two functions: 3A) on end entering AAC, teeth cut and grind up AAC 706 and feed AAC dust up into dust chamber 74 , and, 3B) end used for driving hollow bar into AAC works as would a normal head on a screw would, as it designed to receive a drill bit and teeth have gaps which can receive a Phillips head screw driver bit and allow hollow bar to be counter sunk. Alternately, the bit fits over the end and tightens onto the tube.
[0148] The flange bar is similar to industry rebar except invention is modified by unique flanges 701 which are positioned and angled 705 to act like screw threads and design of being wider 704 and thicker 703 at bar and then narrowing with receding leading edge 704 and getting thinner towards end 703 provides service of keeping bar centered in hole by resistance of flanges against wall as it is inserted and as flanges bite into walls they bind cementitious pieces together and prevent shifting and/or movement while mortar is added around bar it sets up. It has advantages of inexpensive to manufacture and length being custom cut from long bar on site, but has disadvantage of it requiring pre drilling a hole. The fastener 75 , FIG. 7E, is a screw for installing AAC panels onto a wood or steel rafter system, where the fastener features a pair of concentric shaft portions, with the upper portion having broad helical threads, and lower portion with much smaller helical threads. It has the advantage of using these multipurpose threads which are designed for surface area contact, where the tight or lower threads 725 serve the purpose of starting the fastener into the AAC and then properly imbedding into the wood or steel rafters, FIG. 7F. The upper or loose threads 79 properly hold the AAC without stripping or damaging the AAC, as well as to prevent the fastener from going too far into the AAC, as the axial length of the threads 79 correspond to the thickness of the AAC panels 40 . The fastener has features of AAC gougers 77 B and countersink head 77 A, that facilitates environmentally friendly one coat coverage of roofing material 47 , as taught by the present invention, and replaces conventional heavy roofing shingles, etc., to make this invention possible and practical.
[0149] Another fastening device, the nail screw 80 , shown in partial views in FIGS. 8 - 8 D, has particular utility in securing smaller items to a cementitious material, such as AAC. It can be comprised of a strong, hard plastic instead of steel. It is unique by its ability to be driven into the AAC with a hammer, while further having the ability to be withdrawn by means of a rotational hand tool, i.e., hand or powered screw driver 81 (FIG. 8C). This device overcomes problems of prior art in that it will not easily work free over time and yet is removable using the correct tool without damage the item to be secured and/or AAC. The fastener member 80 hereof is comprised of a triangular threaded 82 elongated shank 82 , with very low number of revolutions around shank and is pointed at one end 85 . The pointed end has openings 83 that aid the “N” screw to grip AAC by gathering and compacting AAC dust that presses against AAC wall. The “N” screw is topped at the opposite end by a head portion, where the head portion includes prongs 84 for piercing AAC to provide additional holding of the screw member 80 in place. On the top side of head is a slot 81 for removably receiving a screw driver head, as known in the art, to remove the screw 80 from location. The design allows for unique multiple applications in the same location that no other fastener with such simple construction provides in AAC. Additionally, the elongated shank can be hollow 85 and a standard finish nail 86 be driven through which explodes the tip 87 and further anchors hammer nail. To remove the hammer nail, one first applies a needle nose pliers to remove the finish set nail 86 and then a screw driver and the screw's threads supply enough torque for AAC wall to force exploded tip to re-close and remove screw 80 from the AAC.
[0150] Turning further to the tools of FIGS. 11 - 11 E, a table 90 (FIG. 11A) is of a block and panel architectural fabricator. The table 90 has router bits 110 , 111 , 112 with the potential for variable positions, and ability for different bits 110 , 112 on each router cutting simultaneously so each side of block, panel and/or beam has desired architectural features, including utility chase 111 as an example in FIG. 11C, reference numerals 201 , 203 and beams 30 , 31 , 32 . FIG. 11D is a partial view of a hand held version cutting a casing block 203 . The most unique aspect of the tools hereof is the ability through combined use of the tools and template system of FIG. 16 to fabricate finished openings for windows and doors in a solid AAC wall.
[0151] A tool used for cutting utility chases into erected walls is illustrated in FIG. 11A, which is a partial top view of a hand held utility chase cutter 192 with the bit 120 which simultaneously cuts a notch (FIG. 2BB) for sheetrock 209 and the chase 203 . It uses the template guide system 160 , 163 hereof (FIG. 11A) as does most of the hand held cutting tools. FIG. 11A shows utility chase 202 with sheetrock 209 installed using screws 80 , covering water supply 123 and waste pipes 124 . The utility chase cutter can be used for vertical as well as horizontal runs. Since the bit protrudes beyond the face of the interior wall, it is able to cut down behind the base block and up behind the crown block. Then a standard drill can cut holes for utilities through floor panel. The chase is covered using a single cut to size a piece of sheetrock. The tools hereof have the capabilities of special dust collecting systems.
[0152] There is very limited waste product of AAC according to the preferred practice of this invention, but what waste there is can be easily handled by systems known in the art. Such systems can crush waste cementitious pieces into dust, so they do not have to be taken to landfills, which means habitats manufactured by the instant invention can be constructed with little or no waste AAC from the site having to go to a landfill, thereby lessening construction costs and providing an environmentally friendly practice. The resulting dust may then be used as fertilizer for grass, etc.
[0153] As blocks of AAC are set in place, excess mortar can be forced out beyond the wall face. To solve this problem FIG. 15 shows a partial perspective of present invention joint finisher 150 . The joint finisher has a unique roller 152 which serves several useful function namely, keeps blade 151 at optimal angle for removing excess AAC mortar from block face at joints and roller smoothes out any residual trace amounts of mortar, and the spring pressured cleaning blade 153 removes AAC which may accumulate on the roller, so that now one movement replaces prior art's several tools and motions.
[0154] The hand held finishing tool shown (FIG. 11D) and may be used with a template guide so that an architecturally finished opening results where there was once just a wall. The window is simply slipped in and caulked and/or finish nailed. No additional wood trim or casing is required. The outlet and switch openings, beam notches, etc. require a different type of template guide having prongs. The guiding arms may be kept perpendicular by level bubble on support arm 160 . In difficult positions, such as a corner notch, an angled template guide is used and, as the rotor zip type tool goes around a guide, a chunk of AAC is removed which allows the beam to seat into wall and be finished with mortar and screw.
[0155] For easing an electrician's job of installing electrical wire (FIG. 12A) into a utility channel, the wire inserting tool 170 has a long, specifically angled bar 170 with ability to slip into utility channel 202 and wheel 175 enables installer to simply walk along while the wire feeding wheel 171 by design aligns and lifts wire onto roof of channel where staple fastener 172 shoots a unique staple 174 which does not easily pull out around wire and into the AAC.
[0156] The internal air duct system 180 of this invention, see FIGS. 13 A- 13 B, can be housed in the top beam 206 A and structural beam system. A PVC type pipe may be placed within the cementitious material (AAC) which benefits the AAC by reducing its weight and simultaneously reinforcing it, and further the AAC is benefits the air duct by insulating it, hiding the duct system to enable easy access for vents 181 . The vents 181 can have various sizes for openings as engineered for facilitating desired air flow, and regulated by vent opening size and proximity to air return vents. The system can be located at a centralized location and initial service ducts run through a chase 184 shared by other main utilities, and then hooked up to the internal duct system. The duct corners 182 , as seen in FIG. 13B, are installed by deep socket, large tubular bit 185 which goes around exterior of air duct 180 , and creates a void 183 . The duct is then cut back at a required depth 166 to align with the duct in the adjoining piece, and the AAC is cleared so that the corner coupling 182 slips into the void and over the duct in the top beam 206 A, and likewise in second top beam 206 A, thereby creating a continuous duct system with rounded corners. A manufacturing process of creating void around the duct is to have an inflatable sleeve 186 (FIG. 2K) placed on the pipe while in the mold before slurry is introduced. After the mold is removed, the sleeve is deflated and removed. At the site, by this embodiment, the AAC is simply cut back as required and duct's corner coupling 182 slipped on.
[0157] There is limited waste product with the AAC according to the preferred practice of this invention, but what waste there is can be easily handled by the machine 140 that can crush waste cementitious pieces 142 into dust 141 , so they do not have to be taken to landfills. This means habitats manufactured by the instant invention can be constructed with little or no waste AAC from the site having to go to a landfill, thereby lessening construction costs and providing an environmentally friendly practice. The resulting dust may then be used as fertilizer 144 for grass, trees, etc.
[0158] As blocks of AAC are set in place, excess mortar can be forced out beyond the wall face. To solve this problem, FIGS. 15 and 15A show a joint finisher 150 according to the invention. The joint finisher 150 has a unique roller 152 which serves several useful functions, namely, keeps blade 151 at an optional angle for removing excess AAC mortar from the block face at joints and the roller smoothes out any residual trace amounts of mortar, while the spring pressured cleaning blade 153 removes AAC which may accumulate on the roller. The result, one tool replaces the prior art's tools and motions.
[0159] The hand held finishing tool shown in FIG. 11D may be used with a template guide so that an architecturally finished opening results where there was once a wall. The window is simply slipped in and caulked and/or finished nailed. No additional wood trim or casing is required. The outlet and switch openings, beam notches, etc. require a different type of template guide having prongs. The guiding arms may be kept perpendicular by level bubble on the support arm 160 . In difficult positions, such as a corner notch, an angled template is used and, as the rotor zip type tool goes around a guide, a chunk of AAC is removed which allows the beam to seat into the wall and be finished with mortar and screw.
[0160] It is recognized that changes, variations and modifications may be made to the method of this invention, and to the securing device, particularly by those skilled in the art, without departing from the spirit and scope thereof Accordingly, no limitation is intended to be imposed thereon except as set forth in the accompanying claims. | This disclosure is a system which includes processes, machines, articles of manufacture and compositions of matter required to construct a habitable structure comprised of a cementitious product, preferably autoclaved aerated concrete (“AAC”), formed in unique blocks, panels and beams. This results in an extremely environmentally friendly habitable dwelling, residential or commercial, which, due to the resultant synergy of embodiments, when compared to a similar structure employing prior art and/or current industry's standard materials and methods of construction, is structurally superior and simultaneously yields substantial savings in labor, time and costs. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a calculation apparatus for patent power utilizing patent history data and an operation method thereof.
BACKGROUND ART
[0002] Conventionally, patent evaluation methods are divided into a monetary evaluation method for calculating value of a patent, and a relative evaluation method used in think-tanks etc.
[0003] Examples of the conventional monetary evaluation methods include DCF method by scoring, Black-Scholes model, cost approach, or market approach. Since these methods are monetary and financial evaluations, they are useful in transferring patents etc, but the qualitative analysis (scoring) tends to be subjective, and when evaluating all patents, it costs enormously.
[0004] Meanwhile, examples of the relative evaluation methods include a statistical evaluation by analyzing the number of owned patents, registration rate, the number of applications and the number of claims etc, and technology evaluation by analyzing terms in application and technology chart etc. Since evaluations in these methods are carried out based on data, they are objective and effective in comparison of technological power with competitors, but it is difficult to determine a causal relationship between evaluation items and business activities (exclusive power of patents). For example, it is known that a company having a large number of patents does not always have earning power.
[0005] In addition, as the patent reference 1, when calculating patent value, market information of a product using the patent including market data, financial data, or marketing data, and rating scores regarding commercialization power, technological power, patent's strength, applicability to today's society and total power, are acquired. Subsequently, a profit creation index of the patent is calculated based on earning power of the product and profit contribution of the patent, thereby acquiring a theoretical price of the patent at the evaluation based on the profit creation index, formative effect of product market based on market scale of the product, risk rate and extensibility of the patent.
[0006] Patent Reference 1: Japanese Unexamined Patent Application Publication No. 2005-174313
DISCLOSURE OF THE INVENTION
Problems that the Invention Tries to Solve
[0007] However, when using the monetary evaluation methods as the patent reference 1, it is necessary to examine the market information and the scope of the respective patents, so that it is difficult to evaluate the patents at once. In addition, in the relative evaluation method, as described above, it is difficult to determine the causal relationship between evaluation items and business activities (exclusive power of patents). Therefore, there are difficulties in evaluation of a group of patents, and a suitable method has not been developed yet. In recent days, intellectual properties account for a large portion of corporate value, so that a standard indicator showing accomplishments of management of the intellectual properties is required. Therefore, the present invention provides the calculation apparatus for patent power according to the evaluation capable of determining the causal relationship between evaluation items and business activities (exclusive power of patents).
Means for Solving the Problems
[0008] The present invention provides the following calculation apparatus for patent power and an operation method thereof.
[0009] Concretely speaking, in an aspect of the present invention, a calculation apparatus for patent power, comprising an acquisition unit for patent history data, acquiring patent history data of an application, an extraction unit for item content, searching for a combination of standard item names indicating legal procedures against the application by pattern matching processing utilizing a preliminarily given pattern, in which the standard item name is described in the acquired patent history data, and extracting the item content described in the patent history data correlated with procedure date in accordance with the retrieved combination of standard item names, a storage for search result, storing the extracted item content and the date correlated with the retrieved combination of standard item names, a storage for cost table, storing a cost table, in which a predetermined cost is correlated with a combination of item contents stored being correlated with the combination of standard item names, a storage for obsolescence function, storing obsolescence functions used as measures of the obsolescence of technique in each technical field, a calculation unit for post-obsolescence cost, acquiring cost with respect to each combination of item contents extracted according to the combination of standard item names of each application by means of the cost table stored in the storage for cost table, and calculating the post-obsolescence cost on a calculation reference date by means of the calculation reference date, the procedure date correlated with the combination of item contents, the filing date of the application, and the obsolescence function of the technical field of the application, a totalizing unit, totalizing the calculated post-obsolescence costs regarding the application, and an output unit, outputting the totalized value acquired by the totalizing unit, is provided.
[0010] In another aspect of the present invention, a method for operating a calculation apparatus for patent power, which comprises a storage for cost table, storing a cost table, in which a predetermined cost is correlated with a combination of item contents, correlated with the combination of standard item names and stored, and a storage for obsolescence function, storing obsolescence functions used as measures of the Obsolescence of technique in each technical field, the method comprising the steps of acquiring patent history data of an application, extraction for item content, searching for a combination of standard item names indicating legal procedures against the application by pattern matching processing utilizing a preliminarily given pattern, in which the standard item name is described in the acquired patent history data, and for extracting the item content described in the patent history data correlated with procedure date in accordance with the retrieved combination of standard item names, storing the extracted item content and the date correlated with the retrieved combination of standard item names, calculation of post-obsolescence cost, acquiring cost with respect to each combination of item contents extracted according to the combination of standard item names of each application by means of the cost table stored in the storage for cost table, and calculating the post-obsolescence cost on a calculation reference date by means of the calculation reference date, the procedure date correlated with the combination of item contents, the filing date of the application, and the obsolescence function of the technical field of the application, totalizing the calculated post-obsolescence costs regarding the application, and outputting the totalized value acquired by the totalizing step, is provided.
Effects of the Invention
[0011] According to the calculation apparatus for patent power of the first embodiment, it is possible to carry out the monetary evaluation of the group of patents. Moreover, the totalized value is calculated by the calculation apparatus for patent power utilizing only objective data without scoring, so that arbitrariness is completely excluded.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Embodiments of the present invention will be described hereinbelow with reference to the drawings. The present invention is not to be limited to the above embodiments and able to be embodied in various forms without departing from the scope thereof. The first embodiment will describe Claims 1 and 2 .
First Embodiment
Concept of First Embodiment
[0013] A brief description of the totalized value finally calculated by the calculation apparatus for patent power of the first embodiment is provided. The totalized value is calculated per an application. The calculation apparatus for patent power of the first embodiment carries out the calculation based on a brand new method for directly measuring the exclusive power of patent. Here, we consider that the worth of a patent is measured by the exclusive power of the patent. The exclusive power means a power indicating strength of a patent holder in monopolizing the market, in other words, a power of the patent as an obstacle to other competitors' business. It is possible to liken this exclusive power to a wall or a fence to make the boundary with competitors. When there is no competitor or no one who has an interest, it is meaningless to make the fence. For example, it is nonsense to make the fence on a deserted island to defend from a third party. Meanwhile, when there are competitors, it is highly significant to make the fence. If the fence is a great wall, which can perfectly exclude the third party, it is more highly significant. Accordingly, it is of great significance in making the wall for perfectly defending a large territory in the middle of Tokyo from the third party. This action to exclude the third party is the exclusiveness of the competitors, the large territory is a wide scope of patent right, and the great wall is a patent which is unlikely to be invalid.
[0014] In the business where there are many competitors, the strong patent covering the wide scope of right means the strong exclusive power. To have the strong exclusive power in the market benefits the patent holder. Therefore, the evaluation of the exclusive power of the patent is synonymous with the evaluation of earning power of the patent.
[0015] Subsequently, a description of an evaluation method for the exclusive power is provided.
[0016] When the patent holder wishes to monopolize the market by the patent having the exclusive power, there are competitors to be excluded. Therefore, the competitor to be excluded takes the following actions against the patent having the exclusive power as an obstruction.
[0017] If the patent as the obstruction to the competitor's business is found, the competitor takes the following actions.
[0018] At the outset, the competitor researches the content of the patent, and should determine the action such as a negotiation of licensing, an action to invalidate, or a redesigning. Then, the competitor takes actions against the patent. Accordingly, it is preferable that the calculation apparatus for patent power of the first embodiment evaluates the actions by the third party against the patent as evaluation targets.
[0019] After the invention, there are various actions done to the patent from filing, publication, examination, registration to expiration. Examples of the action include an examination request, a rejection, a decision of a patent grant or a final decision for rejection, a request for inspection of files, an appeal trial, and a trial for invalidation. Among these actions, examples of the action by the third party include the request for inspection of files showing examination history of the patent and the trial for invalidation to invalidate the patent. The calculation apparatus for patent power of the first embodiment can evaluate such actions by the third party (competitor), thereby indexing the exclusive power of the patent.
[0020] Next, the reason why it is preferable to limit the evaluation target to the actions by the third party is described. For example, the action ‘filing’ by the applicant (right holder) is not the evaluation target. The reason for this is that a company having large number of patent applications does not always have earning power by the patent. For example, when most of the patent applications are treated as withdrawn without examination request or finally rejected in the examination, the large number of the patent applications is meaningless and such patent applications are not to be the evaluation targets. Moreover, if the action by the right holder is included in the evaluation target, it is possible for him to arbitrarily change the evaluation of himself.
[0021] Meanwhile, when the patent is non-negligible for the competitor and he cannot help investigating the patent, and as a result of the investigation, he determines that it is difficult to avoid the patent, so that he demands a trial for invalidation, it is expected that such patent is highly evaluated.
Configuration of First Embodiment
[0022] FIG. 1 is a functional block diagram of a calculation apparatus for patent power of a first embodiment. A calculation apparatus for patent power ( 0100 ) in FIG. 1 comprises an ‘acquisition unit for patent history data’ ( 0101 ), an ‘extraction unit for item content’ ( 0102 ), a ‘storage for search result’ ( 0103 ), a ‘storage for cost table’ ( 0104 ), a ‘storage for obsolescence function’ ( 0105 ), a ‘calculation unit for post-obsolescence cost’ ( 0106 ), and a ‘totalizing unit’ ( 0107 ), and an ‘output unit’ ( 0108 ).
[0023] The ‘acquisition unit for patent history data’ ( 0101 ) has a function of acquiring patent history data of an application. An example of the patent history data includes standardized data in Japan acquired by standardizing and processing various information such as examination history information held by Japanese Patent Office. The patent history data includes legal procedures such as the trial for invalidation against a registered patent other than the examination history information. Moreover, not limited to the patent history, examination history information and post-registration information regarding utility model, design, or trademark are included. By referring the patent history data, information of filing date, applicant, inventor, and IPC etc, and existence or non-existence of the examination request, and the examination history can be known.
[0024] The ‘extraction unit for item content’ ( 0102 ) has a function of searching for a combination of standard item names indicating legal procedures against the application by pattern matching processing utilizing a preliminarily given pattern, in which the standard item name is described in the acquired patent history data, and extracting the item content described in the patent history data correlated with procedure date in accordance with the retrieved combination of standard item names.
[0025] Here, examples of the legal procedure against the application include a request for inspection of files and the trial for invalidation.
[0026] The combination of standard item names indicating legal procedures against the application is, for example, in the case of the trial for invalidation against the application, a combination of standard item names such as kind of trial case, kind of final decision, and conclusion of trial decision. By pattern matching processing of the patent history data utilizing this combination, the search for the trial for invalidation as the legal procedure is carried out. The data to search for the trial for invalidation as the legal procedure spreads across the patent history data, so that it is necessary to carry out the pattern matching processing, thereby extracting the item content etc. Subsequently, description of a method for extracting the item content described in the patent history data correlated with procedure date in accordance with the retrieved combination of standard item names is provided. FIG. 2 is a diagram exemplifying a part of patent history data ( 0200 ) (e.g., standardized data). The left side of FIG. 2 shows the standard item name ( 0201 ) and the right side shows the item content ( 0202 ). In FIG. 2 , the item content corresponding to the standardized item name ‘kind of trial case’ is ‘112 (Full-invalid (New))’, the item content corresponding to the standardized item name ‘Kind of final trial decision’ is ‘02 (Dismissal of demand)’, and the item content corresponding to the standardized item name ‘conclusion of trial decision’ is ‘Y (Not invalid)’.
[0027] Moreover, the procedure dates correlated with these item contents are extracted. For example, in the case of the trial for invalidation, the ‘date of demand for trial’ is extracted.
[0028] The ‘storage for search result’ ( 0104 ) has a function of storing the extracted item content and the date correlated with the retrieved combination of standard item names. For example, in FIG. 2 , the item contents ‘112 (Full-invalid (New))’, ‘02 (Dismissal of demand)’, and ‘Y (Not invalid)’ are correlated with the combination of standard item names, and the procedure date 2004 Apr. 1 is correlated with the combination of standard item names, and they are stored. By referring the stored search result, the date of demand for trial, the kind of trial case, the kind of final decision, and the conclusion of trial decision of the trial for invalidation as the legal procedure are acquired.
[0029] The ‘storage for cost table’ ( 0104 ) has a function of storing a cost table, in which a predetermined cost is correlated with a combination of item contents stored being correlated with the combination of standard item names. FIG. 3 is a diagram exemplifying a cost table. In the first line in FIG. 3 , the combination of standardized item names is indicated. For example, the combination of standardized item names corresponding to the demand of trial for invalidation includes the kind of trial case, the kind of final decision, and the trial decision. In the second and third lines, examples of the combination of item contents are indicated. The example in the second line shows a case that the trial for invalidation was demanded, the demand was dismissed, and the decision was ‘Not invalid’. In this case, the cost for the trial for invalidation paid by the third party, for example, 1,000,000 (one million) yen is stored as the cost in the cost table. The example in the third line shows a case that the trial for invalidation was demanded, the demand was dismissed, and the decision was ‘Invalid’. In this case, the patent is invalid and has no value, so that zero is stored in the cost table. The cost may be stored in the cost table by unit of money, value acquired by division using appropriate value, or index corresponding to the legal procedure.
[0030] The ‘storage for obsolescence function’ ( 0105 ) has a function of storing obsolescence functions used as measures of the obsolescence of technique in each technical field. The obsolescence function is acquired as follows. The upper diagram in FIG. 4 is a graph of statistical results indicating how many years from filing the patents become invalid in a certain technical field. The vertical axis indicates the rate of expired patents, and the horizontal axis indicates the number of years from filing. In this statistical data, the point of filing is regarded as a starting point. This may sound quite natural because the obsolescence of technology starts not from the point of registration of patent, but from the point of invention. Therefore, although the point of invention seems to be the most appropriate starting point, it is impossible to work up statistics about it, so that the point of filing is set as the starting point. Concretely speaking, in the upper diagram in FIG. 4 , the number of patents expired within 4 years from the filing is nearly zero. After that, the number of expired patents gradually increases. 25-30% of registered patents expire after 20 years from the filing date, The reason for this is that the term of the patent right is basically 20 years from the filing date. The patent rights, which would be maintained for longer term if the term of the patent right is longer than 20 years, expire at 20 years from the filing date. The technology is not obsolete at once. Therefore, based on the hypothesis that the patent rights, which expire at 20 years from the filing date, would gradually decrease during several years from the point of 20 years, it is expected that the patent rights decrease year-by-year at the rate indicated in the lower graph in FIG. 4 . This is a graph indicating the obsolescence of technology as a source. FIG. 5 shows a result acquired by approximating the lower graph in FIG. 4 by normal distribution and calculating ‘1-normal cumulative distribution’. This curve is the obsolescence function. This may be called as a technological value obsolescence curve. Here, the reason for approximating the rate of expired patents by normal distribution is briefly provided. It is recognized that the respective registered patents has inventive step. Therefore, even if one patent becomes obsolete with technological advancement, no other patent becomes obsolete. Accordingly, each patent is independent, and can be approximated by normal distribution.
[0031] In FIG. 5 , if the term of the patent right is not 20 years, most of patents lose their value around 25 years from the filing date. This graph has a feature that little obsolescence is found in the first several years, the rate of obsolescence accelerates as it approaches the average number of years that the patents expire, and after the average number of years of expiry, the rate of obsolescence becomes more gradual. This function is calculated with respect to each technical field, and is stored as the obsolescence function.
[0032] The ‘calculation unit for post-obsolescence cost’ ( 0106 ) has a function of acquiring cost with respect to each combination of item contents extracted according to the combination of standard item names of each application by means of the cost table stored in the storage for cost table, and calculating the post-obsolescence cost on a calculation reference date by means of the calculation reference date, the procedure date correlated with the combination of item contents, the filing date of the application, and the obsolescence function of the technical field of the application.
[0033] At the outset, description of a method for acquiring cost with respect to each combination of item contents extracted according to the combination of standard item names of each application by means of the cost table stored in the storage for cost table is provided. As shown in FIG. 3 , the storage unit for cost table stores the cost with respect to each combination of item contents extracted according to the combination of standard item names indicating the legal procedures. Then, the cost table is searched by the extracted combination of standard item names, thereby acquiring the cost of matching combination.
[0034] Subsequently, a method for calculating the post-obsolescence cost by utilizing the obsolescence function is described with reference to FIG. 5 . At the outset, the technical field of the application is acquired, and the obsolescence function corresponding thereto is acquired. After that, the calculation reference date and the procedure date correlated with the respective combination of the item contents, and the filing date of the application are acquired. In the case of a retroactive application, the original filing date may be acquired as the filing date. As described above, the reason for this is that the obsolescence of technology starts not from the point of registration of patent, but from the point of invention.
[0035] It is assumed that regarding to one patent, the trial for invalidation is demanded after α years from the filing and decision of maintenance of a patent is sentenced, and that a series of the procedures are 100 points in the cost table. Additionally, the calculation reference date is β years from the filing date. In this case, let a coefficient of residue value of technology for α years is T(α), and a coefficient of residue value of technology for β years is T(β), the post-obsolescence cost at the calculation reference date is:
[0000] The post-obsolescence cost=100 ×T (α)/ T (β)
[0036] Assuming that the calculation reference date is now, if the date of the action (α years) is 2 years from the filing date, and now (β years) is 3 years from the filing date, the patent is not obsolete. if the date of the action (α years) is 2 years from the filing date, and now (β years) is 15 years from the filing date, the patent is seriously obsolete. Therefore, the older the legal action, the smaller its post-obsolescence cost at the present time.
[0037] The ‘totalizing unit’ ( 0107 ) has a function of totalizing the calculated post-obsolescence costs regarding the application. Therefore, it is possible to calculate the patent power for one application.
[0038] The ‘output unit’ ( 0108 ) has a function of outputting the totalized value acquired by the totalizing unit. It is possible to acquire a relation between the patent powers of companies by adding the totalized values with respect to each patent holder company. Thus, the totalized value outputted by the ‘output unit’ ( 0108 ) may be value acquired by adding the totalized values with respect to each specific unit.
Hardware Configuration of First Embodiment
[0039] FIG. 6 is a hardware configuration diagram of the calculation apparatus for patent power of the first embodiment.
[0040] Note that the respective units in the first embodiment can be configured by hardware, software, or both hardware and software. For example, in the case of using a computer, the respective units are implemented by the hardware configured by a CPU, a memory, a bus, an interface, and other peripheral devices etc., and by the software operable on the hardware. Concretely speaking, by sequentially carrying out programs on the memory, the data on the memory and the data inputted via the interface are processed, stored, and outputted etc., thereby implementing functions of the respective units.
[0041] Specifically, as shown in FIG. 6 , a computer comprises a CPU ( 0601 ), a RAM ( 0602 ), a ROM ( 0603 ), an input/output interface (I/O) ( 0604 ), and a HDD ( 0605 ) etc. and they are connected with each other via data communication path such as a system bus ( 0606 ), thereby carrying out transmission/reception of information and processes.
[0042] Additionally, the RAM ( 0602 ) reads out a program for various processes to be executed by the CPU, and provides the work area for the program. A plurality of memory addresses are assigned to the RAM ( 0602 ) and the ROM ( 0603 ), respectively, and the program executed by the CPU ( 0601 ) can be executed by specifying and accessing the address, and exchanging data.
[0043] With reference to FIG. 6 , description of hardware configuration of the first embodiment is provided.
[0044] At the outset, when power of the calculation apparatus for patent power is on, the CPU ( 0601 ) develops the various programs such as a program for acquiring patent history data, a program for extracting item content, a program for storing search result, a program for calculating the post-obsolescence cost, a program for totalizing, a program for outputting, on the work area in the RAM ( 0602 ).
[0045] Subsequently, the CPU ( 0601 ) executes the program for acquiring patent history data, thereby acquiring the patent history data of the evaluation target patent. The acquired patent history data is stored in the data area in the RAM ( 0602 ). Subsequently, the CPU ( 0601 ) execute the program for extracting item content, and reads out the pattern file stored in the storage area in the ROM ( 0603 ) etc, on the data area in the RAM ( 0602 ). In the pattern file, the combination of standard item names of the legal procedures against the application is preliminarily stored. Then, the search for a combination of standard item names indicating legal procedures against the application by pattern matching processing utilizing the pattern file is carried out, thereby extracting the item content and procedure date, which are corresponding to the combination of standard item names. Subsequently, the CPU ( 0601 ) executes the program for storing search result, thereby correlating the extracted item contents and the procedure dates with the combination of standard item names, and storing them to the data area in the RAM ( 0602 ). Subsequently, the CPU ( 0601 ) executes the program for calculating the post-obsolescence cost. The CPU ( 0601 ) reads out the cost table and the obsolescence function to the data area in the RAM ( 0602 ). Then, by searching the cost table, the cost corresponding to the search result stored in the data area is acquired. Subsequently, the post-obsolescence cost is calculated by using the obsolescence function corresponding to the technical field of the application. The calculated post-obsolescence cost is stored in the data area in the RAM ( 0602 ). After that, the CPU ( 0601 ) executes the program for totalizing, thereby totalizing all post-obsolescence costs regarding the application stored in the data area in the RAM ( 0602 ). The totalized value is stored in the data area in the RAM ( 0602 ). Subsequently, the CPU ( 0601 ) executes the program for outputting, thereby outputting the totalized value thorough the input/output interface (I/O) ( 0604 ).
[0046] Moreover, the calculated totalized value may be correlated with the application number etc. and may be stored in the storage such as the HDD ( 0605 ).
Processing Flow of First Embodiment
[0047] FIG. 7 is a flowchart showing processing in the calculation apparatus for patent power in a first embodiment.
[0048] At the outset, in a step S 0701 , the patent history data is acquired. Subsequently, in a step S 0702 , the combination of standard item names indicating legal procedures against the application by pattern matching processing is searched for by utilizing a preliminarily given pattern. Subsequently, in a step S 0703 , a process of extracting the item content described in the patent history data correlated with procedure date in accordance with the retrieved combination of standard item names is executed. Subsequently, in a step S 0704 , a process of storing the extracted item content and the date correlated with the combination of standard item names is executed. Subsequently, in a step S 0705 , the corresponding cost is acquired by searching the cost table. Subsequently, in a step S 0706 , the obsolescence function corresponding to the technical field of the application, the calculation reference date, the procedure date, and the filing date are acquired. Subsequently, in a step S 0707 , the post-obsolescence cost is calculated by using the acquired obsolescence function corresponding to the technical field of the application, the calculation reference date, the procedure date, and the filing date. Subsequently, in a step S 0708 , the calculated all post-obsolescence costs regarding application is totalized. Subsequently, in a step S 0709 , the acquired totalized value is outputted to the display etc.
[0049] Note that the flowchart of FIG. 7 may be regarded as a flowchart of processes to be executed by the computer. Moreover, such programs may be recorded in a media such as a CD or a IC memory.
Brief Description of Effects of First Embodiment
[0050] According to the calculation apparatus for patent power of a first embodiment, it is possible to carry out economic evaluation of the group of patents.
[0051] Conventionally, it costs enormously to evaluate the economic value of one patent (e.g., 300,000 yen per a patent), so that it is difficult to carry out a micro-evaluation of the group of patents. The micro-evaluation is to carry out detailed survey for one patent, thereby calculating its economic value. In the calculation apparatus for patent power of a first embodiment, the evaluation target is the action taken by the third party after investigating a patent as an obstacle to his business and evaluating a degree of its obstuctiveness to his business, so that the result of the micro-evaluation by the third party is indirectly evaluated. Therefore, since the degree of obstuctiveness to the third party's business spreads across in the history information is utilized as the evaluation target, the evaluation is carried out utilizing the data with high quality even if it is a macro-evaluation.
[0052] Moreover, the totalized value per application calculated by the calculation apparatus for patent power is calculated by utilizing only objective data without scoring, so that arbitrariness is completely excluded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 is a functional block diagram of a calculation apparatus for patent power of a first embodiment.
[0054] FIG. 2 is a diagram exemplifying a part of patent history data (e.g., standardized data).
[0055] FIG. 3 is a diagram exemplifying a cost table.
[0056] FIG. 4 is a diagram explaining calculation of obsolescence functions.
[0057] FIG. 5 is a diagram exemplifying the obsolescence functions.
[0058] FIG. 6 is a hardware configuration diagram of the calculation apparatus for patent power of the first embodiment.
[0059] FIG. 7 is a flowchart showing processing in the calculation apparatus for patent power in a first embodiment.
DESCRIPTION OF REFERENCE NUMERALS
[0060] 0100 Calculation apparatus for patent power
[0061] 0101 Acquisition unit for patent history data
[0062] 0102 Extraction unit for item content
[0063] 0103 Storage for search result
[0064] 0104 Storage for cost table
[0065] 0105 Storage for obsolescence function
[0066] 0106 Calculation unit for post-obsolescence cost
[0067] 0107 Totalizing unit
[0068] 0108 Output unit | To propose a patent value evaluating device capable of identifying the causal association with business activity. A patent power calculating device comprises a patent history data acquiring section, an item content extracting section for searching for a combination of names of standard items indicating legal procedures and extracting the item contents and their procedure dates according to the combination of standard item names searched for, a search result holding section for holding the extracted item contents and the procedure dates, a cost table holding section for holding a cost table where the combinations of item contents and prepared costs are associated with one another, an obsolescence function storage section for storing obsolescence functions used as measures of the obsolescences of the techniques in each technical field, a post-obsolescence cost calculating section for acquiring costs from the cost table and calculating the post-obsolescence cost on the calculation reference date by using the calculation reference date, the procedure date, the application date, and the obsolescence function, a totalizing section for totalizing the calculated post-obsolescence costs for the applications, and an output section for outputting the calculated total. | 6 |
FIELD OF THE INVENTION
The invention relates to well water pumping methods and apparatus and, in particular, to methods and apparatus for minimizing sand intrusion into the well and therefore sand content in the pumped water.
Pumps drawing water from wells sunk in strata containing sand may be subject to very great wear because of the erosive action of the sand. Excessive sand content may also render the water unfit for its ultimate use without additional filtering.
Sand intrusion arises from a number of factors. Suction forces particularly in the vicinity of the pump inlet are primarily responsible for drawing the sand from the strata surrounding the borehole. In a vertical borehole, water generally floods into the hole through a well screen with a horizontal velocity. In the borehole, the water is subjected to precipitous vertical movement by the pump suction forces. The pump may subject the inflooding water to sufficient vertical velocities as to create a column of vertically moving water within the well screen which prevents the admission of additional water, in effect constricting the well screen in localized areas. On those areas in which the well screen is not constricted, water passes from the strata through the well screen at velocities much in excess of the velocity it would ordinarily have had if allowed to simply permeate into the borehole without the action of the pump. This relatively high velocity water movement from the strata through the well screen creates turbulences which causes many problems that accelerate the deterioration of water wells including cavern developments in the surrounding strata and gravel screen, release of oxygen, sand deposits in the borehole, high sand content in the water output, etc. Eventually, erosion of the strata surrounding the pump inlet or inlets can cause a partial collapse of the borehole in the vicinity of the pump, the collapse of overlying strata or both. Even without a catastrophic collapse of the sidewall of the borehole, enough sand may be drawn into and collect at the bottom of the borehole as to eventually fill the hole and clog the pump inlet.
U.S. Pat. No. 4,014,387 describes a control system for use in a water well which distributes suction forces generated at a suction pump inlet along a significant length of the well screen and reduces the suction forces at the well screen to low levels so as to prevent the movement of sand grains into the borehole from the strata under the action of the pump. The suction control system of the patent consists of one or more identical tubular elements each consisting of a pair of concentric, rigid cylinders with numerous, small, uniformly sized, shaped and distributed openings therethrough and an intermediate layer of a rigid granular material filling the space between the cylinders. The granules are simply packed loose between the cylinders but, alternatively, may be consolidated into a separate, permeable cylindrical tube. The permeability of the sidewall of each tubular element is substantially uniform around the circumference and along the length of the element. The system of the patent is closed at its lower end causing water to be drawn through only the sidewalls of the individual elements. A sufficient number of elements are supplied to provide a permeable surface of sufficient area and length to reduce the rate of flow of water through the walls of the elements to that of the natural flow rate of water in the strata. This is below a rate sufficient to overcome the inertia of sand in the strata.
One problem of the suction control system described in the patent is that while the patent significantly reduces the intrusion of sand into the borehole, it does not prevent such movement entirely. Specifically, with the system of the patent, sand intrusion tends to increase over time as the system is used in the field. It has been suggested that pumps used with the system described in the patent be started slowly to allow a suction force to be built up gradually in the system. In practice, users often start pumps at full capacity which, it has been found, causes sand to be drawn into the borehole and into the system. Sand drawn into the system may be trapped between the rigid cylinders and permeable layer clogging the layer or, to some extent, drawn into the hollow interior of the system. As the bottom of the system is closed, the reduction of permeable surface area from sand clogging increases the suction forces and water flow rates through the remaining permeable areas of the sidewalls of the system elements. Also, sand suspended between the cylinders or within the body during operation of the pump will tend to drop to the bottom of the body or bottom of the concentric cylinders of the element when the pump is turned off clogging the bottoms of both the system and sidewalls of the individual elements. The removal of the system from the well and the reconditioning of the individual elements to remove trapped sand are very expensive and the principal drawbacks of that patented invention.
OBJECTS OF THE INVENTION
It is a principal object of this invention to provide a new apparatus and method for drawing sand-free water from wells drilled in sandy, water-bearing strata.
It is another object of the present invention to provide such a method and apparatus which is simple in construction, reliable in operation and relatively inexpensive to manufacture and install.
It is yet another object of the invention to provide a method and apparatus for more uniformly distributing pump forces along the length of the wall itself.
It is yet another object of the invention to provide a suction control system utilizing elements of different permeability to differentially control water flow rates into the system.
SUMMARY OF THE INVENTION
One aspect of the invention is a pair of suction control elements of improved construction and performance. A primary suction control element, used under all sand conditions, is tubular and has a sidewall surrounding a hollow interior and defining a pair of open ends of the element. The sidewall is permeable along the major portion of its length and is multi-layered, having a relatively rigid inner layer formed by a tube with a rigidity sufficient to absorb fluid impact loads arising from switching on and off a connected water pump and an outer, granular layer which is directly exposed to water in the well. The tube forming the interior layer of the element sidewall is made porous and permeable by the provision of a multiplicity of openings therethrough uniformly distributed about its circumference and along substantially all of its length beneath the outer, granular layer. The granular layer is also porous and permeable and is formed by particles bonded to one another and to the outer surface of the tube. A collar is provided at one end of the element for coupling the element to a pump flange, adaptor or other element.
A second suction control element is provided for use with the first element. This second element, like the first, is tubular and has a sidewall surrounding a hollow interior and defining a pair of open ends of the element. The major portion of the sidewall is again provided by a relatively rigid tube (i.e., a tube with a rigidity sufficient to absorb fluid impact loads encountered during operation), the exposed surfaces of the tube forming portions of the outer and inner surfaces of the sidewall of the element. The second element also includes a collar at one of the open ends thereof or other means suitable for mechanically and hydraulically coupling that open end with an open end of another suction control element so as to form a multi-element suction tail. The sidewall is provided with a multiplicity of openings therethrough which are uniformly distributed both around the circumference and along substantially the length of the element. The openings have a noticeably greater open cross-sectional area on the outer surface of the tube than on the inner surface so as to maintain a laminar flow of water into the element.
Another aspect of the present invention is the suction control tail formed by combining the improved elements of the invention. The tail has a porous, permeable, tubular sidewall surrounding a hollow interior and is unrestrictly open at its lower end to water in the well and to any sand the water may carry. The upper end of the tail is adapted for mechanical and hydraulic coupling with the inlet of a suitable pump. By means of the pump, water is drawn into the inlet through the permeable sidewall and the open lower end of the tail. The tail is provided with a permeable surface area, the length and permeability of which is such that the rate of flow of water into the well at each point about the tail and pump inlet, while the pump is in operation at maximum capacity, is less than a rate of flow necessary to overcome inertia of sand in the strata surrounding the well. In particular, the rate of flow of water into the well bore with the pump and suction control tail in operation is about 10 mm/sec. or less. Thus water flows from the strata into the well hole essentially sand free.
According to the invention, the outer layer of the first element has an open porosity of less than approximately 30%. Preferably too, the granular particles have uniform sizes of between about 0.8 and 1.2 millimeters and applied in a layer of between 10 and 15 millimeters in thickness to provide an effective permeability to water of between about 3 and 8 cubic meters per hour per meter ("m 3 /h/m"). Unless otherwise noted, the permeabilities hereinafter referred to are relative permeabilities measured under normal load conditions imposed by an associated pump in the configuration used.
Another aspect of the invention is an improved method of pumping water from a well so as to minimize or prevent the intake of sand from the surrounding strata and is accomplished by hydraulically coupling to the intake of a water pump a suction control tail having a sidewall extending away from the pump inlet with a differing permeability along its length, the absolute permeability (i.e., the permeability under identical suction load conditions at each point where permeability is measured) being lower proximal to the pump inlet and higher distal to the pump inlet; completely submerging the tail in the well beneath the water level; and drawing water by means of the pump through the sidewall of the tail at velocities less than a velocity necessary to remove sand from the strata surrounding the well whereby water is withdrawn by the pump essentially sand free.
Also according to the invention, an improved method of pumping water from a well sunk in sandy, water-bearing strata comprises hydraulically coupling to the inlet of a pump one end of a suction control tail having a permeable sidewall defining an opposing, open end unrestrictly admitting water and any suspended sand particles into the tail; completely submerging the suction control tail in the well beneath the level of water; and drawing water from the well by means of the pump through only the permeable sidewall and lower open end of the suction control tail at velocities less than a velocity necessary to remove sand from the strata surrounding the well hole whereby the water is withdrawn from the well essentially sand free.
In each of these methods, water is drawn into the tail at velocities of about 10 mm/sec. or less at all points where water is admitted into the tail.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages and features of the present invention will be apparent from the accompanying description and figures wherein:
FIG. 1 is a sideview, in partial cross-section, of an exemplary first multilayer control element for a suction control tail of the present invention;
FIG. 2 is a cross-section of the element of FIG. 1 along the lines 2--2;
FIG. 3 is a sideview in partial cross-section of an exemplary second single layer control element for a suction control tail of the present invention;
FIG. 4 is a cross-section of the element of FIG. 3 along the lines 4--4;
FIG. 5 depicts the form of the openings in the sidewall of the second element; and
FIG. 6 depicts the exemplary bodies of the previous figures combined in a single suction control tail positioned in a well bore for use with a submersible pump.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 depict an exemplary multi-layer suction control element 10 of the subject invention. The element 10 is tubular in form, has a sidewall 10' defining an open upper end 12 and an open bottom end 14 and surrounding a hollow interior 16. The side wall 10' is formed, in part, by a length of polyvinylchloride (PVC) tubing 18 or other tubular materials of sufficient rigidity and strength as to be able to withstand the forces, particularly fluid impact forces to which the element is subjected during use. Preferably, as much of the length of the tube 18 as is possible is provided with openings 20 which extend transversely through the tube 18 between its outer to inner surfaces 17 and 19. The openings 20 are preferably uniformly sized, shaped and spaced so as to uniformly distribute suction forces and water flow around the circumference and along the length of the tube. The element 10 has a porous outer surface 22 exposed to water in the wall which is provided by a layer 24 of polyvinylchloride or other rigid, granular particles bonded to one another and, preferably, to the outer surface 17 of the tube 18 so as to form a continuous, porous and permeable layer about the outer surface 17 of the tube 18 covering the area of the openings 20. A pair of PVC bands 26 and 28 are attached to the outer surface 17 of the tube 18 at either end of the layer 24 by adhesives or other suitable means. The bands 26 and 28 have a radial thickness at least equal to the maximum radial thickness of the layer 24 so as to provide protection for the layer. The remainder of the sidewall of the tube 10 is formed by a mating collar 30 that is provided at the upper end of the element 10 for attaching the element to the lower end of an identical element, a suitably configured pump flange or an adaptor for hydraulically coupling the element 10 with the inlet of a water pump (none depicted). The collar 30 is formed by a short length of polyvinylchloride tubing 32 having an inner diameter approximately equal to or slightly larger than the outer diameter of the tube 18. The collar 30 is secured to the tube 18 by a suitable means such as an adhesive and/or other suitable sealing and/or securing means. A number of bores 34 are provided around the upper end of the collar 30. The bores 34 may be threaded to accept screws. Similar openings 36 are similarly provided at the lower end of the tube 18 for coupling. Other conventional mechanical pipe coupling structures, such as threads, may instead be provided at either or both ends of the element.
The permeability of the element to water is substantially, if not essentially controlled by that of layer 24 and is less than about 10 m 3 /h/m and is preferably between about 3 and 8 m 3 /h/m. The openings 20 in the tube 18 are horizontal slots preferably packed as closely as possible to minimize flow resistance and are sufficiently narrow to prevent collapse of the overlaying layer 24 and of the element itself. Slots about 25 mm (1 inch) or more in length about the circumference of the tube 18 and about 0.5-0.8 mm (0.02-0.03 inches) in height and having practically the same open cross-sectional area at the outer 17 and inner 19 surfaces of the tube 18 are suggested. The openings 20 are provided in a density of approximately 300 to 800 openings per square meter m 2 (25 to 75 openings/ft 2 ). The openings 20 are depicted as being arranged in parallel columns 37 along the length and around the circumference of the tube but other arrangements are possible.
The polyvinylchloride granules forming the layer 24 are sieved clean and are sized between 0.8 and 1.2 mm (about 0.03 to 0.045 inches). The cleaned, sized granules are combined with a suitable waterproof adhesive such as waterproof rated epoxy resin and are applied in a uniform layer having a uniform thickness "r" (see FIG. 2) of between about 10 and 15 mm (0.4 and 0.6 inches) thick to the outer surface 17 of the tube 18 and cured by a method appropriate for the adhesive selected. Preferably too, the PVC tube outer surface is cleaned of contaminents and roughened to provide better adhesion. Granules and adhesive are provided in relative weight proportions of very approximately 80% granules and 20% adhesive and applied in the indicated uniform thickness of about 10-15 mm to yield a layer having the desired operating permeability to water of about 3 to 8 m 3 /h/m.
FIG. 2 shows the uniform size, shape, cross-sectional area and distribution of the openings 20 through and around the tube 18 as well as the uniform radial thickness "r" of the layer 24 covering the outer surface 17 and openings 20.
FIG. 3 depicts a second suction control tail element 40 for use in combination with the element 10 of FIG. 1 when it is necessary or desirable to spread the suction force of a pump along a greater length of the well screen. Like the element 10, the element 40 has a sidewall 44 defining an open upper end 41 and an open lower end 42 and surrounding a hollow interior 43. The sidewall 44 is formed, in part, by a length of polyvinylchloride tubing 52 with a second, shorter length 54 sealingly bonded at the upper end of the tubing 52 so as to form a coupling collar 46. The element 40 is made porous and permeable along as much of its length as is possible by the provision of a large number of openings 48, through the wall of the tube 52. Again, the openings 48 are uniformly sized, shaped and spaced slots 48. As is better seen in FIG. 4., the slots 48 in element 40, unlike the slots 20 in the element 10, preferably have a distinctly larger cross-sectional area at the outer surface 51, than at the inner surface 53 of the tube 52, to prevent turbulance and create a laminar flow of water accelerating through the openings into the tube 40. Since this element lacks an outer granular layer to control water velocities into the element, the slot system must be constructed so as to provide as low a resistance to water flow as possible. A slot opening 48 is depicted in FIG. 5. The opening is elongated in form and has a major axis 100 of about 77 mm. or less in length and a minor axis 101 of about 0.8 mm. or less in height forming an opening area of about 61.6 mm 2 or less, on the outer surface 51 of the tube. On the inner tube surface, the dimensions of the major axis 100 and minor axis 101 of the openings are about 60 mm. or less and 0.8 mm. or less, respectively, providing an opening area of about 48 mm 2 or less.
Referring to FIGS. 3 and 4, the slot openings 48 are preferably arranged in parallel columns 49 along the length of the tube 52 and uniformly spaced around its circumference. A number of bores 58 and 59 are again provided in the upper portion of the collar 46 and at the lower extremity of the tube 52, respectively, for coupling the element 40 with another element 10 or 40 or for attaching ancillary tail equipment to element 40 as will be later described.
Because the suction control element 40 is intended to be used at the end of one or more multi-layer elements 10 and remote from the pump inlet, the absolute permeability of the sidewall 44 is greater than the absolute permeability of the multi-layer element 10 through its layer 24 and openings 20 under identical suction load conditions. It has been found that such as arrangement aids in maintaining water velocity to a point at which virually no sand is drawn into the interior of the suction control tail.
FIG. 6 depicts in an exemplary fashion the use of the elements 10 and 40 to construct a multi-element suction control tail 60. The upper element 10 of the tail 60 is mechanically and hydraulically coupled at its open upper end to a submersible pump 63, indicated in phantom, by a pressure casing adaptor 62 partially depicted. The casing adaptor 62 sealingly surrounds the submersible pump 63 and is mechanically coupled with the pump in an associated main rising (not depicted) to support the tail 60 in the well. The casing adaptor 62 provides a hydraulic coupling between the pump inlet and the hollow interior of the tail 60 through the upper open end 12 of first element 10. Alternatively, the tail can be hydraulically coupled with the intake of a shaft driven pump or suction tube. In this application, the element 40 more distant from the pump inlet, will exhibit an operating permeability lower than that exhibited by the element 10.
The tail 60 is submerged beneath the water in a well hole 70 to a sufficient depth so as to always be beneath the operational water level, or "OWL" of the well. A well screen is provided by joined lengths of perforated pipe or tubing 72. Perforations 74 are provided in the tubing 72 along the height of the surrounding, water bearing strata 76 to permit water in the strata 76 to enter the well hole 70. Lengths of unperforated pipe or tubing 78 are typically provided above the perforated pipe 72 to prevent contaminents from entering the well. Typically too, the well screen 72 is also surrounded by a gravel pack 80 which provide a primary or initial sand screening function. However, the gravel pack 80 has a poor sand filtering ability and is unable to prevent the intrusion of sand from the surrounding strata 76 into the well hole 70 during conventional pumping operations without the assistance of a suction tail.
The tail 60 is further equipped with centering guides 64 joined to a collar 65 screwed or bolted through the bores 36 and 58, which are also used to join the elements 10 and 40. The centering guides 64 center the tail in the borehole so that pump suction forces are equalized about the well screen. A base piece 66 is also attached to the lower end of the element 40 by means of a collar 68 screwed or bolted through the openings 59 at the lower end of the element 40 to protect the base of the tail 60 and to prevent the lower open end of the element 40 from being accidentally damaged when being introduced into the borehole.
One skilled in the art will appreciate that elements 10 and 40 can be combined in various numbers so as to control water intake velocities in the well hole to about 10 mm./sec. or less for various pump capacities. As an example of the operation of the invention, consider a borehole 70 having an inner diameter of about 33 mm (12 inches) and submersible pump applying a suction load at its inlet for drawing water at an operating rate of about 35 liters per second or "LPS" (about 555 gallons per minute or "gpm"). Under these conditions, the suction force of the pump is sufficiently strong to move sand for a distance of about 15 to 25 feet from the inlet of the pump. A suction control tail formed by a single, multi-layer element 10 of the aforesaid type having an outer diameter of about 150 mms (about 16 inches) and a permeable area length of about 5 meters (16 feet) provides a water flow of about 6.6 LPS (about 105 gpm) per meter of permeable tube length and of about 2 LPS (about 32 gpm) through the open bottom 16 for a total capacity of about 35 LPS (555 gpm). The tail formed by the single element 10 under these conditions generates a water velocity of about 10 mm/sec. or less at the well screen, of about 10 mm/sec or less at about 25 mm (1 inch) from the permeable wall of the multi-layer element 10 and of about 4 (four) mm/sec. or less at the open bottom of the element. This, of course, assumes that the well screen has a permeable area sufficiently large to supply water at a natural flow rate in excess of the 555 gpm capacity of the pump. Such an arrangement would be suitable for well holes sunk in strata containing fine sand (i.e., sand formed by grains having average particle sizes of between about 0.4 mm and 1.5 mm) with some soil or clay and essentially free of very fine sand (i.e., particle sizes of 0.4 mm or less).
In the extreme case of a well sunk in a strata containing significant amounts of very fine grain sand (typically, particle sizes of 0.2 to 0.4 mm and 1.5 specific gravity) and essentially free from soil or clay, a second element 40 with a permeable length of at least about 2 m (6 ft.) and preferably 3 m (10 ft.) is required at the base of element 10, as depicted in FIG. 5, to preclude sand invasion. The tail formed by a 5 m long two-layer element 10 and a 2-3 m long single layer element 40 and operating with the aforesaid pump having a 35 LPS operating rate reduces the maximum water velocity to about 10 mm per second or less at the well screen, to about 10 mm per second or less at about 25 mm (1 inch) from the permeable wall of the upper element 10, to about 7 mm/sec. or less at about 25 mm (1 inch) from the permeable wall of the lower element 40 and to about 4 mm/sec. or less at the lower open end of the tail.
The recited embodiments and operating examples are exemplary only in improvements thereto and variations thereon may be apparent to one skilled in the art. Accordingly, such modifications fall within the scope of the invention as defined by the appending claims. | A suction control tail for use with the water pump to restrict water velocities in a well hole and thereby prevent the instrusion of sand is provided by a two-layer suction control element, or such an element in combination with a single-layer suction control element. Each of the two elements has a porous, permeable sidewall, is open at the bottom to admit water and any suspended sand particles, and is open at the top to hydraulically couple the element to a pump inlet or to the base of another element. The two-layered element is formed by a relatively rigid PVC tube with a multiplicity of opening therethrough and an outer porous, permeable layer over the openings formed by bonded granular PVC particles, the single layer element is formed by a similar, relatively rigid PVC tube having a multiplicity of uniform openings therethrough of diminishing cross-sectional area so as to control water velocities into the element. | 4 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method for microencapsulating materials, particularly temperature-labile or solvent-labile materials, in a polymeric substance. The present invention further relates to microencapsulated substances produced by these methods.
2. Description of the Background Art
Microencapsulation is a process whereby very small particles or droplets of an active or useful substance ("core") are coated with or embedded in a polymer ("shell"), which is essentially inert and serves a protecting or isolating function. The core material is released from the microcapsule through erosion, permeation or rupture of the shell. Microcapsules are useful in numerous applications, including protection or isolation of the core from the environment and the sustained or timed release of the core material. They are particularly useful in medical, pharmaceutical or veterinary formulations. Variation in the thickness or material of the shell can be utilized to control the rate or timing with which the core material is released from the microcapsule.
In order to form microcapsules, such as for controlled release applications, the encapsulating polymer must be processed in the fluid state. The prior art teaches three ways (with multiple variations) of doing this: (1) polymerize liquid monomers or prepolymers in the presence of the core material in order to form a shell around the core; (2) melt the polymer by raising its temperature; (3) dissolve the polymer in a solvent or solvents. The polymerization option (1) is highly chemistry-specific and requires that reactants and reaction conditions do not harm the core material. The melting option (2) requires polymers that melt at low enough temperatures so as to be harmless to the core material. This is often difficult to achieve in practice, particularly in medical and veterinary applications, where core materials are frequently temperature-labile and where microcapsules must have a sufficiently high melting temperature that they do not fuse together under storage conditions. Some version of the dissolution option (3) is the method most frequently used. In many cases, water is one of the solvents of choice. However, therapeutic agents tend to be soluble in water, and when microencapsulated therapeutic agents are needed to be released over or after a prolonged period of time, e.g., over weeks, it is often necessary for the encapsulating polymer to be insoluble in water. Otherwise, the microcapsule would dissolve in vivo before the target release time. Water-insoluble aliphatic polyesters, especially copolymers of lactic and glycolic acid (PLGA) which are used commercially as bioabsorbable surgical sutures, are very well-studied as controlled release polymers. These polymers are soluble in only a few organic solvents (e.g., ethyl acetate, methylene chloride, chloroform, dimethyl formamide, tetrahydrofuran and hexafluoroisopropanol). Furthermore, since their glass transition temperatures are about 50° C., melt processing of PLGA for microencapsulation is not feasible with many temperature-labile therapeutic agents. Consequently, when PLGA is used to microencapsulate a water-soluble therapeutic agent, the method of choice is usually a technique called the double emulsion method (also called the complex emulsion method).
In the double emulsion method, an aqueous solution of the therapeutic agent is emulsified with a larger quantity of non-aqueous solution of PLGA; the solvent is usually methylene chloride. This emulsion is then further emulsified in a still larger quantity of surfactant-containing water, forming a (water-in-oil)-in-water double emulsion. The polymer solvent ("oil") is then allowed to slowly evaporate, hardening the polymer and encapsulating the inner water droplets which contain the therapeutic agent. The double emulsion method can be useful for a wide variety of therapeutic agents, because the agent experiences only mild temperatures (frequently room temperature), and it has exposure to the solvent only at the inner water-oil interface.
The double emulsion method, however, has many drawbacks. The process is extremely long (at least 4 hours), is difficult to scale up, requires large volumes of solvent (about 15 grams solvent per gram polymer) and even more water (about 25 grams of water per gram of polymer), which results in large waste streams. In part because of the large volume of waste solvent, generally less than 85% of the therapeutic agent is actually encapsulated in the solid polymer. Furthermore, methylene chloride has been identified as a carcinogen, so its use is falling out of favor, both because of concerns over residual methylene chloride contamination in the microcapsules and because of strict environmental standards for its use.
Some groups have experimented with the use of supercritical or near-supercritical fluids as solvents in microencapsulation processes. A supercritical fluid ("SCF") is a dense gas that is maintained above its critical pressure and above its critical temperature (the temperature above which it cannot be liquefied by any amount of pressure). Though supercritical fluids have gas-like properties, such as high compressibility and low viscosity, they exhibit many of the properties of liquids, such as high density and high solvating power. A near-supercritical fluid is a fluid that is not technically supercritical, but displays many of the properties of a supercritical fluid, such as high solvating power and compressibility. The use of the term "supercritical fluid" in this specification is intended to encompass near-supercritical fluids. Even substances that are normally solids or liquids at room temperatures can be brought to a supercritical fluid state by the application of appropriate temperature and pressure. A detailed discussion of supercritical fluids and their properties can be found in Debenedetti et al., J. Controlled Release 24:27-44 at 28-29 (1993), Smith, U.S. Pat. No. 4,482,731 (col. 4 line 48 to col. 7 line 23) and in Shine, Chapter 18: Polymers and Supercritical Fluids in Physical Properties of Polymers Handbook 249-256, passim (James E. Mark ed. 1993), all hereby incorporated by reference.
It has been found that the rapid expansion of supercritical fluids causes precipitation of solutes dissolved therein, while the supercritical fluid solvent simply evaporates. Smith, U.S. Pat. Nos. 4,582,731 and 4,734,451. This phenomenon has been adapted for use in making pharmaceutical formulations of drug-loaded microparticles. Debenedetti, et al., supra. Debenedetti, et al. dissolved L-polylactic acid (L-PLA) and the drug lovastatin in supercritical CO 2 , then released the solution through a nozzle, causing formation of microparticles. The rapid decrease in pressure resulted in co-precipitation of the polymer and drug into a heterogenous population of microparticles consisting of microspheres containing single lovastatin needles, larger spheres containing several needles, microspheres without protruding needles and needles without any polymer coating. Manipulation of temperature and pressure conditions permitted production of a fibrous network of needles connected by polymer. This process requires that both the core material and the shell material be soluble in the same supercritical fluid at the same temperature and pressure. Furthermore, variability in the relative rates of precipitation of the two materials results in a heterogenous population of microspheres, as can be seen in part from the results of the Debenedetti group.
Another microencapsulation process involving an "abrupt pressure change," although without the use of supercritical fluids, is discussed in Redding, Jr., U.S. Pat. No. 5,271,881. This process involves using cycles of high and low pressure, brought about by a piston or by ultrasonic waves, to precipitate shell material around a dispersed core material. As noted, this process does not involve the use of supercritical fluids but rather relies on unspecified physical forces, possibly cavitation or shear forces, to cause precipitation of the shell material. The liquid dispersion of core and shell material must be virtually incompressible in order for the forces to have effect. Using this process, it is asserted to be possible to precipitate multiple shells about a core, using a multi-staged process.
Although each of these methods can be useful, there remains a need in the art for a rapid, efficient microencapsulation method that does not require the use of organic solvents or high temperatures that might adversely affect the environment or the microencapsulated material.
SUMMARY OF THE INVENTION
The present invention comprises a method for microencapsulating a core material comprising the steps of a) mixing a core material with a microencapsulating polymer in either a solid particulate or liquid form, b) supplying to the mixture a supercritical fluid capable of dissolving in the polymer under a pressure and temperature sufficient to maintain the fluid in a supercritical state, c) allowing the supercritical fluid to penetrate and swell or liquefy the polymer while maintaining pressure and temperature sufficient to maintain the fluid in a supercritical state, and d) rapidly releasing the pressure to solidify the polymer around the core material to form a microcapsule. This method requires neither the core materials nor the polymer to be soluble in the supercritical fluid; it requires only that the supercritical fluid be soluble in the polymer.
This method avoids the use of the organic solvents used in some traditional microencapsulation processes, not only eliminating any problems associated with the presence of residual solvent in the microcapsules or waste stream, but also permitting microencapsulation of materials incompatible with traditional processes due to their sensitivity to the presence of organic solvents. Furthermore, the ability of the process to function at relatively low temperatures as compared to the normal melting or glass transition point of the shell material permits microencapsulation of temperature-labile substances that otherwise would be degraded or inactivated at the temperatures required by those traditional processes that call for melting the shell material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents one apparatus useful for forming microparticles by polymer liquefaction using supercritical salvation.
FIG. 2 represents a second apparatus useful for forming microparticles by polymer liquefaction using supercritical salvation.
DETAILED DESCRIPTION
The present invention relates to methods for microencapsulating active ingredients under relatively mild conditions by polymer liquefaction using supercritical solvation (PLUSS). A supercritical fluid is used to swell or liquefy a polymeric substance at temperatures significantly below the melting point (for crystalline polymers) or the glass transition point (for amorphous polymers) of the polymer. Intimate mixture under pressure of the polymer material with a core material, either before or after supercritical fluid salvation of the polymer, followed by an abrupt release of pressure, leads to an efficient solidification of the polymeric material around the core material. This method is particularly useful for microencapsulating core material that would be adversely affected by the temperatures required to melt polymeric shell materials under normal atmospheric conditions or that would be adversely affected by the presence of the organic solvents typically used to dissolve polymeric materials in traditional microencapsulation methods.
As used herein the term "microcapsule" encompasses both a particle comprising a monolithic core surrounded by polymer and a particle comprising a dispersion of core material in a polymer matrix.
As used herein the term "shell material" refers to the material that forms the outer coating or the matrix of the microcapsule. Though the shell is generally inert in the application in which the microcapsule is used, and serves the function of isolating, protecting or controlling the release of the core material from the microcapsule into the environment, the shell material may have some functionality, such as biochemical attractant moieties or ionic functionalities. The release of the core material from the shell is generally achieved by erosion, permeation, chemical degradation or rupture of the shell.
As used herein the term "core material" refers to the material inside and surrounded by the shell of the microcapsule. The "core" can be either a single particle or droplet surrounded by a layer of shell material, or a dispersion of particles or droplets in a matrix of shell material. It is the core material that is the primary active agent in the application in which the microcapsule is used, be it the dye compound in a dye composition or the drug in a pharmaceutical composition. Core material can be a crystalline or amorphous solid, or a liquid, solution or suspension. As the goal in a microencapsulation process is to achieve small particles of the core material surrounded by or embedded in a shell, the core material should be finely dispersible form, be it solid or fluid.
Many substances that are used as core materials are temperature-labile or organic solvent-labile. By "temperature-labile" it is meant that the properties of the core material are adversely affected by temperatures above a certain upper temperature limit, above which the physical properties, function or activity of the core material is adversely affected. Examples of adverse effects caused by elevated temperatures on temperature-labile core materials are chemical break-down, loss of biological activity and polymerization. By "organic solvent-labile" it is meant that the properties of the core material are adversely affected by the presence of an organic solvent (such as acetone, toluene, xylene, methylene chloride, ethanol, etc.). Adverse effects include chemical change or re-arrangement, loss of biological activity and dehydration.
As used herein the term "supercritical fluid" ("SCF") should be considered to encompass near-supercritical fluids (highly compressed fluids that are below the critical temperature point, yet exhibit many of the same qualities of true supercritical fluids, such as high solvating power and compressibility). Likewise a "supercritical state" should be considered to encompass a near-supercritical state. Supercritical fluids can be combinations of substances, such as CO 2 with CHCIF 2 .
Preferably, the polymeric shell material and the core material are thoroughly mixed while the polymer is in a solid particulate form prior to the introduction of a supercritical fluid solvent into the system. The polymer and core material preferably are further mixed after polymer liquefaction to achieve an intimate mixture of liquefied polymer and core particles or droplets. If the core material is a liquid (meaning it is a substance in a fluid form or a solution or suspension of a solid), an emulsion should be formed of the core material in the liquefied polymer. Heat can be added to or removed from the system at any time to aid solvation of the polymer. In some situations it may be necessary to liquefy the polymer before addition of the core material. For instance, in applications where the core material is temperature-labile and the temperature required to liquefy the polymer in the supercritical fluid exceeds the upper temperature limit below which the core material is stable, it may be necessary to first liquefy the polymer at the higher temperature, then supercool the liquid to a temperature tolerated by the core material, add the core material and mix.
This process can be applied to a wide variety of core materials such as dyes, inks, adhesives, scents, deodorants, disinfectants, herbicides, pesticides, fungicides, fertilizers, food flavorings and food colorants. Sensitivity to the temperatures and pressures necessary for maintaining supercritical conditions is the only practical limitation on core material selection. The process has particular utility for the microencapsulation of medical, pharmaceutical and veterinary compositions of bioactive agents such as antibiotics, nutritional supplements (such as vitamins and minerals), metabolism modifiers (such as hormones and appetite suppressants), therapeutic agents, analgesics and vaccines. The medical, pharmaceutical or veterinary application of this process is particularly useful for those agents which are temperature-labile or organic solvent-labile, and/or which are desired to be released into the body in a timed or sustained manner, or isolated or protected from the environment for ease of handling and/or ease and stability of storage. An example of such agents are live vaccines comprising lipid-enveloped virus. Such a live vaccine is both temperature-labile and organic solvent-labile because the vaccine loses its effectiveness when exposed to high temperatures and to organic solvents--elevated temperatures will kill the virus and cause degradation or denaturation of the nucleic acid and coat proteins that are its constituents, and an organic solvent would strip away the lipid envelope, also killing the virus. Further, microencapsulation of a live virus serves the function of isolating it from the environment, including the internal environment of the animal to which it is administered, until administered or released, permitting not only safe storage and handling of the vaccine, but also thereby avoiding premature exposure of the vaccine to the animal that could lead to its inactivation (e.g., Infectious Bursal Disease Virus vaccine, administered to chickens, can be inactivated by maternal antibodies in young chicks--microencapsulation protects the vaccine until the levels of these antibodies decline naturally).
Microencapsulation using the methods of the present invention can be achieved at a variety of polymer-to-core material ratios, however, below ratios of about 1:1 there is insufficient shell material to completely surround the core material. At high polymer-to-core ratios, the overall concentration of core material in the microcapsule could become too low to be useful (for example, with Infectious Bursal Disease Virus vaccine, already greater than 99% inert material, above ratios of about 20:1 there is too little active material to be effective at a practical dose volume; however, higher ratios can be used if a highly purified vaccine is used). There is, however, no known inherent upper limit. Additives, such as water, also can be included in the system and can, for instance, aid salvation or emulsion.
A preferred embodiment of the present invention is the use of PLUSS to microencapsulate live virus vaccines such as Infectious Bursal Disease Virus vaccine or vaccines containing live enveloped virus (virus surrounded by a lipid layer). In this preferred embodiment a bioerodible polymer (such as polycaprolactone or poly lactic/glycolic acid copolymer) in a fine powder form is mixed with a dry vaccine preparation likewise in fine powder form. Suitable polymer:vaccine ratios for this preferred embodiment are from about 2:1 to about 10:1, preferably about 5:1. The mixed polymer/vaccine powder is charged to a pressure vessel where a supercritical fluid is added, preferably supercritical CO 2 (though other SCFs such as supercritical N 2 O also are suitable) . The CO 2 also can be supplied in a non-supercritical state, then be brought to a supercritical state. This preferred embodiment also will operate with CO 2 at near-supercritical conditions (e.g., at 21° C. instead of the critical temperature of 31° C.). Supercritical CO 2 can be supplied in ratios of about 0.05 gram CO 2 per gram polymer to about 4 grams CO 2 per gram polymer. A preferred solvent:polymer ratio is about 2 grams solvent per gram polymer. Pressure is preferably maintained between about 1000 and 6000 psi, preferably 4000 psi, to maintain the supercritical state of the fluid while the polymer is liquefied by the supercritical fluid. After liquefaction is complete, pressure is released rapidly, permitting the polymer to expand and the SCF to evaporate, forming microcapsules of polymer-enclosed core material. A typical batch processing time in this preferred embodiment is about 2 hours, most of which is devoted to the polymer liquefaction step. Once liquefaction or swelling of the polymer has occurred, and intimate mixture with the core material is established, the process can move directly to the depressurization step.
Any polymer that is subject to swelling by a supercritical fluid and that is compatible with the desired application can be used in the present invention. Swelling is a process whereby the supercritical fluid dissolves in or permeates the polymer, leading to a depression of the polymer's melting point. This depression of the polymer's melting-point allows it to liquefy (i.e. become fluid without dissolving) at sub-melting-point temperatures. In an SCF-swelled polymer, the SCF is a minor component in the system, unlike dissolution, where it is a major component in the system. Although any SCF that dissolves a polymer can swell it, not every SCF that swells a polymer will dissolve it. Shine, Polymers and Supercritical Fluids, incorporated by reference supra, lists numerous polymers which dissolve in supercritical fluids, and hence also swell in those supercritical fluids, along with supercritical fluids in which the polymers are soluble (see, e.g., Shine Table 18.3). This reference also lists the temperature and pressure parameters within which supercritical fluid dissolution occurs for these SCF/polymer combinations. This reference also lists polymers which are known to swell and liquefy in the presence of carbon dioxide specifically (see, e.g., Shine Table 18.4). Persons of ordinary skill in the art can use references such as this to assist in selecting polymers and SCFs for use in the present invention. Although the higher molecular weight polymers can be more difficult to work with (e.g. they tend to plug up the lines), there are no process limitations on the types of polymers that can be used. Several polymers which are used in medical and pharmaceutical formulation applications can be swelled by supercritical fluids, including polymethyl acrylate, polycaprolactone, poly-L-lactic acid, poly DL-lactic acid, polyglycolic acid and polylactic/glycolic acid copolymer. Several of these polymers are soluble in supercritical fluids which are relatively inert and nontoxic, such as carbon dioxide. A partial list of polymers useful in medical, pharmaceutical and veterinary applications includes the following:
poly(glycolic acid)
poly(lactic acid)
poly(caprolactone)
poly(hydroxy butyric acid)
poly(hydroxy valeric acid)
poly(ethylene adipate)
co- or terpolymers of the above, especially lactic/glycolic and butyric/valeric co- or terpolymers
poly (ortho esters)
poly (anhydrides)
poly (1,4-dioxane-2,5-diones)
polyoxylates
poly (1,3-dioxane-2-one) and its copolymers
poly (p-dioxanone)
poly (amino acids)
pseudopoly (amino acids)
poly (amides) (e.g., gelatin)
cellulosics (e.g., cellulose, cellulose acetate butyrate, carboxyl methyl cellulose, hydroxy propyl cellulose).
Selection of an appropriate polymer for use in a particular application would be governed largely by the application contemplated. For instance, in medical and veterinary applications, biocompatible, non-water-soluble, bioerodible or permeable polymers that do not break down into toxic degradation products are most suitable. Generally, polymers useful for medical, pharmaceutical or veterinary applications will be biodegradable or hydrolyzable and will contain a carbonyl or ether (including cyclic ether) linkage. For non-medical or non-veterinary uses, virtually any polymer which can be swelled by a supercritical fluid can be used, as long as the polymer and supercritical fluid are compatible with the core material to be encapsulated, a determination which is readily made from information available in the published literature. All varieties of copolymers of preferred polymers can be used.
Selection of the supercritical fluid is largely determined as a function of the selection of the polymer, the selection of the two being made together to suit the needs of the user. Considerations of toxicity and general ease of handling of the SCF is a principal consideration. The fluid also must swell the polymer to a sufficient extent so that, when the pressure on the mixture is released, the fluid will occupy the overwhelming majority (e.g. >90%, preferably >95%, and most preferably >99%) of the total volume of the mixture. Practically speaking, this requires that the fluid have an appropriate combination of high density (i.e., much greater than the density at atmospheric temperature and pressure) and high solubility in the polymer. Typically, both density and solubility increase with increasing pressure, but solubility may either increase or decrease with increasing temperature, depending on the polymer/fluid mixture. High solubility and high density are features of supercritical fluids that are also found in compressed liquids, so compressed liquids may also be suitable for the process.
Depending on which process constraints are paramount--the need for a particular shell property, limitations on solvating conditions such as temperature and pressure, or concern over the presence of toxins in the waste stream or as a residue in the final product--the selection will be governed more by SCF properties or by polymer properties. On the whole, selection of an appropriate polymer/SCF combination suited for a particular application is within the ordinary skill in the art. It should be noted that the nature of the core material per se actually imposes few practical restrictions on the choice of the polymer/SCF combination, apart from situations where an organic compound (such as ethane, propane or CHClF 2 ) is used as the supercritical fluid and the core material is adversely affected by the presence of that organic compound. Therefore, a particular polymer/SCF combination can be used under virtually identical process parameters (pressure, temperature, polymer/core and polymer/SCF ratios) for a variety of core materials.
FIG. 1 is a schematic diagram of an apparatus useful in performing a preferred embodiment of the process of the present invention wherein the supercritical fluid is a gas at room temperature. Polymeric coating material is introduced into the view cell 1 which is connected to a supply of the SCF swelling material (not shown), and through a back-pressure regulator 2A to a source of high pressure fluid 2, such as nitrogen, water or hydraulic fluid. The view cell comprises a piston 3 which is moved by the application of the high pressure inert gas. The apparatus optionally can have a heater 4 for the application of heat should that be necessary to fully liquefy the polymer. The core substance is charged to the view cell either before or after polymer liquefaction, the polymer and core material being intimately mixed by means of a magnetic stirring rod moved by a magnetic motor 5. Once intimate mixture is achieved between the liquefied polymer and the core material, valves 6 are opened permitting expansion of the polymer/core material mixture into a receiving vessel 7. The supercritical fluid returns to a gaseous state during this process and escapes through a vent 8. A camcorder or other viewing or recording device 9 may be attached to the view cell in such a manner to permit observation of the mixing and expansion processes. Similarly, pressure probes 10 and temperature probes 11 can be incorporated to permit monitoring of these parameters during the process.
FIG. 2 is a schematic diagram of another apparatus useful in performing a preferred embodiment of the process of the present invention. Polymeric coating material is introduced into cylinder 1 with piston 2 partially advanced and piston 4 fully advanced in cylinder 3. The supercritical fluid swelling agent 5 is added by pump 6 to cylinder 1, passing through static mixer 7. Desired pressure is applied to cylinder 1 by adjusting back pressure regulator 8, which is connected to a source of high pressure fluid, 14. The polymer can be allowed to soak in the swelling agent in cylinder 1 in order to facilitate liquefaction. The core material to be encapsulated is placed in the biofeed cylinder 10, which is pressurized with the SCF swelling agent 5, forcing the core material into cylinder 3. The polymer, core material and SCF swelling agent then are thoroughly mixed by repeated passing through static mixer 7, due to the reciprocating action of pistons 2 and 4, which are controlled by back pressure regulators 8 and 9. The temperature in the cylinders 1 and 3 and static mixer 7 is controlled by a surrounding air bath (not shown). In this apparatus, it is possible initially to liquefy the polymer with SCF swelling agent at a somewhat elevated temperature, and subsequently lower the temperature before mixing in the core material, in order to minimize exposure of the core to prolonged elevated temperature. After all components have been thoroughly mixed, the mixture is forced into transfer line 11, which may optionally have a nozzle at its end, into receiving vessel 12, which is maintained at a pressure, usually atmospheric, which is much lower than the pressure in the cylinders. The SCF swelling agent, now a gas, is vented through filter 13, while the polymer-encapsulated core material remains in receiving vessel 12.
Any suitable apparatus which permits intimate mixture of the polymer and core materials, the introduction of the supercritical fluid at a pressure sufficient to maintain its supercritical state, release of pressure from the system, expansion of the preparation and separation of the SCF can be used for this process. The selection and/or manufacture of such apparatus is within the ordinary skill in the art and can be done using components which are easily constructed or obtained from commercial suppliers.
The process of the present invention results in a product having core material efficiently encapsulated by polymeric material, resulting in little waste of ingredients. The encapsulated material can be recovered either as fine particles, elongated particles, or a highly porous structure which can be easily ground into particles of the desired size range. This is highly desirable as the substances used as core materials are frequently expensive and/or difficult to manufacture. The encapsulated product is readily processed by per se known methods into any number of suitable forms, such as free-flowing powders, suspensions, coatings or tablets. For instance, microcapsules could be compressed with excipients into tablets, or mixed in a buffered aqueous solution to form an injectable formulation, or applied as a slurry and dried as a surface coating. The nature of the secondary processing is governed by the ultimate use to which the product will be put, and these secondary processing methods are per se known in the art.
The following examples, in the veterinary art, are meant to illustrate but in no way to limit the present invention. The broad applicability of this process to numerous technical fields is apparent and persons of ordinary skill in numerous technical fields will be able to adapt this process and the products made thereby in a variety of ways within the scope of the claimed invention.
EXAMPLE 1
Polycaprolactone (PCL) (mol. wt. 4000) was ground to a powder with a mortar and pestle and then refrigerated. The contents of two vials of Infectious Bursal Disease Virus (IBDV) vaccine (Serial No. 2491) were ground in a mortar and pestle. The ground IBDV vaccine was weighed at 0.9803 g then placed in a sterile bag and refrigerated. The PCL and vaccine were mixed in a 5:1 ratio (4.9042 g PCL to 0.9803 g vaccine) in the sterile bag and shaken until they appeared uniformly dispersed. The mixture then was charged to the view cell of the PLUSS apparatus (see FIG. 1).
After charging, the cell was sealed and CO 2 was charged to a pressure of 4,000 PSI. The polymer/vaccine/CO 2 mixture was soaked for two hours at 22° C. and 4,000 PSI, after which the temperature was gradually raised to 37.5° C. Initial polymer liquefaction was observed at approximately 26.5° C.; liquefaction was complete at 37.5° C. Only one polymer rich phase was apparent. No CO 2 rich phase was visible, apart from bubbles at the top of the view cell. The IBDV vaccine appeared insoluble or incompletely miscible in the polymer/CO 2 phase with polymer and vaccine partitioned into white and orange areas, respectively.
Pressure was released by opening the valve to the polymer collection chamber. Expansion of the fluid polymer was sudden and complete. Approximately 84% of the charged solids were recovered from the collection chamber and view cell. The expanded solids removed were fine to porous. Under a light microscope the expanded solids appeared as agglomerations of fine particles. Large particles were easily separable into smaller particles by application of light pressure. Samples were frozen for later analysis.
EXAMPLE 2
Microencapsulated vaccine samples prepared according to Example 1 were thawed and assayed for IBDV viability. Samples were first washed 3 times with sterile water in order to remove any virus which was not encapsulated. After washing, the microcapsules were dissolved in methylene chloride to release the encapsulated virus. The IBDV was extracted from the methylene chloride solution by contacting it with sterile water. Both the water used to wash the encapsulated vaccine and the water extract from the methylene chloride solution were assayed for IBDV viability by a standard microtiter technique and compared with a control IBDV which was not subjected to PLUSS encapsulation. Briefly, the water solutions were further diluted (1:10 1 -1:10 6 ) in sterile diluent. The dilutions were inoculated onto primary chicken embryos fibroblast (CEF) cells in 96-well microtiter plates and were incubated at 37° C. in a 5% CO 2 incubator. Titration endpoints were determined at the point where the CEFs exhibited cytopathic effects such as cell rounding and degeneration, generally 4-5 days after IBDV inoculation. IBDV titers were calculated by the method of Reed and Muench ("A simple method for estimating fifty percent endpoints." Am. J. Hyg. 27:439-497 (1938)). The results are set forth in Table I, below. Since infectivity assays are dependent on the ability of a virus to infect, replicate and damage cells such as CEFs, the assay results indicate the amount of live infectious virus associated with the surface and interior of the polymer microcapsules. The higher the titer values, the greater the concentration of live infectious virus. A difference in titer values of one unit corresponds to a factor of 10 difference in virus concentration.
TABLE I______________________________________SAMPLE TITER______________________________________Water from third washing 4.2(surface virus)Water from methylene 5.7chloride extraction(encapsulated virus)Control 5.7______________________________________ | The present invention comprises a method for microencapsulating a core material comprising the steps of a) mixing a core material with an encapsulating polymer, b) supplying a supercritical fluid capable of swelling the polymer to the mixture under a temperature and a pressure sufficient to maintain the fluid in a supercritical state, c) allowing the supercritical fluid to penetrate and liquefy the polymer while maintaining temperature and pressure sufficient to maintain the fluid in a supercritical state, and d) rapidly releasing the pressure to solidify the polymer around the core material to form a microcapsule. This method requires neither that the polymer nor core materials to be soluble in the supercritical fluid and can be used to rapidly and efficiently microencapsulate a variety of materials for a variety of applications. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for fabricating a semiconductor device, in particular to a method for fabricating a semiconductor device in which circuit elements such as transistors are electrically isolated from each other by trench isolation regions.
2. Description of the Related Art
In a semiconductor device in which a large number of circuit elements are formed on a semiconductor substrate, it is required to electrically isolate element formation regions in which the elements are to be formed from each other. A trench isolation structure is widely used as such isolation means, because the trench isolation region itself can be extremely small in area. In this structure, a trench is formed in portions of the semiconductor substrate that are allocated for isolation regions, and then buried with an insulating film.
It was, however, reported by the IEEE IEDM (International Electron Device Meeting) Technical Digest (1999, pp. 827-830) that a stress applied from the trench isolation regions to the element formation regions deteriorates the electric characteristics of the elements formed therein. One of the major origins of such stress is due to an expansion or shrinkage of the insulating film filling the trench, that is caused by later thermal treatments such as a heat treatment for an improvement in a quality of the insulating film filling the trench (called hereinafter “trench insulating film”), a thermal oxidation for forming a gate oxide film and so on, and an annealing treatment for activating ion-implanted impurities.
There have been proposed two countermeasure methods for suppressing such stress. The first one is to attempt not to transmit the stress due to the expansion and/or shrinkage of the trench insulating film to the element formation region. The second one is to attempt to reduce the expansion and/or shrinkage of the trench insulating film itself.
The first method is such that a stress buffer layer is formed between the trench insulating film and the element formation region, and is disclosed, for example, in Japanese Laid-open (Kokai) Patent Publication Hei 11-176924 or Hei 1-281746. Taking the 11-176924 Publication as an example, this method will be explained with reference to FIGS. 1A-1D.
As shown in FIG. 1A, a pad oxide film 12 and a pad nitride film 13 are formed on a silicon substrate 11 and a trench pattern is formed therein by use of photolithography techniques and etching techniques. The pad oxide film 12 is generally formed by thermal oxidation to relax a stress between the silicon substrate 11 and the pad nitride film 13 .
Next, as shown in FIG. 1B, using a pad nitride film pattern as a mask, the silicon substrate 11 is etched to form a trench T. Subsequently, in order to recover crystal defects of the substrate 11 around the trench T, which are generated during etching, a thermal oxide film 14 is formed on the side walls and the bottom of the trench T. Then, in accordance with the first method, a silicon nitride film 15 is deposited as a buffer layer for the purpose of absorbing the stress given by the trench insulating film that will be formed in a subsequent step.
After that, as shown in FIG. 1C, the inside of the trench T is buried with a high density plasma CVD oxide film 16 , followed by performing the CMP (Chemical Mechanical Polishing) to leave the high density plasma CVD oxide film in the trench T.
Subsequently, as shown in FIG. 1D, the pad nitride film 13 and the pad oxide film 12 are removed by wet etching to expose active regions. After that, it will be continued to a transistor device forming process.
On the other hand, the second method is to fill the trench with a plurality of insulating films that are different in composition ratio of film materials from each layer. This method is disclosed, for example, in Japanese Laid-open (Kokai) Patent Publication Hei 5-304205 or 9-260484, and will be explained referring to FIG. 2 A and FIG. 2 B. These figures are entered in the Hei 5-304205 Publication.
As shown in FIG. 2A, a trench pattern is formed in a silicon substrate 21 and a thermal oxide layer 22 is formed on the side walls and the bottom of the trench. Then, a first silicon nitride layer 23 which is silicon-rich and has relatively less stress and higher conductivity is deposited on the oxide layer. Subsequently, a second silicon nitride layer 24 which has a nearly stoichiometric composition ratio and has relatively larger stress and lower conductivity is fully buried in the trench. Then, as shown in FIG. 2B, all film layers except in the trench are removed using the CMP technique and a wet etching technique to expose active regions. The layers 23 and 24 may expand or shrink in opposite direction to each other.
The present inventor has, however, recognized that there are significant problems with both of the above methods. That is, in the first method, as shown in FIG. 1D, the volume of the high density plasma CVD oxide film 16 as an insulating film inside the trench T is much larger than that of the buffer layer 15 . For this reason, the buffer effect is not sufficient to maintain desired electrical characteristics of the elements. In particular, the high density plasma oxide film, that is suitable to fill without void such a fine or narrow trench as having sub-micron width for realizing the high integration and fine patterns, presents a large compressive stress. Therefore, the thin buffer layer does not have a sufficient buffer effect. If the buffer layer is formed thick, such thick layer no longer serves as a buffer layer. Rather, it constitutes apart of the trench insulating film.
It is to be noted that since the high density plasma insulation layer is formed by a high density plasma CVD method in which deposition and sputter etching occurs mutually, the high density plasma insulation layer is clearly distinguished from an ordinary plasma CVD insulating film in aspect of deposition process/mechanism. The high density plasma CVD insulating film can completely fill or bury a trench having a width of 0.5 μm or less without void. On the other hand, the trench employing the ordinary plasma CVD insulating film as the trench insulating film is almost always accompanied with a void. Characteristics of the high density plasma CVD insulating film and the differences thereof from the ordinary plasma CVD insulating film are described in the IEEE IEDM Technical Digest (1996, pp. 841-844).
In the second method, it is difficult to control the composition ratio of film materials in each layer to a desired value. The reproducibility is thus poor in this method. Furthermore, this method uses an insulating film other than a high density plasma CVD method is employed, the trench insulating film can not bury a trench having a width of 0.5 μm or less without generation of any void.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to provide an improved method of fabricating a semiconductor device having a trench isolation structure.
Another object of the present invention is to provide a method of fabricating a semiconductor device in which the stress applied to each element formation region from each trench isolation region is efficiently suppressed.
Still another object of the present invention is to provide a method of fabricating a semiconductor device having a trench isolation structure wherein a trench with a sub-micron width of 0.5 μm or less is filled with an insulating film without generation of a void in the trench and with suppressing stress to an element formation region surrounded by the trench.
Yet another object of the present invention is to provide method of fabricating a semiconductor device having a trench isolation structure with controllability and reproducibility.
A method according to the present invention is featured in that an insulating layer, which is to fill a trench selectively provided in a semiconductor substrate, is formed through at least two, separate deposition steps, and a heat treatment is performed after the first deposition step and before the second deposition step.
In other words, the trench insulating layer is not formed at single deposition step, but is performed at least two, separate deposition steps with the heat treatments conducted between these deposition steps. As a matter of course, the insulating film deposited through the first deposition step does not completely fill the trench, leaving a space in the trench, and under this condition, the heat treatment is carried out. By this heat treatment, the trench insulating film formed through the first deposition shrinks or expands. However, in this case, the insulating film is physically free on the side of surface which is exposed to the space in the trench. Accordingly, there is a degree of freedom in the rearrangement of atoms in the insulating film, and the application of the stress due to the expansion or shrinkage of the trench insulating film to the element formation region can be effectively prevented. It is further to be noted that the trench insulating film falls essentially in a thermally stable state after the expansion or shrinkage during the heat treatment. Therefore, even if later thermal treatments such as a thermal oxidation process for forming a gate oxide film and so on and an annealing treatment for activating ion-implanted impurities are carried out, re-expansion or re-shrinkage of the trench insulating film does not substantially occur.
Thus, the method according to the present invention is to make a part or a great part of the trench insulating layer thermally stabilized prior to the trench being completely filled with an insulating film. As a result, the stress applied to each element formation region from each trench isolation region is efficiently suppressed during a further thermal treatment.
With respect to the trench insulating film that has been formed through the final deposition, it may generate some stress during the heat treatment applied thereto because there is no such space as described above. However, such stress can be confined within the level not to cause the substantive deterioration of the characteristics of elements, because the volume of the insulating film deposited at the last deposition step is relatively small.
It is convenient to use a high density plasma CVD insulating film, particularly a high density plasma CVD silicon oxide film, as an insulating film that is to fill the trench. Thus, at least two times of deposition of a high-density plasma silicon oxide film are carried out with performing a heat treatment after each deposition. As a result, the trench with a sub-micron width such as 0.5 μm or less is filled completely with the high-density plasma silicon oxide film without generation of any void in the trench and with substantive suppression of stress applied to the element formation region.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages and features of the present invention will be readily understood by considering the following description in conjunction with the accompanying drawings, in which:
FIGS. 1A-1D are cross-sectional views illustrating the steps of the method for fabricating a semiconductor device according to one prior art;
FIGS. 2A-2B are cross-sectional views illustrating the steps of the method for fabricating a semiconductor device according to another prior art;
FIGS. 3A-3F are cross-sectional views illustrating the steps of the method for fabricating a semiconductor device according to a first embodiment of the present invention; and
FIGS. 4A-4F are cross-sectional views illustrating the steps of the method for fabricating a semiconductor device according to a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Description will now proceed to embodiments of the invention.
As shown in FIG. 3A, according to the first embodiment of the present invention, a pad oxide film 2 having a thickness of 10 nm and a pad nitride film 3 having a thickness of 0.2 μm are sequentially formed on a silicon substrate 1 and are patterned using usual lithography techniques and etching techniques, to expose those portions of the semiconductor substrate 1 where trench isolation regions are to be subsequently formed. The width of the exposed portions, in other words, trenches is designed to be 0.4 μm in the present embodiment.
Then, as shown in FIG. 3B, using the pad oxide film 2 and/or the pad nitride film 3 as a mask, the silicon substrate 1 is etched by a depth of 0.4 μm to form a trench 4 , whose width and depth are equal together. After that, the thermal oxidation is performed to a thermal oxide film 5 having a film thickness of 10 nm on substrate 1 defining the side walls and the bottom of the trench. The purpose of this thermal oxidation to recover crystal defects of the substrate 1 , that have been generated during the trench etching.
Then, as shown in FIG. 3C, a first high density plasma CVD oxide film 6 is deposited using the high-density plasma CVD method. In accordance with the present invention, however, the film thickness of the oxide film 6 is set so as not to fully bury the trench. In this embodiment, the oxide film 6 is deposited to have a thickness of 0.1 μm. Therefore, the trench 4 is filled by the oxide film 6 by 0.2 μm in its width direction, thereby leaving some gap or space 41 in the trench 4 , as shown in FIG. 3 C.
Subsequently, a heat treatment is conducted according further to the present invention. In this embodiment, this heat treatment is performed in an atmosphere of an inert gas such as nitrogen at 800° C. for 10 minutes. During this heat treatment, the expansion of the high density plasma oxide film 6 occurs and then moves into a thermally stable state. The space 41 in the trench 4 releases the silicon substrate 1 from the stress due to the expansion of the film 6 .
Next, as shown in FIG. 3D, a second high density plasma CVD deposition is carried out to form an oxide film 7 over the entire surface of the wafer including the space 41 of the trench 4 . This film 7 is deposited with thickness of 0.1 μm. Thus, the trench 41 is completely filled with high density plasma CVD oxide films 6 and 7 without any void in the trench 4 .
A heat treatment is conducted in an atmosphere of an inert gas such as nitrogen at 800 C for 10 minutes to bring the oxide film 7 into a thermally stable state. At this time, there is no longer any substantial space in the trench 4 . For this reason, the expansion of the oxide film 7 intends to give some stress to the silicon substrate 1 . However, the oxide film 6 , which has been already brought into the thermally stable state, exists between the oxide film 7 and the substrate 1 . Therefore, the stress from the oxide film 7 to the substrate 1 is suppressed to such a level that dose not affect substantial changes in electrical characteristics of transistors which will be later formed in the elements formation regions or active regions surrounded by the trench 4 .
Then, as shown in FIG. 3E, for the surface planerization, the first and second high density plasma oxide films 6 and 7 other than in the trench are removed by the CMP method, which process is terminated at the time when the pad nitride film 3 has been exposed.
Next, as shown in FIG. 3F, the pad nitride film 3 and the pad oxide film 2 are removed by wet etching to expose active regions or element formation regions 101 . After that, the remaining steps are executed to form circuit elements such as transistors and electrical conductive layers (wiring) in and/or on the element formation regions 101 . While such steps include thermal treatments such as a thermal oxidation or an annealing process, the stress from the trench insulating films 6 and 7 to the substrate 1 hardly occurs, because both of the films 6 and 7 are in the thermally stable state.
As described above, the trench insulating layer is not formed by a single deposition step, but is formed by two, separate deposition steps as indicated by two high density plasma CVD oxide films 6 and 7 with the heat treatment before the deposition of the second oxide film 7 . Accordingly, the expansion of the high density plasma CVD oxide film 6 occurs under the existence of the space 41 , and the expansion of the high density plasma CVD oxide film 7 occurs under the existence of the thermally stabilized film 6 . In addition, the thermal treatments during the transistor formation stops are performed under the existence of the thermally stabilized films 6 and 7 . Therefore, the stress applied to each element formation region of the silicon substrate 1 is efficiently suppressed to such a level that does not deteriorate transistor characteristics.
The stress suppression effects are enhanced by forming the trench insulation layer with three or more deposition steps. In this case, the manufacturing steps are prolonged to lower the process throughput. Accordingly, it convenient to form the trench insulating layer by two or three depositions. In other words, the film thickness of the high density plasma oxide film at each deposition for the trench insulation layer is appropriate to be ⅙ to ¼ of a trench width. The heat treatment performed on each high density plasma oxide film is to bring it into the thermally stable state. The temperature range from 700° C. to 1000° C. is preferable for such purpose.
It is to be noted that the heat treatment to the uppermost layer of the high density plasma CVD oxide film may be done after the surface planerization. That is, the heat treatment for the oxide film 7 can be done after the CMP at the stage of FIG. 3 E.
Next, a second embodiment of the invention will be described referring to FIG. 4 .
In the first embodiment set forth, the method was conducted in which the trench was fully buried with the high density plasma oxide film and then CMP was performed. If a high density plasma oxide film has an extremely huge difference of a coefficient of thermal expansion to the silicon substrate, it is possible that crystal defects may be generated in the silicon substrate near the trench when the heat treatment is conducted under the conditions that the oxide film resides on the entire surface of the silicon substrate. This embodiment will exhibit the way to avoid this problem.
First, as shown in FIG. 4A, a pad oxide film 2 and a pad nitride film 3 are sequentially formed on a silicon substrate 1 , a trench pattern is formed thereon and then a trench 4 having a width of 0.4 μm and a depth of 0.4 μm is formed in the silicon substrate.
Then, as shown in FIG. 4B, a first high density plasma oxide film 6 is deposited to have a film thickness of 0.1 μm.
Subsequently, as shown in FIG. 4C, the first high density plasma CVD oxide film 6 on the pad nitride film 3 is removed by CMP, and thereafter a heat treatment is performed in a nitrogen atmosphere at 700° C. to 1000° C. for 10 minutes.
Next, as shown in FIG. 4D, a second high density plasma CVD oxide film 7 is further deposited to have a film thickness of 0.1 μm to fully bury the trench.
Then, as shown in FIG. 4E, CMP is conducted to remove the second high density plasma oxide film 7 except in the trench. After that, the heat treatment is performed in the nitrogen atmosphere at 700° C. to 1000° C. for 10 minutes.
Subsequently, as shown in FIG. 4F, the pad nitride film 3 and the pad oxide film 2 are removed by wet etching.
In the method according to the embodiment, in each deposition step a high density plasma CVD oxide film is deposited inside the trench 4 , the high density plasma oxide film on the pad nitride film is removed and then a heat treatment is performed. Therefore, even though there exits an extremely huge difference of a rate of thermal shrinkage or coefficient of thermal expansion between the high density plasma oxide film and the silicon substrate 1 , the stress can be relaxed without generating any crystal defects in the silicon substrate.
Furthermore, the silicon nitride film 3 is used as a stopper of CMP so that CMP can be terminated at a predetermined position.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | A method for fabricating a semiconductor device is provided in which a stress applied to each element formation region from each trench isolation region is sufficiently suppressed. The method is featured in that an insulating layer, which is to fill a trench selectively provided in a semiconductor substrate, is formed through at least two, separate deposition steps, and a heat treatment is performed after each deposition step. That is, first, a trench is formed on the silicon substrate and a insulating film is deposited in the trench on condition that the insulating film does not fully bury the trench. Then, a heat treatment is conducted. Finally, an insulating film is deposited in the trench to fully bury the trench, and subsequently the heat treatment is conducted. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a device for driving a drilling or percussion tool having a spindle that rotates with respect to a housing.
A device of this kind has been previously described in European patent application 84201720.4, upon which foreign priority is claimed by the applicant.
The present invention improves the means for converting the rotary motion of the drive shaft into an oscillatory motion of a drive member, and improves an associated elastic member, resulting in a design which is simple in construction, and a drilling or percussion tool which occupies less space and has a more favorable weight. One end of the spindle is adapted to fasten to a tool piece and the other end is connected to an oscillating percussion body movable in the housing by means of a guideway. A drive shaft rotates the tool spindle into rotation or actuates the percussion body via a transmission that is provided with means for converting the rotary motion of the drive shaft into an oscillatory motion of a drive member. The drive member is connected to the percussion body through an elastic member having a non-linear spring characteristic.
According to the invention the improved device is distinguished in that the drive member is mounted on the drive shaft or a shaft coupled therewith, which may take place at an angle deviating from 90 degrees to the center line thereof, and the elastic member is rotatably connected to the drive plate-like member, which is provided with a coupling means for engaging the percussion body.
Owing to the direct mounting of the drive member on the shaft associated therewith, the conversion mechanism can be made particularly simple and small. Moreover, the frequency of the oscillating motion can be boosted considerably, with retention of sufficient energy per stroke, which in some embodiments has a considerably better percussion effect on the intended workpiece.
In the preferred embodiment the coupling means is a tongue fastened to the plate which projects into an aperature arranged in the percussion body. In this embodiment the percussion body can be made small and is thereby suitable for high oscillation frequencies.
It can be advantageous to give the aperature a larger dimension in the direction of the stroke than the tongue of the elastic member, so that the desired non-linear spring characteristic is also obtained by using a plurality of stiff elastic members.
In another embodiment there is arranged extending along the elastic member a spring plate wherein the spring constant is less than that of the elastic member Since the spring plate will be cushioned during the movement to a greater or lesser extent against the elastic member, a non-linear spring characteristic results.
If the drive member is mounted directly onto the motor shaft, it is preferable to provide the drive member on the motor side with a clutch, through which not only is assembly simplified, but the bending loads on that shaft will be reduced.
The invention further relates to a device which is provided with a percussion mechanism, for instance in the form described above, wherein the percussive force is transmitted directly to the tool piece to be coupled to the tool spindle. To that end the tool spindle is provided according to the invention with a tool-holding body, which is made with means for the rotation-proof fastening of a tool shank in the tool holder, which nonetheless permits an axial movement of the tool with respect to the drive shaft.
The above and other characteristics will be further elucidated in the detailed description below of a number of alternative embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an axial section of a device according to the invention which is embodied as an electrical hand tool.
FIG. 2 shows a tension-deflection characteristic of an elastic member proposed according to the invention.
FIG. 3 shows an axial section corresponding to FIG. 1 of a part of the device on an enlarged scale.
FIG. 4 shows a cross section view according to line IV--IV in FIG. 3.
FIGS. 5a and 5b show a cross section corresponding to FIG. 3 of two versions of a part of the device on an enlarged scale.
FIG. 6 shows a cross section view according to the line VI--IV in FIG. 5a.
FIG. 7 shows a cross section corresponding to FIG. 3 of a fourth version of a part of the device on an enlarged scale.
FIG. 8 shows a cross section view according to the line VIII--VIII in FIG. 7.
FIG. 9 shows a longitudinal section of a part of the device of FIG. 1 according to a fifth version on an enlarged scale.
FIG. 10 shows a cross section corresponding to FIG. 9 of a part of the device according to a sixth version, however with portions of the housing of the device shown cut away.
FIG. 11 shows a longitudinal section corresponding to FIG. 9 according to a seventh version of the device according to the invention.
FIG. 12 shows a cross section according to the line XII--XII in FIG. 11.
FIG. 13 shows a longitudinal section corresponding to FIG. 11 of a part of the device on an enlarged scale, in which a different tool holding means is shown.
FIG. 14 shows a cross section corresponding to FIG. 1, in which the air intake and outlet openings are disposed differently in the housing in order to achieve a different cooling air flow.
FIG. 15 shows a view of the front part of an electric hand tool provided with dust removal means suited to a device from FIG. 14.
FIG. 16 shows an axial cross section corresponding to FIG. 1 of an electric hand tool according to an eighth version having two drive motors.
FIG. 17 shows a top view of a part of the device of FIG. 16 according to the line XVII--XVII.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference number 1 indicates the housing of an electric drilling tool which comprises in the usual way a electric motor 2, for instance the collector type, and also cooperating with the drive shaft 3 is transmission 4 in the form of a double gear wheel drive and a tool spindle 5. A tool (not shown) can be fastened at the free end of the tool spindle 5 in arbitrary manner. At the opposite inner end of the tool spindle 5 an extension thereof there is included a percussion body 6 which is movable through slide bearings 7 to and fro in the housing 1 in a freely slidable way. The driving of the percussion body 6 for engendering reciprocating movement thereof is possible by means of a driving body 8 with an associated elastic member 9, whereof the construction and the operation will be further elucidated hereinbelow.
It should be mentioned in this connection that according to the known embodiments for hand tools, the housing is provided with a handgrip 10 in which a switch 11 is mounted for the empowerment and switching off of the electric motor 2. The operation and the function of the switch 11 forms no part of the invention and is assumed known, as is equally the principal operation of the electric motor 2 for driving the tool spindle 5 through the transmission 4.
There now follows a description of the driving of the percussion body 6 by means of the drive member 8 and elastic member 9. To that end reference is also made to the cross section on enlarged scale according to FIG. 3.
On the intermediate shaft 12 of the transmission, drive member 8 is supported, the manner of support being modified according to the embodiment of drive member 8. Drive member 8 can extend a fixed angle deviating from 90 degrees with respect to the center line of intermediate shaft 12, this and other matters being so arranged that elastic member 9, in the form of a plate to be described in further detail hereinbelow, similarly extends an angle deviating from 90 degrees to the center line of intermediate shaft 12. On rotation of the shaft 12 drive member 8 with elastic plate 9 will therefore come to acquire a rocking motion which extends between position A (drawn with sold lines in FIG. 1) and position B (drawn with broken lines). It is observed thereby that plate 9 is mounted rotatably on drive member 8, so that plate 9 undergoes an exclusively reciprocating motion, while drive member 8 rotates together with shaft 12. The connection between drive member 8 and shaft 12 is brought about via an axial claw coupling, whereof member 13 is fixed firmly to drive member 8, and member 14 is slidable with a sleeve 15. Sleeve 15 has a passage opening with internal toothing 16, which cooperates with toothing 17 on shaft 12, which toothing 17 engages with gear wheel 18 of tool spindle 5. Moreover, shaft 12 is provided with a shoulder 18, compression spring 19 being held between shoulder 18 and sleeve 15.
It is further observed that tool spindle 5 is mounted to a certain extent axially slidably in the bearing of the housing, so that on the impression of tool spindles in the direction of arrow Pl, gear wheel 18 is carried therewith to the right, which slides sleeve 15 along to the right and causes member 14 of the dog clutch to engage with member 13 and thus with drive member 8.
The elastic plate-shaped member 9 has a bushing through which percussion body 6 is freely movably housed, whereby it is to be understood that body 6 displays a notch 20 at the level of the plate. Into this notch projects tongue 21 of plate 9 (see FIG. 4), this and other matters being so arranged that on reciprocating motion of plate 9 from Position A to position B, and vice versa, tongue 21 thrusts against the end faces of notch 20, through which percussion body 6 is carried in a retarded manner along with the motion of plate 9. The dimensioning of the stroke of plate 9 is such that percussion body 6 repeatedly hits against the free end of tool spindle 5, whereby a hammering effect results.
The working of the device described above is therefore as follows: as drive shaft 3 is made to rotate, the intermediate shaft 12 will be brought into rotation through the first gear wheel transmission, which intermediate shaft 12 causes via the second gear wheel transmission, gear wheel 18 to rotate and thereby rotate tool spindle 5; when tool spindle 5 is impressed, which occurs through the placing of the tool against the workpiece, the shaft is pushed into the housing 1, through which dog clutch 13 and 14 come into action and plate 9 will undergo a reciprocating motion. This will cause percussion body 6 to move to and fro in housing 1 and repeatedly strike against tool spindle 5, through which the combined rotary and percussion drilling effect is brought about.
In the above described embodiment, a non-linear spring characteristic is obtained simply by adopting a relatively stiff plate as the elastic member 9.
This and other matters are shown in the force-distance curve in FIG. 2, wherein the deflection S of the elastic member is shown horizontally and the associated force K is shown on the vertical axis. Since spring plate 9 has a normal linear spring characteristic, this characteristic can be indicated by straight line 24. This straight line intersects the horizontal line at point A, which indicates the one position of spring plate 9 with respect to notch 20, of which the longitudinal dimension corresponds to the line segment AB. The linear characteristic will continue on the left-hand side of the vertical axis in the system of FIG. 2 according to straight line 25. On account of the stepped form of line 24 and 25, the desired non-linear characteristic is obtained, which is necessary for the special working of the device according to the invention. With a less stiff plate 9, a more strongly inclining characteristic will be obtained, as is indicated by the lines 24' and 25' respectively.
In particular embodiments it can be advantageous to arrange a second elastic plate next to elastic plate 9, as is indicated by 26 in FIG. 1. The second elastic plate 26 (see also FIGS. 3 and 4) has a more pliant spring characteristic and therefore a lower spring constant than plate 9. In the interval AB the spring characteristic indicated by lines 24" and 25" will, for example, be followed until plate 9 cooperates. The lines 24" and 25" intersect the S axis at points C and D. The distance CD is the clearance between the spring systems and notch 20 of percussion body 6. A construction of the kind will at least cause the sharp angle between the segments BA and 24 to take a smoother course, as is indicated by-line segment 27. If there is also a second spring plate 26 arranged to the right side of plate 9, this smoothed course can equally be brought about on the left-hand side of the vertical axis of the system in FIG. 2 according to line 27.
The embodiment according to FIG. 3 departs from that in FIG. 1 insofar as that dog clutch 13 and 14 is omitted in this instance. The drive body 8 is shaped here in the form of a rounded rectangular shoulder with respect to shaft 12 tiltable bush, which is clasped firmly mounted collar 28 between a on shaft 12 with an oblique thrust surface 29 and a freely slidable sleeve 30 with respect to shaft 12, also with an oblique thrust surface 31. The thrust surfaces 28 and 31 lie mutually parallel to each other.
The sleeve 30, is in the manner described hereinabove according to FIG. 1, and is similarly moveable toward the right by gear wheel 18 in opposition to the pressure of compression spring 15. When the gear wheel 18 is moved toward the right, the thrust surfaces 29 and 31 will hence be moved toward each other, so that drive member 8 is set into a position deviating from 90 degrees with respect to shaft 12. In this way the elastic plate 9 will similarly be made to incline in a position between the extremes A, B in FIG. 1.
It is also observed that plate 9 is mounted with respect to drive member 8 by means of a radial ball bearing 32. To that end plate 9 is fastened between two normal spring washers 33 on the outer ring of the ball bearing housing 32. In a corresponding way, an optional spring plate 26 is mounted.
The FIGS. 5a, 5b and 6 show an alternative embodiment of the driving mechanism for the percussion body 6. Identical components are indicated by the same reference numerals.
Noteworthy is the form of spring plate 9 as an elastic body. A second spring plate 26 is not used here, but plate 2b is executed with a circuitous-shaped or meandering tongue 35, of which there are two arranged on each opposing side of Plate 9, such that a lower spring constant is brought about. The extremity of the tongue again projects into notch 20 in Percussion body 6.
The plate 9 is here too clamped between two spring washers 33 on the outer race of a radial ball bearing. The radial ball bearing is fastened to drive body 8, which is arranged tiltably with respect to intermediate shaft 12. The drive body 8 is tilted by means of a sliding bushing 15, which is now provided with a radially directed steering surface 31', which cooperates with a radially inward facing steering surface 36 of driving member 8. Through the movement of bushing 15 toward the right against the pressure of a compression spring, steering surface 31 will come into contact with steering surface 35 and cause member 8 to tilt. Through this plate 9 acquires an angle deviating from 90 degrees with respect to intermediate shaft 12 and plate 9 can rock to and fro between the two extreme positions A and B in the manner described above. The extremities of the tongues 35 will deflect out of the plane of plate 9, through which a lower spring constant results. Hence the line 24'/25' in FIG. 2 can be achieved.
FIG. 5b departs from the embodiment according to FIG. 5a with respect to the mounting of plate 9 in relation to drive member 8. To that end, use is not made of the radial ball bearing 32, but of an axial thrust bearing 37, whereby each ball bearing 39 is mounted between plate 9 and on the one side an axial wall member 40 of drive member 8 and on the other side, ring 41. The ring 41 is mounted on a reduced portion of the drive member 8 by means of a spring washer 42. The drive member is here, similarly corresponding to FIG. 5a, tiltable by means of sleeve 15, which is slidable to the right.
FIGS. 7 and 8 show that the elastic member in the form of a stiff plate 9 cooperates with a specially shaped spring Plate 26, which is made more pliable in comparison to the spring plate in FIG. 4. Through this sharper transitions results at the points A and B of the spring tension-deflection characteristic in the system according to FIG. 2.
In this embodiment drive member 8 is executed with a bearing ring 43 arranged directly on the intermediate shaft, around which ring a second bearing ring 44 is mounted whereof the outer surface displays portion 45, whereof the center line forms an angle with that of the drilled hole in the shell 43. In this way a radial ball bearing 32 arranged on this outer surface 35 can adopt an oblique position with respect to the intermediate shaft 12, and the spring plate 9 which is mounted in the manner according to FIG. 5a.
In this embodiment the clutch between intermediate shaft 12 and drive body 8 is absent. The hammering operation of percussion body 6 can be inactivated by fixing this body in the drawn position, for example by passing a pin 6' through a hole in the slide bearing 7 into the percussion body 6.
FIG. 9 shows an embodiment in which percussion body 6 is not accommodated in a sliding support in housing 1 but is suspended in two parallel spring plates 46. The lower end of each plate 46 is fastened in a support 47 of the housing 1. The free upper end of each plate 46 is firmly secured to percussion body 6. A displacement of percussion body 6 to the right or to the left respectively in FIG. 9, results in a translation of percussion body 6, one of the end positions being drawn in the FIG. 9, in this instance in contact with the free end of tool shaft 5.
To this embodiment percussion body 6 is not made with a notch but with two projections 20' which are arranged at a distance from each other. In the space between the projections 20', a tongue 21 of plate 9 can project. In this embodiment the plate is provided on both sides with a spring plate 26. It is clear that the forms of both plate 9 and of plate 26 may correspond to the plate forms described above and shown in the preceding figures The mounting of the plates 9 and 26 respectively can take place in the same way as in the various other embodiments.
Finally it is observed that shaft 12 for drive body 8 is not coupled to the drive shaft of motor 2 by means of a first transmission, but through a tongue and groove coupling 40, so that shaft 12 has the same rotation speed as the motor shaft 12. The coupling is located at the position of the first motor bearing 49, this and other details being such that assembly or disassembly of the motor 2 can take place without it being necessary to dismantle shaft 12.
FIG. 10 shows an embodiment in which percussion body 6 is guided in an axial blind drilled hole 50 in the tool spindle. The end of percussion body 6 projecting outside the drilled hole 50 displays notch 20, into which tongue 21 of spring plate 9 projects. The spring plate is turned over at a central portion 21 to form sleeve 51 in which groove 52 is arranged. In groove 52 a ball cage 53 can be accommodated which similarly runs in a sloping ball track 54 of the drive body 8. The drive body 8 is mounted directly onto the shaft 3 coming from the motor 2 by means of two radial ball bearings 55 separated by a mutual distance.
The motor shaft 3 is made with a toothed end portion 17 which cooperates with the gear wheel 18. The toothed portion 17 similarly engages with the slidable clutch member 14 of a dog clutch which cooperates with a clutch member 13 of drive member 8. The part 14 of dog clutch can be moved to the right or to the left respectively by any arbitrary means, for example by a separate actuation means 55, in order to bring about the coupling between shaft 3 and drive member 8.
It is further observed that a slip coupling in the form of a ball clutch is arranged between gear wheel 18 and tool spindle 5. The gear wheel 18 is mounted freely rotatable on tool spindle 5 between two fixed rings, 56 and 57 respectively. A slidable ring 58 can be pushed, owing to axial splines on the outside of tool spindle 5 and on the inside of ring 58 respectively, in the direction of the left side face of gear wheel 18 by means of a packet of cupped spring washers 59 which abut against the ring 57. Held in gear wheel 18 are balls 60 which are each pressed by ring 58 into one chamber of gear wheel 18. The ring is provided with ball-receiving pits.
On normal loading the force will be transmitted via gear wheel 18, ball friction clutch and ring 58 to tool spindle 5. On overloading, ring 58 will be moved to the left against the resistance of the cupped spring washers, whereby balls 60 are forced out of their pits in ring 58, whereby gear wheel 18 can turn freely with respect to ring 58. The construction shown offers the advantage that percussion mechanism 6 operates independently of the friction safety clutch.
FIGS. 11 and 12 show a following embodiment in which the rotating drive of a tool can be inactivated while the percussion mechanism remains in operation. To that end tool spindle 5 is provided with a portion 60 with external splines, upon which is arranged a slidable ring with internal splines 61. In this way ring 61 is slidable in an axial direction with respect to spindle 5, but remains non-rotatable in respect thereof. On the side facing gear wheel 18 ring 61 is provided with dowels 62, which can engage with recesses in the side face of gear wheel 18. When the dowels 62 fall into these recesses, gear wheel 18 is non-rotatable with respect to ring 61. A compression spring is held between a wall member 63 of the housing 1 and ring 61.
At the top of housing 1 there is mounted a hand-operable rotary knob which is turnable around a vertical axis. On the underside of the knob there is arranged pin 66, which projects into an annular groove of ring 61.
Through the turning of knob 65 from the position shown in the drawing through an angle of 180 degrees, pin 66 will move to the right in FIG. 11, taking with it ring 61 in opposition to the pressure of compression spring 64. In that position the dowels 62 come to lie free of gear wheel 18, whence gear wheel 18 is freely rotatable with respect to ring 61 and hence freely rotatable with respect to tool spindle 5.
The other parts of the transmission agree with those described in the embodiment according to FIG. 1.
On the starting of the motor 2 in the shown situation, a rotational motion is impacted to tool spindle 5, since the intermediate shaft 12 brings gear wheel 18 into rotation, which transmits the rotational motion to ring 61 and thus to tool spindle 5. The drive member 8 comes into operation in the manner described hereinabove as soon as tool spindle 5 is moved towards the right in FIG. 11, whence clutch 13 and 14 are engaged and drive member 8 with plate 9 connected thereto acquires a rocking motion. This rocking motion is translated into a reciprocating motion of the percussion body 6.
If only a percussive motion is required, knob 65 may be turned around, through which ring 61 is moved to the right and the coupling between ring 61 and gear wheel 18 does not occur even when tool spindle 5 is impressed to the right. The rotary motion of intermediate shaft 12 is translated only into a driving of drive member 8 and the reciprocating motion of plate 9 and thus of percussion body 6. The gear wheel 18 revolves thereby freely on tool spindle 5 and tool spindle 5 will exert exclusively a hammering effect.
It is observed that notch 20 in percussion body 6 is located on the underside or on the side facing the intermediate shaft 12, so that plate 9 extends exclusively on the underside of percussion body 6. Here two spring plates 26 and 26' are arranged next to plate 9, a U-shaped fissure 68 being arranged for greater elasticity in one or both plates, whereby the spring length is increased.
In this embodiment an indication is also made of how the tool, for example a drill-bit G, should preferably be held. This may be with the known drill receiving device, which is screwed onto a screw thread of tool spindle 5. This holder device consists of a central part 70, around which a threaded part 71 is mounted. At the front of central part 70 and inside threaded part 71, wedge shaped jaws 72 are placed, whereof the inward facing parts 73 fall into recesses in the shank of the drill-bit G. The length of the parts 73 is less than the length of the recess in the drill-bit G, so that the drill-bit can undergo a certain axial movement with respect to the receiving apparatus, while nonetheless a rotary motion can be transmitted. In this way it is possible to mount the end face of the drill shank G directly against the end face of too spindles, so that the percussive energy is delivered from the percussion body 6 via tool spindle 5 directly to the drill-bit G.
An alternative embodiment of the holder head is shown in FIG. 13, in which the portion of tool spindle 15 protruding form housing 1 is executed with regularly around the circumference hollowed out parts 75, into which roller bodies 76 fit. These lie enclosed (in both the axial and in the radial sense) in the recesses 75. Tool spindle end 5 also carries a sleeve-like housing 76' with recesses 77 similarly for the receiving of the roller bodies 76. The length of sleeve-like housing 76' is such that this can accommodate the shank end of the drill-bit G. This shank end is also made with recesses 78 for the accepting of roller bodies 79. The length of recess 78 is however here greater than that of the bodies 79, so that an axial movement of the shank G with respect to roller bodies 79 is possible, but not a radial movement. The roller bodies 79 fit analogously to the bodies 75 into chambers 80 of sleeve 76'. The bodies 75 and 79 respectively are held in their places by the appropriate rings 81 and 82 respectively which are mounted slidably on the outside of the sleeve 76'. Between the rings there is mounted a compression spring 83, which on the one hand ensures that ring 81 rests against a shoulder 84 of sleeve 76' and on the other hand ensures that ring 82 rests against the end face of a collar 85 mounted firmly on sleeve 76'. The collar 85 is, for instance, made of plastic material. For the fastening of the collar 85 on the sleeve 76', the latter is provided with a groove-shaped recess 86 in which a thickened edge 87 of the collar locks grippingly. The sleeve 76' with the members supported thereby, can be removed from the end of tool spindle 5 by sliding ring 81 to the left in opposition to the pressure of the compression spring 83, whence the roller bodies 76 can be moved out of the recesses 75, whereafter sleeve 76' can be removed. The refitting takes place in reverse manner.
The shank of drill-bit G can be fitted in a similar way by sliding ring 82 to the right in opposition to the pressure of spring 83.
For the purposes of protection, ring 82 may also be provided with a skirt part 88 extending over the compression spring 83 and partly over ring 81.
It is to be preferred that the percussion mechanism is cooled, to which end a motor housing 1 is normally provided with cooling are openings (see FIG. 1). According to the present invention it is recommended that the cooling air is passed forcibly along the percussion mechanism and that use is thereby made of the blade wheel 90 already present on electric motor 2. This twin blade wheel 90 serves for the usual cooling of the electric motor 2, but now also, after the making of appropriately disposed passage openings in the motor housing 1, for the creation of a cooling air stream along the percussion mechanism. To that end, in a partition 91 of the housing 1 there is made a passage opening 92, behind which a filter 93 is situated. Similarly there is made beneath the motor bearing a passage opening 94 (see FIG. 1) through which a cooling air stream results following arrows P2 and P3 along the percussion mechanism and the motor 2 respectively. The air stream can be discharged via the outlet opening 95. The intake of the air normally takes place through slit-shaped openings in the handgrip 10 of the housing 1.
FIG. 14 give a divergent configuration, in which on the underside of the housing 1 there is placed an intake opening 97. Owing to this opening 97, it is possible to carry the air stream via the percussion mechanism and passage opening 92, directly to motor 2 and to discharge the air stream through an outlet opening 95. In this embodiment passage opening 94 is absent.
The opening 97 is excellently suited for the attachment of a flexible tube, as is shown in FIG. 15. This flexible tube 98 is connected to a handgrip 100 which is fastened in the usual way by means of a mounting ring to the housing 1. The handgrip 100 is made hollow and comprises a dust bag 101, which is arranged freely inside the handgrip. The dust bag extends from bottom to top and is firmly mounted on the central intake opening 102 inside the handgrip, which stands in connection with a second flexible tube 103. This flexible tube leads to a drill foot 104, which may be joined in known fashion with the handgrip through rod 105. Dust produced by drilling can be led through the hollow drill foot 104 and the tube 103 into the dust bag 101, the air stream being engendered by the fan 90 of the electric motor.
FIGS. 16 and 17 show an embodiment in which the hammer and rotary drilling apparatus is provided with two driving motors 2 and 2', whereof motor 2 serves for the bringing into rotation of tool spindle 5 by way of transmission 110. Tool spindle 5 is mounted in a bushing 111 which is rotatably held by rolling bearings 112 in housing 1 of the machine. The bushing 111 is provided with gear wheel 18 which cooperates with the pinion of the shaft of motor 2. The bushing 111 moreover accommodates percussion body 6, such that the end face of percussion body 6 can come into contact with the end face of tool spindle 5.
The motor 2' serves for the driving of a percussion body, to which end the motor drives via a first transmission 113, an intermediate shaft 12 which is mounted by means of rolling bearing 114 in the housing 1. The side of transmission 113 remote from the intermediate shaft 12 is provided with concentric disc 115, concentric pin 116 being mounted by means of rolling bearing 117 in drive member 118. The drive member has in top view a triangular form (see FIG. 17) and is so positioned that the top angle of the triangle is disposed towards percussion body 6. Along each side of the triangle there is mounted an elastic member 9 in the form of a strip spring 119 to the drive member 118 which can take place in arbitrary fashion, for example using screws 120.
At the side close to percussion body 6, the end of each strip spring is similarly fastened to a triangular body 121, of which the form corresponds to that of drive member 118. The fastening similarly takes place by means of screws 120. The triangular member 121 is provided with pin 122, onto which a fork-shaped end part 123 of percussion member 6 grips rotatably. Also coupled to pin 122 is a transverse guide member 124, which member is slidably conducted along parallel guide bars 125. The bars are firmly mounted in housing 1.
In this embodiment drive member 118 is mounted rotatably around a motor shaft or a shaft cooperating therewith, which drive member so loads a pair of elastic members 119 that on the actuation of motor 2' and as a consequence of concentric members 115 and 116, the distance between the members 118 and 121 is repeatedly enlarged and reduced. This causes a flexing of flexible members 119, which members uncoil against the flanks of triangular members 118 and 121, which results in a non-linear spring characteristic. The percussion body 6, which is held freely slidable in housing 1, follows the reciprocating motion of drive member 118 in a delayed manner, such that the strip springs 119 are stretched to a greater or lesser extent. The percussion body 6 thereby repeatedly reaches the end face of tool spindle 5, which can be bought into rotation by the empowerment of motor 2.
The above described device can therefore have three functions, namely rotary drilling only, hammering only or a combination of hammer and rotary drilling. In the last case the full power of the two motors can be utilized, which results in a doubling of the power in comparison to the other embodiments.
While the preferred embodiments have been described, variations thereto will occur to those skilled in the art within the scope of the present inventive concept which are delineated by the claims which follow. The invention is not restricted to the embodiments described hereinabove. | This invention relates to a device for driving a drilling or percussion tool having a spindle that rotates with respect to a housing. One end of the spindle is adapted to fasten to a tool piece and the other end is connected to an osciliating percussion body movable in the housing by means of a guideway. A drive shaft rotates the tool spindle into rotation or actuates the percussion body via a transmission that is provided with means for converting the rotary motion of the drive shaft into an oscillatory motion of a drive member. The drive member is connected to the percussion body through an elastic member having a non-linear spring characteristic. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/906,272 filed on Mar. 12, 2007, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to cervical support devices, and, more particularly, to a system for providing low profile cervical support to the vertebrae.
BACKGROUND OF THE INVENTION
[0003] With the advent of modern surgical techniques, methods and systems using rigid cervical support devices have been developed to manage instability of the upper cervical spine in a human body. Such methods and systems have been implemented successfully in patients with cervical disorders requiring stabilization resulting in improved spinal support for the neck and head as well as improvements in relief from pain resulting from such instability.
[0004] One drawback to systems providing sub-axial cervical spine fixation is stabilization support for certain upper vertebrae, referred to as the C1 and C2 vertebrae. Until recently, common techniques for the placement of screws in the C2 for fixation to a fixation network such as a lateral mass screw and rod fixation system resulted in significant risks to the vertebral artery. These risks were reduced by the discovery of techniques for the unique placement of screws in the C2 for connecting the C2 to the rigid cervical rods. A description of C2 fixation problems and a technique of the type suitable for solving such problems is disclosed in “Posterior C2 Fixation Using Bilateral, Crossing C2 Laminar Screws” by Neil M. Wright, MD in the Journal of Spinal Disorders & Techniques, Vol. 17, No. 2 (April 2004), which is incorporated herein by reference.
[0005] While fit for their intended purpose, one problem created by such C2 fixation techniques is that the location and angle of the screw entry and alignment is not well suited for screw insertion and attachment to a rigid cervical rod using existing rigid cervical fixation hardware during surgery.
[0006] Thus, the need exists for a system and method to connect the C2 vertebrae to a fixation schema using the improved techniques that reduce risk to the vertebral artery that have been identified above.
SUMMARY OF THE INVENTION
[0007] The present invention relates to an apparatus for connecting between an upper cervical vertebrae and a cervical fixation network that includes a screw having a portion with a tapered shaft with a helical rim for rotationally entering and gripping the upper cervical vertebrae. A bridge is configured to route between the cervical fixation network and the screw. A connector holding the screw and bridge together includes a portion of the screw and the bridge that is configured differently for a complementary, low-profile engagement of the bridge and screw.
[0008] The invention further includes a device for connecting to an upper cervical vertebrae including a screw having a portion with a tapered shaft threaded for rotationally entering and gripping the upper cervical vertebrae. The screw includes a connector portion for directly contacting a strip routed to a cervical fixation network to provide a low profile connection.
[0009] In another aspect of the invention, a device is included for connecting between a post anchored in an upper cervical vertebrae and a cervical fixation network. The device includes a bridge having at least one end configured for complementary connection to a post. The bridge includes at least one portion that adjusts relative to the post for routing of the bridge between the post and the cervical fixation network.
[0010] In yet another aspect of the invention, a connector for use in a cervical fixation device includes a base configured to receive at least two rods in a locking engagement. The base includes at least one channel having an aperture to receive at least one rod at any location along a shaft of the rod and a set screw fastened into the base to hold the at least two rods against the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Other aspects, advantages and novel features of the invention will become more apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings wherein:
[0012] FIG. 1 is a diagram incorporating functional block for certain structures of a screw with a connector and bridge according to the present invention;
[0013] FIG. 2A is a top plan view of a screw according to the present invention;
[0014] FIG. 2B is a side view of the screw in FIG. 2A according to the present invention;
[0015] FIG. 2C is an exploded perspective side view of a screw with a connector according to the present invention;
[0016] FIG. 3A is a top plan view of a screw according to the present invention;
[0017] FIG. 3B is a side view of the screw in FIG. 3A according to the present invention;
[0018] FIG. 4A is a top plan view of a screw according to the present invention;
[0019] FIG. 4B is a side view of the screw in FIG. 4A according to the present invention;
[0020] FIG. 5 is a side view of a bridge according to the present invention;
[0021] FIG. 6 is a side view of a bridge according to the present invention;
[0022] FIG. 7 is a side view of a bridge according to the present invention;
[0023] FIG. 8 is a side view of the screw with connector of FIG. 2C and bridge of FIG. 6 connected between a C2 vertebrae and a fixation network according to the present invention;
[0024] FIG. 9A is a front view of an alternate screw and bridge configuration according to the present invention;
[0025] FIG. 9B is a side view of the screw and bridge of FIG. 9A with a different rotational displacement relative to FIG. 9A according to the present invention;
[0026] FIG. 10A is a side view of a connector according to the present invention; and
[0027] FIG. 10B is a front view of the connector of FIG. 10A according to the present invention.
DETAILED DESCRIPTION
[0028] With reference to the drawings for purposes of illustration, an improved system 20 is provided for fixation of the C2 to a rigid cervical fixation network 22 such as, but not limited to, a screw and rod system, using a screw or post 24 . Advantageously, a low profile bridge 26 is provided between the rigid cervical fixation network 22 and the screw 24 . Furthermore, a connector 28 is included that facilitates connection of the screw 24 to the bridge 26 . Presently the screw 24 , connector 28 and the bridge 26 may be made from any material or material combination, without limitation, suitable for insertion into a living body. For example, but not by means of limitation, the materials may include stainless steel, a cobalt/chrome alloy, titanium or any alloy combination thereof. Presently, titanium alloy materials are preferred in the medical community and therefore, for that reason, would be preferred in this invention. However, changes in materials preferred by the medical community may be substituted so long as those substitutions conform to the preferred features of the invention described below, including, but not limited to, strength of the screw to withstand rotational torque into a bone mass and strength of the combination of the screw with connector and the bridge to provide the desired amount of cervical fixation.
[0029] C2 screw and Connector
[0030] With reference to FIGS. 2A-C , the screw 24 is a threaded fastener that includes a shaft 30 , cylindrical and tapering to a point 32 at one end with a helical ridge 34 or thread formed on it. The helical ridge is of the self-tapping type for rotational insertion into the C2 vertebrae. The shaft diameter narrows to form a shaft connector portion 36 , cylindrical and non-tapering with a helical ridge or thread 38 formed on it. A ledge or ridge 40 is formed at the point along the shaft where the wider tapered shaft transitions to the non-tapered head shaft portion 36 . The helical ridge 38 of the shaft connector portion 36 is of a non-self tapping type for insertion into an aperture 42 of a nut 44 ( FIG. 2C ) preformed with a complementary cylindrical wall having a helix. The free end of the shaft connector portion ( FIG. 2A ) is shaped to allow locking engagement 46 with a fastening tool such as a screwdriver or wrench. As presently illustrated in FIG. 2A , a hexagonal socket 46 for receiving a hex wrench is shown which permits rotation of the shaft causing the tapered portion of the shaft to be received in the C2 vertebrae. At the region of the ridge 40 , the ridge preferably has radial width of 0.5 mm where the shaft of the shaft connector portion 36 has a radial diameter of 1 to 2 mm and the shaft of the tapered portion 30 at the ridge has a diameter of 3 to 4 mm. The length of the screw may vary according to the size of the C2 vertebrae in which the screw is to be inserted.
[0031] The shaft connector portion 36 has a length sufficient to receive a wide slotted aperture 48 from a screw connector portion 50 of a strip 52 comprising a portion of the bridge about the narrow diameter of the shaft connector portion 36 that rests upon the ledge 40 of the shaft. The wide slotted aperture 48 extends along the length of the metal strip 52 for a length sufficient to allow positional adjustments between the metal strip 52 and the screw 24 . The nut 44 may include a locking device. Locking devices of the type suitable for this purpose may include, but are not limited to, nylon lock nuts, a serrated-face nut, a nut with a lock washer, such as a star washer, locking adhesives, a castellated nut with a pin, a split beam lock nut or any combination thereof. The nut 44 may be capped and may include an outer surface for tightening such as, but not limited to, a polygonal circumference for tightening by a wrench or a serrated face for gripping and tightening by hand or pliers.
[0032] With reference to FIGS. 3A-B , where like structures to FIGS. 2A-C incorporate the reference numerals above, a screw 24 having a tapered shaft portion 30 and a non-tapered shaft portion 36 includes a wider region 56 that tapers quickly from the ridge 40 to the tapered shaft diameter providing a conical outline similar to the bell of a bugle. The wider region 56 allows for the ridge width range to vary from 0.5 to 1 mm and for the range of the shaft connector portion 36 diameter to include a range of 1 to 4 mm. It should be noted that the wider region may be non-tapered and cylindrical without departing from the present invention.
[0033] With reference to FIGS. 4A-B , where like structures to FIGS. 2A-C incorporate the reference numerals above, a screw 24 having a tapered shaft portion 30 and a non-tapered shaft portion 36 includes a wider region 58 that extends between the two shaft portions providing a non-tapered outline having a polygonal shaped circumference that accommodates a rotational torque tool such as a wrench. For purposes of illustration only, a hexagonal shape is shown. The wider region 58 allows for the ridge width range to vary from 0.5 to 1 mm and for the range of the shaft connector portion 36 diameter to include a range of 1 to 4 mm. It should be noted that in this embodiment, the locking engagement 46 at the head of screw may be optional.
[0034] Regardless of the embodiment preferred for a particular use, each of the screws described provides a threaded fastener for secure fixation to a bone mass. The connector features a low profile solution for fixation of the screw to a rigid cervical fixation network. Furthermore the connector configuration permits adjustment of the positional relationship between the bridge and the screw.
[0035] Bridge
[0036] With reference to FIG. 5 , a bridge includes a plate or strip 52 in which the length of the bridge 26 is adapted for a general range of distances for connection between a C2 screw 24 and a rigid cervical fixation network 22 . The bridge width and thickness are proportionally configured in respective sizes according to criteria such as the modulus of elasticity of the material used, the forces received on the material when installed to provide fixed support under such forces in a fixation network, a degree of flexibility when a threshold of force is exceeded through manual pressure applied by a user during insertion to conform the plate to a compatible mating with each of the screw and the fixation network. The plate or strip 52 includes a fixation network connector 60 at one end in the form of a C-shaped sleeve 62 with a semi-cylindrical interior wall 64 with an opening for receiving a rod 66 from a fixation network. The opening of the sleeve faces out away from the opposite end of bridge. The C-shaped sleeve includes a rigid connection to the rod. The rigid connection may be accomplished by any rigid connection means suitable for a permanent rigid connection, which by way of example and not by limitation, can be by crimping or bending by force of the sleeve 62 onto the rod 66 or secured by a set screw 68 inserted through a bore hole 70 in the C-shaped sleeve 62 for rigid fixation of the rod between the screw and the C-shaped wall. A the opposite end of the bridge the strip includes the screw connector portion 74 having a wide slotted aperture 76 sized and shaped such that it is elongated along the length for spatial displacement of the bridge 26 relative to the screw 24 and dimensioned such that opposing sides the strip about the aperture may rest upon the ridge 40 ( FIG. 4C ) which snuggly receives the shaft connector portion 36 of the screw 24 there between. As presently illustrated, the bridge includes a generally 90-degree twist 78 ( FIG. 5 ) in the strip 52 to demonstrate in this written description that the region between the ends may be twisted and bent to route the bridge 26 from the screw having an angle of insertion at a point in the C2 vertebrae to a fixation network having a different angle and for providing a low profile path there between the contours of the bone masses along the route. The single 90-degree angle illustrated in the application is merely to facilitate understanding and illustration of the ends of the bridge while demonstrating the ability of the structure to be bent.
[0037] With reference to FIG. 6 , where like structures to FIG. 5 incorporate the reference numerals above, the plate or strip 52 includes a fixation network connector 60 at one end in the form of a C-shaped sleeve 80 with a semi-cylindrical interior wall 82 with an opening for receiving a rod 66 from a fixation network. The opening of the sleeve faces inward toward the opposite end of bridge. The C-shaped sleeve 80 includes a rigid connection to the rod. The rigid connection may be accomplished by any rigid connection means suitable for a permanent rigid connection, which by way of example and not by limitation, can be by crimping or bending by force of the sleeve 80 onto the rod 66 or secured by a set screw 68 inserted through a bore hole 70 in the C-shaped sleeve 80 for rigid fixation of the rod 66 between the screw 68 and the C-shaped wall 82 .
[0038] With reference to FIG. 7 , where like structures to FIG. 5 incorporate the reference numerals above, the plate or strip 52 includes a fixation network connector 60 at one end in which the strip transitions from a generally rectilinear cross-sectional shape to a generally cylindrical shape to form a rod 86 having a diameter sized to conventional rod diameters of a fixation network. The rod shape then may be connected to the fixation network using a fixation network connector for adding a rod to a fixation network.
[0039] It will further be appreciated that other configurations for the fixation network connector may be used without departing from the features of the present invention. Furthermore, the bridge may span between to screws in which the opposite ends of the bridge may include screw connector portions 74 at each end.
[0040] When in use, an example ( FIG. 8 ) of a screw 24 , a connector and bridge 26 is shown for attachment between a C2 vertebrae 100 and rod 102 of a fixation network 22 having two rods traversing the C2 vertebrae 100 and running the along the length of the spine for possible connection of the C2 vertebrae 100 to other vertebrae (not shown) as medically desired for the patient's medical needs. The embodiment of the screw 24 as shown in FIG. 2C and the embodiment of the bridge 26 as shown in FIG. 6 are used for illustration purposes only, but where like reference numerals of like structures are used herein. Each of the screws 24 is entered into the lamina 104 portion of the C2 vertebrae 100 from opposing angled sides using conventional insertion techniques. As shown in this configuration there is no rotational configuration of the bridge 26 required. The fixation network connector 60 in this exemplary embodiment is made by both crimping and using the setscrew 68 to hold each bridge 26 rigidly with respective rods 102 . It is understood by one of ordinary skill in the art of fixation network insertion that any combination of the above described screws and bridges may be used to accomplish this connection. It is further understood by those skilled in the art of inserting fixation networks in a living body that the cervical structures encountered in a living body may vary and that screws and bridges of varying embodiments and dimensions within the ranges and lengths described may be provided and used as needed medically to make the connection.
[0041] With reference to FIGS. 9A-B , an alternative embodiment of a screw 120 and bridge 122 in the form of a rod in which the connector 124 is hingedly attached together by a hinge pin 125 to allow for the angle 126 of a thread tapered shaft portion 128 of the screw 120 to be adjusted relative to the angle of the bridge 122 . This configuration reduces the profile of the connector 124 at the screw 120 and allows for the bridge 122 to be angled appropriately after insertion of the screw 120 for routing to a fixation network, in which the rod shape of the bridge 122 is sized to conform with existing rod configurations for connection of the rod to a fixation network using connectors. As shown for purposes of illustration, the bridge 122 may be connected to another rod 130 using a connector 132 for two rods using a setscrew 134 . However, it will be appreciated by those skilled in the art that any of the connector configurations described above may be used herein without departing this invention. It will further be appreciated that this embodiment allows for the rotationally hinged connection between the screw and the bridge to operate as a manual insertion tool to facilitate rotational entry of the screw in the C2 vertebrae and at recommended location and insertion angle by bending of the hinge sufficiently to use the leverage of the bridge to achieve the desired rotational movement.
[0042] With reference to FIGS. 10A-B , a connector 200 formed to connect two rods traversing at generally 90 degrees includes generally base 202 having a seat 204 forming a channel with a C-shaped opening 206 for receiving a first rod 208 there through. The seat 204 is presently preferred to be, but not limited to, concave in cross-section. An aperture 210 allows for a second rod 212 to slide through the connector at an angle offset from the first rod. As presently illustrated the aperture 210 is generally perpendicular to the seat 204 ; however, the angular displacement of the aperture 210 relative to the seat 204 may vary and a plurality of connectors allowing for rods to intersect at various angles may be used. The first and second rods are held fast by the connector using a setscrew 214 inserted through a borehole 216 which the compresses the two rods 212 and 208 together between the setscrew 214 and the seat 204 . It will further be appreciated that the shape of the rods may be varied to increase the fastening between them by for example including a flat surface about at least a portion of the circumference such that when the two flat surfaces overlie each other the surface area in contact increases the amount of force required to move the rods relative to each other and the connector.
[0043] Although the invention has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. | An apparatus for connecting between an upper cervical vertebrae and a cervical fixation network that includes a screw for rotationally entering and gripping the upper cervical vertebrae. A bridge is configured to route between the cervical fixation network and the screw. A connector holding the screw and bridge together includes a portion of the screw and the bridge that is configured differently for a complementary, low profile engagement of the bridge and screw in which varying configurations of the connector and bridge, either alone, or in combination, are envisioned. | 0 |
RELATED APPLICATIONS
This application is a divisional of application Ser. No. 11/360,434 filed on Feb. 24, 2006 now U.S. Pat. No. 7,578,103.
BACKGROUND OF THE INVENTION
Some structures are designed with a higher than usual level of safety against partial or complete failure due to their functions and the disastrous consequences of their structural disintegration. However, many of such structures have been designed and built without considering some of the very high impactive or impulsive loads on the assumption that the probabilities of occurrence of such loads are extremely low. As time elapses, the changing circumstances of the world may render this probabilistic assessment obsolete and the probabilities of occurrence of such hazards become non-negligible. As an example of having structures subjected to unexpected hazards is the terrorist attack of Sep. 11, 2001, where three aircrafts crashed upon the two towers of the World Trade Center and the Pentagon building in the United States of America. Many other important structures such as: nuclear reactor containments, nuclear waste storages, large oil or natural gas reservoirs, large chemical containers, ammunition storages and military installations, could be threatened in the future by similar attacks or by accidents or in case of war.
Many of such hardened and rigid structures have reinforced concrete outside walls that may—in some buildings—exceed 2.0 meters in thickness. However, the thickness is usually less when the wall is made of pre-stressed concrete. It is also common to have the structure lined with a layer of steel or a non-metallic material. Moreover, reinforced concrete structures which are partially or completely buried under compacted layers of soil are common, especially, in military installations. Furthermore, it is also a common concept of design to have a cluster of buildings where the building which is required to be the most protected is surrounded by the others.
The common character of most of the above mentioned concepts is the very high rigidity of the outside walls of the structure, which represents a strong shield that is hard to penetrate by hard or soft missiles. However, the challenges represented by a crash of a large civilian air craft or a smart missile which could penetrate thick walls of reinforced concrete, require innovative designs that offer more protection for such important structures and to increase their capabilities to withstand very high impactive and impulsive loads.
SUMMARY OF THE INVENTION
This present invention is based on a novel approach that allows some types of structures to absorb very high energy, which could be generated by soft or hard missiles or by other types of impactive and impulsive loads. In this invention, the main structure is protected by a movable outer shield where the main structure and the movable outer shield are spaced apart and the space between them is filled with a selected crushable filling material. Moreover, the outer shield is initially fixed by an anchorage system; however, if the load exceeds certain limit, the anchorage system collapses and the outer shield becomes unconstrained and—under the effect of the load—undergoes free body motion crushing the filling material and absorbing very high energy.
The following remarks should be considered in regard of this structural system:
1. If the load is less than a certain value, then the outer shield should undergo limited small displacements, causing some strains in the filling layer. This represents the first level of load resistance, which should be sufficient to withstand impactive and impulsive loads and some other types of loads as well; such as tornados and earthquakes up to a certain value. 2. If the load exceeds that value, then the anchorage system should collapse allowing the outer shield to have a rigid body motion by sliding against the sliding-plane and crushing the filling layer, which should absorb a substantial amount of energy. This represents the second level of load resistance. As the shield reaches the maximum possible displacement, a missile—if one is the source of the load—should face three barriers represented by the outer shield, the crushed and compacted filling layer, and finally the wall of the main structure. These three elements can resist an additional and substantial impact force, while the missile's kinetic energy would have been substantially reduced. The collective resistance of these elements represents the third level of load resistance. 3. The possibility of perforating the main structure of this structural system or causing a loss of air tightness to it by a hard missile is considerably lower than it is for other systems due to several reasons:
A. Allowing the outer shield to undergo large displacements substantially reduces the extremely high force generated by the impact of two rigid bodies. B. Creating discontinuities in the impacted structure by having three different layers, which prevents the propagation of stress waves. C. Reducing the possibilities of spalling and scabbing of concrete at the impacted area of the main structure. These phenomena should occur in reinforced concrete walls—even the very thick ones—when impacted by a hard missile. D. Absorbing a substantial amount of the kinetic energy of the hard missile by perforating the outer shield and crushing the filling material before the missile could hit the main structure.
4. In this structural system, the impact force could be resisted by having the anchors and the filling material on the side of the impact subjected to compressive stresses and by having the anchors and the filling material on the opposite side of the impact subjected to tensile stresses. This is an advantage over ordinary structural systems where the load is applied only on the impacted side. 5. Part of the energy of the load is dissipated in the friction generated during the sliding motion of the outer shield under its own weight and any vertical downward force component of the load. 6. The elevation of the sliding-plane should be determined based on the circumstances of each structure including the level of protection provided by the surrounding buildings, the location of the structure, its size, the limit of the outer shield weight. It is possible to have the sliding-plane little above the foundation level of the main structure or at the base level in case of—for instance—an elevated tank. Moreover, it could be possible in some structures to have more than one sliding-plane in the outer shield. 7. Having the crushable layer made of a fire resisting material and adding thin layers made of another fire-resisting material between the crushable layer and the main structure should provide effective fire protection to the structure. This protection is particularly important if the load is due to a crash or explosion which is—in most cases—followed by a fire. 8. This structural system could be used in constructing new structures or in fortifying existing structures as well. In the latter case, the existing structure should be considered as the main structure of the system. The system could also be used for structures with different shapes and sizes. 9. This structural system provides protection to its main structure from extreme weather conditions and large cyclic seasonal temperature variation. This protection maybe necessary in case of an existing structure that has considerable cracking. Moreover, this system could be used to substitute an existing structure for the partial loss of pre-stressing if it is an aging pre-stressed concrete structure. 10. It is possible to design the crushable layer so that it could be used during construction as formwork for a reinforced concrete outer shield which could significantly reduce the construction cost. Moreover, the outer shield could be made of reinforced concrete, steel or any other suitable material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the structural system, where 1 is the main structure, 2 is the crushable layer, 3 a is the movable part of the outer shield, and 4 - 4 is the sliding-plane.
FIG. 2 is a cross-sectional view taken along line I-I of FIG. 1 assuming that the main structure is cylindrical in shape.
FIG. 3 is a cross-sectional view taken along line I-I of FIG. 1 assuming that the main structure is cylindrical in shape and is provided with four counterforts.
FIG. 4 is a cross-sectional view taken along line I-I of FIG. 1 assuming that the main structure is cubic in shape.
FIG. 5 is an enlarged view of circle II of FIG. 2 .
FIG. 6 is a partial cross-sectional view along the vertical axis of the main structure, showing the main components of the system, the sliding-plane; 3 b , the fixed part of the outer shield and; 5 , a construction joint between the main structure and the fixed part of the outer shield.
FIG. 7 is an enlarged view of circle III of FIG. 6 . It shows the details at the sliding-plane, where 6 is a fixed plate; 7 , a sliding plate; 8 , anchor bolts for mounting the fixed and sliding plates to the fixed and movable parts of the outer shields, respectively; 9 , a sealant to seal the gap between the fixed and movable parts of the outer shield from outside; 10 , an anchor rod connecting the outer shield and the main structure; 11 , a base plate for the anchor rod; 12 , an anchor bolt fixing the base plate to the main structure; 13 , a hole drilled through the outer shield; 14 , an adhesive material filling the space between the anchor rod and the walls of the hole; and 15 , a sealant to plug the hole of the outer shield from outside.
FIG. 8 is a partial cross-sectional view along the sliding-plane 4 - 4 of FIG. 1 in the direction of the arrows, where 16 is a key, which is a projection of the movable part of the outer shield; 17 , two sides of a keyway which is a slot created into the fixed part of the outer shield in which the key is embedded and; 18 , a crushable material filling the space between the key and the two sides of the keyway.
FIG. 9 is a cross-sectional view along line I-I of FIG. 1 showing the displaced outer shield due to an impactive or impulsive load.
FIG. 10 , shows the assumed location of a coordinate system used to explain the concept of this invention.
DESCRIPTION OF THE INVENTION
The current invention is related to a structural system that could withstand severe loading conditions, especially, high impactive and impulsive loads which may result from blast pressure, tornado-generated missiles, aircraft strike, and other sources. This system provides protection to the main structure 1 , by having a movable outer shield 3 a spaced apart from the main structure and a crushable filling layer 2 is filling the space in between. The high energy absorption capacity of this system is due in part to the ability of the outer shield to slide against a sliding-plane 4 - 4 crushing the filling layer. The outer shield has a fixed part 3 b , which should be separated by a structural joint 5 from the main structure. This fixed part carries a fixed plate 6 , which defines the sliding-plane. The movable part of the outer shield has a plate 7 , which is provided with sliding means in order to allow the movable part of the outer shield to slide against the fixed plate. Both of the two plates are anchored to the outer shield by anchors 8 . A sealant 9 is used to seal the outside gap between the two plates. The anchorage system could be designed in many different ways; one of them for example is to have rigid anchor rods 10 embedded at one end into holes 13 drilled through the outer shield, where the space between each bar and the walls of the hole in which it is embedded is filled with an adhesive material 14 . The other end of each anchor rod is connected to a base plate 11 and the plate is mounted to the main structure by anchors 12 . The holes are drilled through the outer shield at some selected locations and sealed from outside by a sealant 15 in order to protect the connections from humidity and other weather effects. Moreover, in order to resist the twisting movement which should result from an eccentric load, keys 16 and keyways 17 are created between the movable and the fixed parts of the outer shield with a relatively large clearance between the key and the sides of the keyway filled with a crushable material 18 . A second way to make the connections of the anchorage system is to fix the movable part of the outer shield 3 a to the fixed part 3 b using vertical dowels, which should be sheared off at the impact. Assuming that the main structure is cylindrical in shape, and is located in a Cartesian space so that the Z axis coincides with the vertical axis of the structure as shown in FIG. 10 , then a general impactive or impulsive load can be considered as the equivalent of the following six components: X, Y, Z, M x , M y and M z , where X, Y and Z are the force components in the directions of the X, Y, and Z axes, respectively and M x , M y and M z are the moments about the X, Y, and Z axes, respectively. The Most damaging component to the structure is the force component that is in the radial direction normal to the vertical wall. This force is the resultant force of the X and Y components. In the current invention, this force is resisted as follows depending on its magnitude and area of application:
1. At a relatively small load, the outer shield should undergo a limited displacement crushing the filling layer locally at the area of the impact. Some of the connections of the anchorage system may fail as well. 2. At a higher level of loading, all the connections of the anchorage system should fail and the outer shield should undergo a free body motion sliding against the sliding-plane and crushing the filling material until the total energy of the load is absorbed or until the outer shield reaches the maximum possible displacement. 3. At the highest loading condition, the displaced outer shield, the compressed filling layer and the main structure should act as a structural system subjected to the effect of the remaining unabsorbed energy.
The vertical force component Z is resisted by the own weight of the shield if it is an uplifting force or by the reaction of the fixed plate if it is acting downward. The twisting moment M z is created mainly by the tangential friction and is resisted by the key-keyway interaction. Other moment components: M x and M y should have an overturning action, however, they are counteracted by the stabilizing moment which is due to the own weight of the shield. Moreover, the possibilities of overturning the shield by an impactive or an impulsive load are very remote since that requires the disintegration of the shield or the main structure itself.
There are two types of missiles: soft missiles and hard missiles. The type of missile is determined according to its relative rigidity comparing to the impacted structure. The effect of any of the two types of missiles upon a structure can be studied by analyzing the effect of the associated load-time function on the global stability of the structure. However, in case of a rigid missile, it is necessary to assess the possibilities of perforating the structure by the missile as well. As a hard missile hits a rigid structure, a very high impact force is generated for a very short period of time causing local damage to the structure at the location of the impact. This local damage, while does not undermine the integrity of the structure, however, it could result in serious consequences, in case—for example—a reservoir that contains flammable material or a nuclear reactor containment that is required to be airtight.
This structural system—with its hardened rigid outer shield—offers protection against both types of missiles. The protection against the effect of the load on the global stability of the structure was discussed earlier in this description, while the protection against the perforation risk was discussed in the invention summary.
It should be noticed that the relative strength of the different elements of this structural system should be observed in order to have the required performance under severe loading conditions. For instance, the anchorage system should be designed so that it collapses first before the outer shield is perforated by a representative missile. However, since there is a wide variety of loading conditions, then the design of this structural system should be optimized depending on the circumstances of each application.
One of the materials which could be utilized in making the filling crushable layer is the Stabilized Aluminum Foam (SAF), which has the following properties:
1. High energy absorption capacity. 2. Low heat conductivity. 3. Fire Resistance. 4. High soundproofing. 5. High damping capacity. 6. Environmentally safe.
The following is an explanatory example of designing a system that is capable of withstanding very high impactive load utilizing the Stabilized Aluminum Foam:
An elevated 18 m high cylindrical reservoir has an outside diameter of 40 m and contains highly flammable material. Due to the construction of a nearby airport, it was found that the reservoir is vulnerable to aircraft strikes. It is required to protect the reservoir so that it becomes capable of withstanding a normal impact of an aircraft landing at a speed of 300 km/h. The weight of the aircraft is assumed to be 250 tons and the estimated impact force is 244 MN.
Assuming that the structural system comprises of the following:
1. an outer shield made of reinforced concrete where both of its top cover and side walls are 2′ thick and its total weight is 56 MN, 2. a crushable filling layer made of 18″ thick Stabilized Aluminum Foam, 3. an anchorage system that consists of 48 dowels, each fail in shear if subjected to a shear force of 0.41 MN. Then: 1. The kinetic energy of the aircraft=868 MJ 2. Volume of SAF covering the impacted side=29.1×18=523.8 m 3 3. Volume of the uncrushed SAF following a crash=10.4×18=187.2 m 3 4. Volume of crushed SAF=523.8−187.2=336.6 m 3 5. Energy absorbed in crushing the SAF=0.8 MJ/m 3 ×336.6 m 3 =269 MJ 6. Energy absorbed in moving the outer shield=56 MN×0.8×0.46 m=20.5 MJ 7. Estimated energy absorbed in collapsing the anchorage system, keys, plastic deformations of the outer shield and friction=38.5 MJ 8. Estimated energy absorbed in crushing the aircraft=540 MJ 9. Total energy absorbed=868 MJ
It should be noticed that the force generated by the impact is enough to crush the SAF and to slide the outer shield:
Impact force=244 MN Force required to crush foam=40×18×0.30=216 MN Force required to slide the outer ring=56 MN×0.15=8.4 MN Force required to collapse the anchorage system=48×0.41 MN=19.6 MN Total force required=216+8.4+19.6=244 MN
In this example, the first level of load resistance is defined by the capacity of the anchorage system which is 19.6 MN; the second level of load resistance is the range of loads between 19.6 and 244 MN, where the latter is the required load to displace the outer shield to the position of maximum displacement. The third level of load resistance is defined by loads higher than 244 MN.
In the previous example, the landing weight, the landing speed and the impact force of the aircraft are representative values for a jumbo jet. It was shown that the total kinetic energy of the aircraft could be absorbed in displacing the outer shield alone, which indicates that this structural system is capable of protecting the main structure against even higher impactive or impulsive loads.
Moreover, it should be noticed that following the impact, the displaced outer shield should exert additional moments on the main structure due to the eccentricity of the structure's own-weight in this case. This moment should increase the stresses at some locations; however, these additional stresses should not be significant due to the small ratio between the maximum displacement and the radius of the structure, which is in this example=0.36/20.0=0.018.
Furthermore, if the force required to displace the outer shield is very high due to the large surface area of the main structure, and consequently, the large surface area of the crushable layer, then it is possible to decrease this force by creating recesses in the crushable layer. The thickness of the foam at the recessed areas should be equal to the thickness of the main layer at the densification strain. For instance, the thickness of the crushable layer in the previous example is 0.46 m and the thickness of this layer at the densification strain is 0.09 m, then it is possible to decrease the thickness of the crushable layer to 0.09 m at several areas. This should result in decreasing the force required to displace the shield without undermining the function of the crushable layer.
While particular embodiments of the invention have been disclosed, it is evident that many alternatives and modifications will be apparent to those skilled in the art in light of the forgoing description. Accordingly, it is intended to cover all such alternatives and modifications as fall within the spirit and broad scope of the appended claims. | A structural system that is capable of absorbing high impactive and impulsive loads comprises of the following elements:
(a) Main Structure: should be one of certain types of structures such as: containments, reservoirs, tanks, storages, etc. (b) Crushable Filling Layer: a layer made of crushable, thermally isolating and fire resisting material surrounding the outer walls of the main structure and filling a space between the main structure and an outer shield. (c) Outer Shield: an outside hardened structure fixed by an anchorage system and resting on a sliding-plane. (d) Anchorage System: a set of anchors that hold the outer shield in place and collapses if the impactive or impulsive load exceeds certain level allowing the outer shield to slide crushing the filling layer and absorbing substantial amount of energy. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-In Part of currently pending U.S. patent application Ser. No. 12/546,086 which was filed on Aug. 24, 2009 and which itself is a Continuation-In Part of now abandoned U.S. patent application Ser. No. 11/618,227 filed on Dec. 29, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
This invention relates to methods and compositions for producing stable disinfectants (such as chloramine) for use as a biocidal composition. Industrial water systems are subject to various sorts of fouling. Fouling can occur in the form of mineral fouling, biological fouling, and often combinations of the two. In fact mineral fouling often provides an anchor and substrate for biological infestations, and some organisms leach or secrete minerals onto industrial water system surfaces.
Fouling may occurs as a result of a variety of mechanisms including deposition of air-borne and water-borne and water-formed contaminants, water stagnation, process leaks, and other factors. If allowed to progress, fouling can cause a system to suffer from decreased operational efficiency, premature equipment failure, loss in productivity, loss in product quality, and (in particular in the case of microbial fouling) increased health-related risks.
Biological fouling results from rapidly spreading microbial communities that develop on any wetted or semi-wetted surface of the water system. Once these microorganisms are present in the bulk water they will form of biofilms on the system's solid surfaces.
Exopolymeric substance secreted from the microorganisms aid in the formation of biofilms as the microbial communities develop. These biofilms are complex ecosystems that establish a means for concentrating nutrients and offer protection for growth. Biofilms can accelerate scale, corrosion, and other fouling processes. Not only do biofilms contribute to reduction of system efficiencies, but they also provide an excellent environment for microbial proliferation that can include pathogenic bacteria. It is therefore important that biofilms and other fouling processes be reduced to the greatest extent possible to maximize process efficiency and minimize the health-related risks from water-borne pathogens.
Several factors contribute to the problem of biological fouling and govern its extent. Water temperature; water pH; organic and inorganic nutrients, growth conditions such as aerobic or anaerobic conditions, and in some cases the presence or absence of sunlight, etc., can play an important role. These factors also help in deciding what types of microorganisms might be present in the water system.
Many different Prior Art approaches have been attempted to control biological fouling of industrial processes. The most commonly used method is the application of biocidal compounds to the process waters. The biocides applied may be oxidizing or non-oxidizing in nature. Due to several different factors such as economics and environmental concerns, the oxidizing biocides are preferred. Oxidizing biocides such as chlorine gas, hypochlorous acid, bromine derived biocides, and other oxidizing biocides are widely used in the treatment of industrial water systems.
One factor in establishing the efficacy of oxidizing biocides is the presence of components within the water matrix that would constitute a chlorine demand or oxidizing biocide demand. Chlorine-consuming substances include, but are not limited to, microorganisms, organic molecules, ammonia and amino derivatives; sulfides, cyanides, oxidizable cations, pulp lignins, starch, sugars, oil, water treatment additives like scale and corrosion inhibitors, etc. Microbial growth in die water and in biofilms contributes to the chlorine demand of the water and to the chlorine demand of the system to be treated. Conventional oxidizing biocides were found to be ineffective in waters containing a high chlorine demand, including heavy slimes. Non-oxidizing biocides are usually recommended for such waters.
As described in U.S. patent application Ser. Nos. 12/546,086 and 11/618,227, Chloramines are effective and are typically used in conditions where a high demand for oxidizing biocides such as chlorine exists or under conditions that benefit from the persistence of an oxidizing biocide. Domestic water systems are increasingly being treated with chloramines. Chloramines are generally formed when free chlorine reacts with ammonia present or added to the waters. Many different methods for production of chloramines have been documented. Certain key parameters of the reaction between the chlorine and the nitrogen source determine the stability and efficacy of the produced biocidal compound.
Prior Art methods of producing chloramines have been described for example in U.S. Pat. Nos. 7,285,224, 6,132,628, 5,976386, 7,067,063, and 3,254,952 and US Published Patent Application and 2007/0123423. The Prior Art methods generally rely on the combination of an ammonium stabilizer component and a sodium hypochlorite component in a dilute or concentrated form to produce a solution of chloramines followed by immediate introduction into the water system being treated. Also typically the combination of the chemical components is conducted in a continuous and synchronous fashion in a conduit. To achieve this the components are either added to separate diluent (such as water) streams followed by the combination of the different streams containing the diluted components or the components are added simultaneously to the same stream at different locations, or the concentrated from of the components are combined. The components comprise a nitrogen source typically in the form of a ammonium salt (such as a sulfate, bromide, or chloride) and a chlorine or Bromine donor in the form of gas or combined with alkali earth metal (such as sodium, potassium, or calcium). Also the prior art methods have relied upon controlling the pH of the mixed solution by addition of a component at a high pH or by the separate addition of a caustic solution.
The limitations of these Prior Art methods have imposed a number of drawbacks on their use. Most limiting is the fact that the produced chloramine must be immediately used and cannot be stored for future use because it is subject to rapid degradation. The chloramine also must be generated outside of the system being treated and must be rapidly piped in to the system. As a result various economic, efficiency, and process, constraints limit the use and practicality of these Prior Art methods. Thus there is clear need and utility for a methods and compositions useful in improving the production and use of stable chloramine for use as a biocidal composition.
The art described in this section is not intended to constitute an admission that any patent, publication or other information referred to herein is “Prior Art” with respect to this invention, unless specifically designated as such. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 CFR §1.56(a) exists.
BRIEF SUMMARY OF THE INVENTION
At least one embodiment of the invention is directed to a method of producing stable disinfectant for use as a biocidal composition. The method comprises: A) providing reagents, B) asynchronously feeding the at least two of the reagents into a wide space, and C) allowing all the reagents to come into contact and mix with each other. The reagents comprise: a) an amine source of disinfectant in concentrated form, b) an oxidizing halogen compound in concentrated form, and c) a diluent.
The amine source may be chloramine. The diluent may comprise enough caustic to reduce the pH of the combination of reagents to no more than 12.5. The concentration of the disinfectant in concentrated form may be in the range from 5%-80% and after it is mixed with the diluent it drops to 0.01%-5%. The concentration of the oxidizing halogen compound in concentrated form may be within the range of 3%-18% and after it is mixed with the diluent it drops to 0.01%-3%. The molar ratio of chloramine to oxidizing halogen may be within the range of 0:1:1 to 10:1. The oxidizing halogen may be a chlorine source and may be sodium hypochlorite. The disinfectant may be produced according to a batch process, a continuous dose process, a slug dose process and any combination thereof.
Additional features and advantages are described herein, and will be apparent from, the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
FIG. 1 is a drawing of a separate addition method of producing chloramine using a wide space in the blending lines or a batch method.
FIG. 2 is a drawing of a continuous dilution method of producing chloramine using a wide space in the blending lines or a batch method.
FIG. 3 is a drawing of a prior mixing method of producing dilute chloramine using a wide space in the blending lines or a batch method.
FIG. 4 is a drawing of a prior mixing and subsequent dilution method of producing chloramine using a wide space in the blending lines or a batch method.
FIG. 5 is a drawing of a sequential addition method of producing dilute chloramine.
FIG. 6 is a drawing of a sequential feed method of introducing chloramine into a system to be treated.
FIG. 7 is a drawing of a periodic addition method of introducing chloramine into a system to be treated.
FIG. 8 is a drawing of a first form of alternating addition method of introducing chloramine into a system to be treated.
FIG. 9 is a drawing of a second form of alternating addition method of introducing chloramine into a system to be treated.
FIG. 10 is a drawing of a third form of alternating addition method of introducing chloramine into a system to be treated.
FIG. 11 is a drawing of a fourth form of alternating addition method of introducing chloramine into a system to be treated.
FIG. 12 is a drawing of a first form of alternating feeding addition method of introducing chloramine into a system to be treated.
FIG. 13 is a drawing of a second form of alternating feeding addition method of introducing chloramine into a system to be treated.
FIG. 14 is a drawing of a third form of alternating feeding addition method of introducing chloramine into a system to be treated.
FIG. 15 is a drawing of a third form of alternating feeding addition method of introducing chloramine into a system to be treated where the amine and halogen components are added at the same location in the conduit.
FIG. 16 is a drawing of a third form of alternating feeding addition method of introducing chloramine into a system to be treated where the amine and halogen components are added at the same location in the conduit.
FIG. 17 is a drawing of a third form of alternating feeding addition method of introducing chloramine into a system to be treated where the amine and halogen components are added at the same location in the conduit.
FIG. 18 is a drawing of a third form of alternating feeding addition method of introducing chloramine into a system to be treated where the amine and halogen components are added at the same location in the conduit.
FIG. 19 is a drawing of a third form of alternating feeding addition method of introducing chloramine into a system to be treated where the amine and halogen components are added at the same location in the conduit.
DETAILED DESCRIPTION OF THE INVENTION
The following definitions are provided to determine how terms used in this application, and in particular how the claims, are to be construed. The organization of the definitions is for convenience only and is not intended to limit any of the definitions to any particular category.
“Amine Source” means any inorganic or organic compound comprising an ammonium ion and/or moiety which can be oxidized and/or halogenated by an oxidizing halogen.
“Asynchronous Mixing” means mixing such that over a discrete period of time the amount or concentration of a material mixed and then fed into a system fluctuates. Asynchronous Mixing of biocides is more likely to result in the particular formulation ideal for killing the particular organism present happening to result and it also creates a dynamic environment which makes it difficult for organisms to adapt to.
“Batch Process” means chemical process in which only a finite number of reagents can be fed into a reaction operation over a period of time having a discrete start time and end time and which produces a finite amount of product.
“Channeling” means a process in which mixture of materials flowing through a line separates into different flowing layers sorted by density, viscosity, temperature or some other property. Channeling can be prevented by use of a wide space in the mixing line.
“Chlorine demand” means the quantity of chlorine that is reduced or otherwise transformed to inert forms of chlorine by substances in the water; standard methods have been established for measuring it. In this specification and claims “chlorine demand” includes the properties innate to the results of measurements and procedures outlined in “Standard Methods for the examination of water and waste water,”, 16th edition, Methods §409, pages 316-319. The methods are based on applying a specific dose of chlorine to the medium and measuring the residual chlorine left after a given contact time. Chlorine-consuming substances include ammonia and amino derivatives; sulfides, cyanides, oxidizable cations, pulp lignins, starch, sugars, oil, water treatment additives like scale, and corrosion inhibitors.
“Concentrated” means the materials are used as delivered, without the addition of a diluent. Where sodium hypochlorite is used, the concentration will range from 3-18% as total available chlorine. The concentration of the amine solutions may range from 5-80%.
“Continuous Process” means an ongoing chemical process, which is capable of theoretically continuing over an unlimited period of time in which reagents can be continuously fed into a reaction operation to continuously produce product. Continuous Process and Batch Process are mutually exclusive.
“Fouling” means the unwanted deposition of organic or inorganic material on a surface.
“Oxidizing Halogen” means a halogen bearing composition of matter including but not limited to chlorine, bromine or iodine derivatives, most preferably a chlorine or bromine derivative such as hypochlorous acid or hypobromous acid, wherein the composition is capable of oxidizing an amine source.
“Wide Space” means an area in the mixing line where the diameter of the line is larger than the largest individual reagent supply line leading into it and in which the transition from the smaller to larger diameter is not streamlined, whereby when a liquid flows into this area the change in diameter results in eddies which mix the fed materials in an erratic manner and prevents channeling. This wide space allows for adequate mixing, functioning differently than a standard conduit. The wide space could be an isolated batch tank.
In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk - Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, Sohn & Sons, Inc.) this definition shall control how the term is to be defined in the claims.
In at least one embodiment chloramine is generated by a process in which the chemical reagents are introduced into a wide space for the production of chloramine. In at least one embodiment one or more of the reagents are introduced either automatically via a controller device, such as a PLC device or a timer, or manually. Any number of measurements can be used to regulate the flow of reagents, including but not limited to tank volume, ORP, residual chlorine, pH, temperature, and microbial activity. The wide space can take the shape of a plumbed wide zone in a conduit that is then connected to the process being treated or can be a separate container, for example a tank. A diluent which is any appropriate liquid including but not limited to water is also streamed into the wide space.
In FIGS. 1-19 there are shown a number of arrangements for an apparatus used in the inventive method. These apparatuses involve the feeding of at least three items into the wide space ( 4 ). Feed item A ( 1 ) is a concentrated or a diluted chlorine source, typically sodium hypochlorite. Feed item B ( 2 ) is a concentrated or a diluted stabilizer composition which is a nitrogen hearing composition. The nitrogen hearing portion can be an organic material or an ammonium salt. The salt form can be a result of the nitrogen bearing item being in the form of a sulfate, bromide or chloride. The nitrogen bearing material can also include ammonium sulfamate. At some point Feed hem A ( 1 ), Feed item B ( 2 ), come into contact with a diluent ( 3 ). In at least one embodiment the diluent comprises water. In at least one embodiment the diluent comprises enough caustic to maintain the pH of the combination of Feed items A and B ( 1 , 2 ) to no more than 12.5. Other means of caustic addition include adding caustic to the halogen and/or stabilizer solution to maintain the pH of the combination of Feed items A and B ( 1 , 2 ) to no more than 12.5.
Referring now to FIG. 1 there is shown a method in which Feed items A and B ( 1 , 2 ) are added as concentrates or as diluted products. Additional diluent ( 3 ) may or may not be added or the products may be batch diluted on-site. The setup optional mixer to aid mixing of the different components. The chloramine as produced in the tank is then introduced into the process water system ( 7 ) needing to be treated. The introduction may be by way of a pump ( 6 ). The chloramine is produced in the wide space ( 4 ) and is then introduced into the process water system needing to be treated.
Referring now to FIG. 2 there is shown a method in which Feed items A and B ( 1 , 2 ) are diluted continuously as they are introduced into the wide space ( 4 ). Feed Items A and B ( 1 , 2 ) and diluent ( 3 ) may be blended in any order. In at least one embodiment not all components are diluted. The setup may contain an optional in-line or static mixer to aid mixing of one or more chemical components and the diluent. Also, the setup may include a mixer in the tank to aid in the blending of the different solutions. The chloramine as produced in the tank is then introduced into the process water system requiring treatment.
Referring now to FIG. 3 there is shown a method in which Feed Items A and B ( 1 , 2 ) are either concentrates or diluted and are mixed with each other prior to being introduced into the tank. The setup may contain an optional in-line mixer to aid mixing of the chloramine and the diluent. Also, the setup may include a mixer in the tank to aid in the blending of the different solutions. The diluent can optionally be introduced into the tank in a separate stream.
Referring now to FIG. 4 there is shown a method in which Feed Items A and B ( 1 , 2 ) can be mixed prior to entering the tank followed by the addition of the diluent to the conduit before entering the wide space ( 4 ). Feed Items A and B ( 1 , 2 ) may be concentrates or diluted prior to blending. The setup may contain an optional in-line mixer to aid in the blending of the chloramine and the diluent. Also, the setup may include a mixer in the tank to aid in efficient blending of the different solutions.
Referring now to FIG. 5 there is shown a method in which Feed items A and B ( 1 , 2 ) are added sequentially to a stream of the diluent. The combination of Feed Items A and B ( 1 , 2 ) result in the formation of the chloramine, which is then introduced into the wide space ( 4 ) along with the diluent. The setup may contain an optional in-line mixer to aid mixing of the chemical components and the diluent. Also, the setup may include a mixer in the tank to aid in efficient mixing of the different solutions.
Referring now to FIGS. 6-13 there are shown methods in which Feed Items A and B ( 1 , 2 ) are synchronously or asynchronously combined in a diluted form (concentrate added to a diluent) via a controller device, such as a PLC device or a timer, or manually and the resulting chloramine is introduced, synchronously or asynchronously, into the process to be treated. In this method, any number of chemical components can be introduced into the diluent stream. The diluent can be water or any other liquid stream appropriate for the dilution of the chemical components. The method may comprise a valve ( 5 ) to control the flow. A solid arrow line after the valve ( 5 ), depicts a continuous flow while a dashed line represents an interrupted or discontinuous flow.
Referring now to FIG. 6 there is shown a method in which Feed Items A and B ( 1 , 2 ) are added sequentially into the conduit in a continuous manner and the feed of the resulting chloramine to the process being treated is continuous.
Referring now to FIG. 7 there is shown a method in which Feed Items A and B ( 1 , 2 ) are added sequentially into the conduit in a continuous manner but the feed of the resulting chloramine to the process being treated is discontinuous.
Referring now to FIGS. 8, 9, 10, and 11 there are shown a method in which Feed Items A and B ( 1 , 2 ) are added sequentially into the conduit but the addition of one of Feed Items A or B is periodic. The feed of the resulting chloramine to the process being treated can be either continuous or periodic.
Referring now to FIGS. 12 and 13 there are shown methods in which Feed Items A and B ( 1 , 2 .) are added sequentially into the conduit but the addition of all the chemical components is periodic. The feed of the resulting chloramine to the process being treated can be either continuous or periodic.
Referring now to FIGS. 14, 15, 16, 17, 18, and 19 there are shown methods in which Feed Items A and B ( 1 , 2 ) are added simultaneously at the same location in the conduit and the addition of all the reactants can be continuous or periodic. The feed of the resulting chloramine to the process being treated can be either continuous or periodic.
The inventive methods facilitate the production of chloramine in ways that display numerous advantages. The method facilitates batch production and can be performed under dilute conditions. The ability to fine tune the amounts of chloramine, stabilizer, and halogen components allows for enhanced process compatibility and program performance through optimized chemical use. In at least one embodiment the production is coupled to a monitor device which measures quantity produced, and/or product quality.
As described earlier, the production of a halogenated amine disinfectant (for example chloramine) utilizes an amine source, an oxidizing halogenated compound and a diluent (preferably water) as chemical components. The concentration of the amine source in the concentrate form of the solution can range from 5%-80% and in the dilute form it can range from 0.01%-5%. Similarly, the concentration of the oxidizing halogenated composition in the concentrated form can range from 3%-18% and in the dilute form it can range from 0.01%-3%. From the perspective of blending ratio between the reactants, the molar ratio can range from 0.1:1 (N:Cl) to 10:1 (N:Cl). The ratio at which blending optimizes the formation of chloramine will determine the flow rates of the reactant in relation to time (invented method #1 above) or in relation to the flow rate of the diluent (invented method #2 above). The need for pH control at the time of blending may be achieved through the addition of other chemical components, for example caustic or an acid, or other means.
Among other reasons, this invention is superior to the prior art because it results in a form of stabilized-chlorine that has enhanced persistence of chlorine in fouled water systems thus providing for improved biofouling control.
The invention also moots the need for continuous operation of the chloramine feed system. Also, since the chloramine is produced in a dilute batch mode, the equipment required for production is simplified and the need for expensive, compatible materials is reduced. This also results in a safer system as there is no danger of a “runaway” reaction in controlled batch production that exits in continuous reactions. The controlled nature of the reaction also allows for precise dose changes in response instant changes in the reaction conditions.
The chloramine can be produced in a batch mode and then be dosed continuously or intermittently into the system being treated. This method also provides the ability to periodically deliver shock doses at much higher concentrations than would normally be applied and then allowing the chlorine residual to decay prior to subsequent treatment. Application of chloramine in such a shock dose regime provides for more persistent and widely distributed chlorine residual. Enhanced persistence of chlorine allows for better control over microbiological populations that may not be adequately controlled at lower chlorine doses or that may tend to develop as ‘resistant’ populations.
In at least one embodiment the chloramine is added according to an asynchronous mixing process. Unlike for example in U.S. Pat. Nos. 6,132,628 and 5,976,386 the asynchronous mixing of the reagents is more likely to result in the particular formulation ideal for killing the particular organism present happening to result and it also creates a dynamic environment which makes it difficult for organisms to adapt to. Such a moving target allows for a more thorough biocidal effect.
In at least one embodiment the asynchronous mixing process is a batch process. The reagents are made in discrete batches and are blended and added for a discrete period of time.
In at least one embodiment the asynchronous mixing process is a continuous process. The flow of reagents is not linked to a single blending. At any time there is an alternation of which reagents are fed. At some times all of the reagents are being fed and at other times some or none of the reagents are fed.
In at least one embodiment the flow of reagents is inhibited and does not pass directly from the conduit in which it is mixed into the system to be treated. Instead the reagent flow is stopped for a period of time in a tank or wide space for a period of time where at least some mixing occurs and only then do the reagents continue on to the system being treated.
In at least one embodiment, the chloramine is produced by the blending of an amine and chlorine (or bromine) source in a certain ratio. Chloramines provide for a more persistent chlorine residual in fouled water systems. Therefore, there are times when it would be beneficial to not dose chloramine but to dose only one of the two reactants (amine source or the chlorine compound). The need for such a strategy will vary from one application to another. For example, in conditions where there is the likelihood of low halogen consumption, a periodic addition of the amine source alone (no halogen) will aid quenching the free hypochlorous acid, formed or introduced, and thereby reduce corrosion. Minimizing free halogen also provides for improved compatibility with other chemicals that might be added to water systems, including but not limited to strength aids, retention or drainage aids, sizing chemicals, optical brightening agents, and dyes. Similarly, under conditions of high halogen demand, it would be prudent to periodically administer the oxidizing halogen alone (without amine) so that the halogen reduces some of the Chlorine demand and improves the long-term persistence of the chloramine and chlorine residual in the water system.
In at least one embodiment the process water system being treated for microbial control include but are not limited to cooling water systems, domestic water systems, boiler water systems, biofouling control or cleaning of RO membrane systems, in Food and Beverage applications such as flume water treatment, washing of fruits, salads and vegetables, treatment of waste water systems, ballast water systems, and paper, tissue, towel and board manufacturing processes, including machine chests, head box waters, broke chests, shower water etc.
In at least one embodiment the flow of at least one of the reagents is governed by a feeding mechanism. The feeding mechanism may be in informational communication with one or more forms of diagnostic equipment. The diagnostic equipment may measure and transmit the measurement of such variables as pH, temperature, amount of biological infestation, type of biological infestation, and concentrations of one or more compositions of matter. The measurement may be of any portion of the system to be treated and/or in any portion of the teed line(s). In at least one embodiment at least one of the forms of diagnostic equipment is at least one form of equipment described in U.S. Pat. No. 7,981,679. In at least one embodiment the feeding mechanism is constructed and arranged to increase, decrease, or cease the flow of at least one reagent in response to receiving at least one transmitted measurement.
In at least one embodiment the asynchronous flow of reagents is accomplished according to a “slug dose” strategy. In a slug dose the feeding alternates between low or non doses of one or more reagents and then concentrated feedings. For example over a 2.4 hour period extending between hour 0 and hour 24, at some point between hour zero and hour 6 nothing is fed into the system, then tee up to 6 hours bleach or ammonium sulfate is added, then for up to 6 hours both bleach and ammonium sulfate are added. In this regiment the concentration of free bleach free ammonium sulfate chlorine and formed chloramine varies. The slug dose can be targeted to be in synch with the expected growth and persistence of particular thrills of biological infestation. In at least one embodiment multiple slug doses can be fed per 24 hour period interspersed with periods of time in which nothing is fed to the system.
In at least one embodiment the asynchronous flow of reagents is accomplished according to a “continuous dose” strategy. In a continuous dose there is constantly some reagent being fed into the system but what and how much of each reagent changes. For example over a 24 hour period extending between hour 0 and hour 24, at some point between hour zero and hour 6 all of the reagents are fed into the system, then for up to 6 hours only bleach or only ammonium sulfate is added, then for up to 6 hours both bleach and ammonium sulfate are added. In this regiment the concentration of free bleach free ammonium sulfate chlorine and formed chloramine also varies. In addition the continuous dose can also be targeted to be in synch with the expected growth and persistence of particular forms of biological infestation. In at least one embodiment multiple doses of only bleach and/or only ammonium sulfate can be fed per 24 hour period interspersed with periods of time in which both are fed to the system.
While this invention may be embodied in many different forms, there described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Additionally, the invention also encompasses any possible combination of some or all of the various embodiments described and incorporated herein. Furthermore the invention also encompasses combinations in which one, some, or all but one of the various embodiments described and/or incorporated herein are excluded.
The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, hut not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, (e.g. 1 to 6.1), and ending with a maximum value of 10 or less, (e.g. 23 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range.
This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | A method of producing stable disinfectant for use as a biocidal composition. The method comprises: providing reagents, asynchronously feeding the reagents into a wide space, and allowing all the reagents to come into contact and mix with each other. The reagents comprise: a) an amine source in concentrated form, b) an oxidizing halogen compound in concentrated form, and c) a diluent. The use of asynchronous feeding and a wide space results in a dynamic biocide regimen. This regimen results in a changing environment that infestations have difficulty adapting to. This method also imparts superior results due to the avoidance of channeling effects which would otherwise weaken the effects of the biocide. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing carbon black filled polyethylene resins and more particularly to a process for producing carbon black filled polyethylene resins in situ in a fluidized bed reactor.
2. Description of the Prior Art
The introduction of high activity Ziegler-Natta catalyst systems has led to the development of new polymerization processes based on gas phase reactors such as disclosed in U.S. Pat. No. 4,482,687 issued Nov. 13, 1984. These processes offer many advantages over bulk monomer slurry processes or solvent processes. They are more economical and inherently safer in that they eliminate the need to handle and recover large quantities of solvent while advantageously providing low pressure process operation.
The versatility of the gas phase fluid bed reactor has contributed to its rapid acceptance. Alpha-olefins polymers produced in this type of reactor cover a wide range of density, molecular weight distribution and melt indexes. In fact new and better products have been synthesized in gas phase reactors because of the flexibility and adaptability of the gas phase reactor to a large spectrum of operating conditions.
Polyethylene resins are particularly amenable for production in fluidized bed reactors. For many industrial applications it is beneficial, if not required, that the polyethylene resins contain carbon black. For example, products which are currently being produced with carbon black filled polyethylene resins include pipes, tubes, sheets, wire and cable constructions, and other molded or extruded polyethylene articles.
Currently, carbon black filled polyethylene resins, used for example, in black jacketing applications are generally produced by either the masterbatch or the direct addition approach. The masterbatch technique normally involves three basic steps, i.e., the preparation of the natural feedstock; the preparation of the masterbatch containing carbon black; and the blending of the natural feedstock with the masterbatch which is thereafter compounded in an intensive mixer such as a Banbury mixer, a Farrel continuous mixer (FCM) or a single or twin screw extruder.
In the direct addition technique, the natural feedstock is produced, and a blend of carbon black and the natural resin is compounded in an intensive mixer such as a Banbury or a FCM mixer.
The masterbatch technique offers a number of advantages over the direct addition technique which include good dispersion of carbon black within the resin matrix particularly with low viscosity resins.
However both of these techniques are time consuming and expensive.
It would be extremely beneficial and economically attractive if carbon black filled polyethylene resins could be produced in situ, i.e., during the fluidized bed polymerization procedure, since the costly and time consuming steps discussed above could therefore be eliminated.
SUMMARY OF THE INVENTION
Broadly contemplated the present invention provides a process for producing polyethylene resins containing carbon black in a gas fluidized bed reactor which comprises introducing into said reactor, polymerizable monomers capable of producing polyethylene resins at polymerizable reaction temperatures in the presence of a catalyst while directly introducing into said reactor during said polymerization, carbon black, in an amount to produce said polyethylene resins containing carbon black.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a typical gas fluidized bed reaction scheme for producing polyethylene resin containing carbon black.
DETAILED DESCRIPTION OF THE INVENTION
The fluidized bed reactor can be the one described in U.S. Pat. No. 4,558,790. Other types of conventional reactors for the gas phase production of polyethylene can also be employed. Under conventional procedures, at the start up, the bed is usually made up of polyethylene granular resin. During the course of the polymerization, the bed comprises formed polymer particles, growing polymer particles, and catalyst particles fluidized by polymerizable and modifying gaseous components introduced at a flow rate or velocity sufficient to cause the particles to separate and act as a fluid. The fluidizing gas is made up of the initial feed, make-up feed, and cycle (recycle) gas, i.e., monomer and, if desired, modifiers and/or an inert carrier gas.
The polyethylene resins produced in the process of the present invention are those which are characterized as "non-sticky" polymers, i.e., they are free-flowing polymers as contrasted for example to the "sticky polymers" described in the copending application Ser. No. 07/413,704 filed on Sept. 28, 1989 and which is assigned to a common assignee.
The polyethylene resins can be homopolymers of ethylene or copolymers of a major mol percent (≧ 90%) of ethylene, and a minor mol percent (≦ 10%) of one or more C 3 to C 8 alpha olefins. The preferred C 3 to C 8 alpha olefins are propylene, butene-1, pentene-1, hexene-1, and octene-1.
The ethylene polymers have a melt flow ratio of ≧ 18 to ≦ 150, and preferably of ≧ 30 to ≦ 80. The melt flow ratio value is another means of indicating the molecular weight distribution of a polymer.
The homopolymers have a density (gm/cc) of about ≧0.958 to ≦0.972 and preferably of about ≧0.961 to ≦0.968.
The copolymers have a density of about ≧0.91 to ≦0.96 and preferably ≧0.917 to ≦0.955, and most preferably, of about ≧0.917 to ≦0.935. The density of the copolymer, at a given melt index level for the copolymer, is primarily regulated by the amount of the C 3 to C 8 comonomer which is copolymerized with the ethylene. In the absence of the comonomer, the ethylene would homopolymerize with the catalyst of the present invention to provide homopolymers having a density of about ≧0.96. Thus the addition of progressively larger amounts of the comonomers to the copolymers results in a progressive lowering of the density of the copolymer. The amount of each of the various C 3 to C 8 comonomers needed to achieve the same result will vary from monomer to monomer, under the same reaction conditions.
Thus, to achieve the same results, in the copolymers, in terms of a given density, at a given melt index level, large molar amounts of the different comonomers would be needed in the order of C 3 >C 4 >C 5 >C 6 >C 7 >C 8 .
The melt index of a homopolymer or copolymer is a reflection of its molecular weight. Polymers having a relatively high molecular weight, have a relatively low melt index. Ultra-high molecular weight ethylene polymers have a high load (HLMI) melt index of about 0.0 and a very high molecular weight ethylene polymers have a high load melt index (HLMI) of about 0.0 to about 1.0. The polymers of the present invention have a standard or normal load melt index of ≧0.0 to about 50, and preferably of about 0.5 to 35, and a high load melt index (HLMI) of about 7 to about 950. The melt index of the polymers which are used in the process of the present invention is a function of a combination of the polymerization temperature of the reaction, the density of the copolymer and the hydrogen/monomer ratio in the reaction system. Thus, the melt index is raised by increasing the polymerization temperature and/or by decreasing the density of the polymer and/or by increasing the hydrogen/monomer ratio.
The polymers of the present invention are produced as granular materials which have an average particle size of the order of about 0.005 to about 0.06 inches, and preferably of about 0.02 to about 0.04 inches, in diameter. The particle size is important for the purposes of readily fluidizing the polymer particles in the fluid bed reactor, as described below. The polymers of the present invention have a settled bulk density of about 15 to 32 pounds per cubic foot.
The carbon black filled homopolymers and copolymers of the present invention are useful for a wide variety of purposes particularly in black jacketing applications and pipe.
The carbon black materials which are employed in the process have a primary particle size of about 10 to 100 nano meters and an average size of aggregate (primary structure) of about 0.1 to about 10 microns. The specific surface area of the carbon black is about 30 to 1,500 m/ 2 gm and display a dibutylphthalate (DBP) absorption of about 80 to about 350 cc/100 grams.
The amount of carbon black utilized generally depends on the type of polymer to be produced. In general, the carbon black can be employed in amounts of about 0.1% to about 50% by weight preferably about 2% to about 40% based on the weight of the final product produced.
The carbon black can be introduced into the reactor either at the bottom of the reactor or to the recycle line directed into the bottom of the reactor. It is preferred to treat the carbon black prior to entry into the reactor to remove traces of moisture and oxygen. This can be accomplished by purging the material with nitrogen gas, and heating by conventional procedures.
A fluidized bed reaction system which is particularly suited for production of polyolefin resin by the practice of the process of the present invention is illustrated in the drawing. With reference thereto and particularly to FIG. 1, the reactor 10 comprises a reaction zone 12 and a velocity reduction zone 14.
In general, the height to diameter ratio of the reaction zone can vary in the range of about 2.7:1 to about 5:1. The range, of course, can vary to larger or smaller ratios and depends upon the desired production capacity. The cross-sectional area of the velocity reduction zone 14 is typically within the range of about 2.5 to about 2.9 multiplied by the cross-sectional area of the reaction zone 12.
The reaction zone 12 includes a bed of growing polymer particles, formed polymer particles and a minor amount of catalyst all fluidized by the continuous flow of polymerizable and modifying gaseous components in the form of make-up feed and recycle fluid through the reaction zone. To maintain a viable fluidized bed, the superficial gas velocity (SGV) through the bed must exceed the minimum flow required for fluidization which is typically from about 0.2 to about 0.8 ft/sec. depending on the average particle size of the product. Preferably the SGV is at least 1.0 ft/sec. above the minimum flow for fluidization of from about 1.2 to about 6.0 ft/sec. Ordinarily, the SGV will not exceed 6.0 ft/sec. and it is usually no more than 5.5 ft/sec.
Particles in the bed help to prevent the formation of localized "hot spots" and to entrap and distribute the particulate catalyst through the reaction zone. Accordingly, on start up, the reactor is charged with a base of particulate polymer particles before gas flow is initiated. Such particles may be the same as the polymer to be formed or different. When different, they are withdrawn with the desired newly formed polymer particles as the first product. Eventually, a fluidized bed consisting of desired polymer particles supplants the start-up bed.
The catalysts used are often sensitive to oxygen, thus the catalyst used to produce polymer in the fluidized bed is preferably stored in a reservoir 16 under a blanket of a gas which is inert to the stored material, such as nitrogen or argon.
Fluidization is achieved by a high rate of fluid recycle to and through the bed, typically on the order of about 50 to about 150 times the rate of feed of make-up fluid. This high rate of recycle provides the requisite superficial gas velocity necessary to maintain the fluidized bed. The fluidized bed has the general appearance of a dense mass of individually moving particles as created by the percolation of gas through the bed. The pressure drop through the bed is equal to or slightly greater than the weight of the bed divided by the cross-sectional area. It is thus dependent on the geometry of the reactor.
Make-up fluid can be fed at point 18 via recycle line 22 although it is also possible to introduce make up fluid between heat exchanger 24 and velocity reduction zone 14 in recycle line 22. The composition of the recycle stream is measured by a gas analyzer 21 and the composition and amount of the make-up stream is then adjusted accordingly to maintain an essentially steady state gaseous composition within the reaction zone.
The gas analyzer is a conventional gas analyzer which operates in conventional manner to indicate recycle stream composition and which is adapted to regulate the feed and is commercially available from a wide variety of sources. The gas analyzer 21 can be positioned to receive gas from a point between the velocity reduction zone 14 and the dispenser 38, preferably after the compressor 30.
To ensure complete fluidization, the recycle stream and, where desired, part of the make-up stream are returned through recycle line 22 to the reactor at base 26 below the bed preferably there is a gas distributor plate 28 above the point of return to aid in fluidizing the bed uniformly and to support the solid particles prior to start-up or when the system is shut down. The stream passing upwardly through the bed absorbs the heat of reaction generated by the polymerization reaction.
The portion of the gaseous stream flowing through the fluidized bed which did not react in the bed becomes the recycle stream which leaves the reaction zone 12 and passes into a velocity reduction zone 14 above the bed where a major portion of the entrained particles drop back into the bed thereby reducing solid particle carryover.
The recycle stream exiting the compressor is then returned to the reactor at its base 26 and thence to the fluidized bed through a gas distributor plate 28. A fluid flow deflector 32 is preferably installed at the inlet to the reactor to prevent contained polymer particles from settling out and agglomerating into a solid mass and to maintain entrained or to re-entrain any liquid or solid particles which may settle out or become disentrained.
The fluid flow deflector, comprises an annular disc supported at a stand off distance above the reactor inlet 26 by the spacers 32a and divides the entering recycle stream into a central upward flow stream and an upward peripheral annular flow stream along the lower side walls of the reactor. The flow streams mix and then pass through protective screen 27, the holes or ports 29 of the distributor plate 28 and the angle caps 36a and 36b, secured to the upper surface of the distributor plate, and eventually into the fluidized bed.
The central upward flow stream in the mixing chamber 26a assists in the entrainment of liquid droplets in the bottom head or mixing chamber and in carrying the entrained liquid to the fluidized bed section during a condensing mode of reactor operation. The peripheral flow assists in minimizing build-up of solid particles in the bottom head because it sweeps the inner surfaces of the reactor walls. The peripheral flow also contributes to the re-atomization and re-entrainment of any liquid which may be disentrained at the walls or accumulate at the bottom of the diffuser mixing chamber, particularly with a high level of liquid in the recycle stream. The annular deflector means 32, which provides both central upward and outer peripheral flow in the mixing chamber, permits a reactor to be operated without the problems of liquid flooding or excessive build up of solids at the bottom of the reactor.
The temperature of the bed is basically dependent on three factors: (1) the rate of catalyst injection which controls the rate of polymerization and the attendant rate of heat generation; (2) the temperature of the gas recycle stream and (3) the volume of the recycle stream passing through the fluidized bed. Of course, the amount of liquid/solid introduced into the bed either with the recycle stream and/or by separate introduction also affects the temperature since this liquid vaporizes in the bed and solids typically absorb heat both of which serve to reduce the temperature. Normally the rate of catalyst injection is used to control the rate of polymer production. The temperature of the bed is controlled at an essentially constant temperature under steady state conditions by constantly removing the heat of reaction. By "steady state" is meant a state of operation where there is no change in the system with time. Thus, the amount of heat generated in the process is balanced by the amount of heat being removed and the total quantity of material entering the system is balanced by the amount of material being removed. As a result, the temperature, pressure, and composition at any given point in the system is not changing with time. No noticeable temperature gradient appears to exist within the upper portion of the bed. A temperature gradient will exist in the bottom of the bed in a layer or region extending above the distributor plate, e.g., for about 6 to about 12 inches, as a result of the difference between the temperature of the inlet fluid and temperature of the remainder of the bed. However, in the upper portion or region above this bottom layer, the temperature of the bed is essentially constant at the maximum desired temperature.
Good gas distribution plays an important role in the efficient operation of the reactor. The fluidized bed contains growing and formed particulate polymer particles, carbon black particles as well as catalyst particles. As the polymer particles are hot and possible active, they must be prevented from settling, for if a quiescent mass is allowed to exist, any active catalyst present will continue to react and can cause fusion of the polymer particles resulting, in an extreme case, in the formation of a solid mass in the reactor which can only be removed with great difficulty and at the expense of an extended downtime. Since the fluidized bed in a typical commercial size reactor may contain many thousand pounds of solids at any given time, the removal of a solid mass of this size would require a substantial effort. Diffusing recycle fluid through the bed at a rate sufficient to maintain fluidization throughout the bed is, therefore, essential.
Any fluid inert to the catalyst and reactants and which, if a liquid, will volatilize under the conditions present in the fluidized bed, can also be present in the recycle stream. Other materials, such as catalyst activator compounds, if utilized are preferably added to the reaction system downstream from compressor 30. Thus the materials may be fed into the recycle system from dispenser 38 through line 40 as shown in FIG. 1.
The fluid bed reactor may be operated at pressures of up to about 1000 psig. The reactor is preferably operated at a pressure of from about 250 to about 500 psig, with operation at the higher pressures in such ranges favoring heat transfer since an increase in pressure increases the unit volume heat capacity of the gas.
The catalyst which is preferably a transition metal catalyst is injected intermittently or continuously into the bed at a desired rate at a point 42 which is above the distributor plate 28. Preferably, the catalyst is injected at a point in the bed where good mixing with polymer particles occurs. Injecting the catalyst at a point above the distributor plate is an important feature for satisfactory operation of a fluidized bed polymerization reactor. Since catalysts are highly active, injection of the catalyst into the area below the distributor plate may cause polymerization to begin there and eventually cause plugging of the distributor plate. Injection into the fluidized bed aids in distributing the catalyst throughout the bed and tends to preclude the formation of localized spots of high catalyst concentration which may result in the formation of "hot spots". Injection of the catalyst into the reactor is preferably carried out in the lower portion of the fluidized bed to provide uniform distribution and to minimize catalyst carryover into the recycle line where polymerization may begin and plugging of the recycle line and heat exchanger may eventually occur.
A gas which is inert to the catalyst, such as nitrogen or argon, is preferably used to carry the catalyst into the bed.
The carbon black materials are introduced into the reactor from Vessel 31 through line 31a together with inert gas or alternatively through 31b where it is joined with recycle line 22.
The rate of polymer production in the bed depends on the rate of catalyst injection and the concentration of monomer(s) in the recycle stream. The production rate is conveniently controlled by simply adjusting the rate of catalyst injection.
Under a given set of operating conditions, the fluidized bed is maintained at essentially a constant height by withdrawing a portion of the bed as product at the rate of formation of the particular polymer product. Complete instrumentation of both the fluidized bed and the recycle stream cooling system is, of course, useful to detect any temperature change in the bed so as to enable either the operator or a conventional automatic control system to make a suitable adjustment in the temperature of the recycle stream or adjust the rate of catalyst injection.
On discharge of particulate polymer product from the reactor 10, it is desirable, and preferable, to separate fluid from the product and to return the fluid to the recycle line 22. There are numerous ways known to the art to accomplish this. One system is shown in the drawings. Thus, fluid and product leave the reactor 10 at point 44 and enter the product discharge tank 46 through a valve 48 which is designed to have minimum restriction to flow when opened, e.g., a ball valve. Positioned above and below product discharge tank 46 are conventional valves 50, 52 with the latter being adapted to provide passage of product into the product surge tank 54. The product surge tank 54 has venting means illustrated by line 56 and gas entry means illustrated by line 58. Also positioned at the base of product surge tank 54 is a discharge valve 60 which, when in the open position, discharges product for conveying to storage. Valve 50, when in the open position, releases fluid to surge tank 62. Fluid from product discharge tank 46 is directed through a filter 64 and thence through surge tank 62, a compressor 66 and into recycle line 22 through line 68.
In a typical mode of operation, valve 48 is open and valves 50, 52 are in a closed position. Product and fluid enter product discharge tank 46. Valve 48 closes and the product is allowed to settle in product discharge tank 46. Valve 50 is then opened permitting fluid to flow from product discharge tank 46 to surge tank 62 from which it is continually compressed back into recycle line 22. Valve 50 is then closed and valve 52 is opened and product in the product discharge tank 46 flows into the product surge tank 54. Valve 52 is then closed. The product is purged with inert gas preferably nitrogen, which enters the product surge tank 54 through line 58 and is vented through line 56. Product is then discharged from product surge tank 54 through valve 60 and conveyed through line 20 to storage.
The particular timing sequence of the valves is accomplished by the use of conventional programmable controllers which are well known in the art. The valves can be kept substantially free of agglomerated particles by installation of means for directing a stream of gas periodically through the valves and back to the reactor.
The following Examples will illustrate the present invention.
EXAMPLE 1
This Example demonstrates the production of carbon filled polyethylene resins by conventional procedures i.e, by the direct addition technique.
An ethylene butene copolymer resin was produced in a fluidized bed reactor under conventional procedures using a titanium catalyst at reactor temperatures of about 85° C. The superficial gas velocity was typically about 1.8 ft/s. The copolymer had a density of 0.920 and a melt index of about 0.76 gm/10 min. The product is available from Union Carbide Chemicals and Plastics Company Inc. under the designation GRSN 7510.
The resin was added to a high intensity mixer (FCM) together with about 21/2% of pelletized carbon black available from Columbian Chemical Co. Type N110 and a conventional additive package.
The carbon filled products produced were thereafter extruded into pelletized form which can then be sold commercially for a variety of applications such as wire and cable, pipe and sheet applications.
EXAMPLE 2
This Example demonstrates the production of carbon filled resins by the masterbatch technique.
The procedure of Example 1 was repeated to produce the polyethylene resin of Example 1.
A masterbatch was prepared by mixing the resin with 35 to 50% carbon black used in Example 1 in a high intensity mixer such as a FCM. The pelleted masterbatch was subsequently let down into the produced polyethylene resin in a second mixing step performed in a Banbury mixer.
The carbon filled products were thereafter extruded into pelletized form for use in conventional areas of use.
In both Examples 1 and 2 the carbon black was mixed with the resin in a molten state resulting in the carbon black being encapsulated by the resin.
EXAMPLE 3
This Example demonstrates the production of carbon filled ethylene butene copolymers (as in Example 1) according to the process of the present invention.
The fluidized bed reactor used was a pilot mechanically fluidized bed reactor (inner diameter of about 16 inches) with a vanadium catalyst at a reactor temperature of about 85° C. at 300 psig. Trisobutyl aluminum (TIBA) and UCON II were used as the cocatalyst and promoter, respectively.
The typical value of H 2 /C 2 ratios was about 0.024. The superficial gas velocity was typically equivalent to about 1.8 ft/s. Carbon black in fluff form as in Examples 1 and 2 was continuously added directly to the reactor in an amount of about 3% by weight based on the weight of the total weight of the produced carbon black filled resin.
The resin which was produced in granular form had a carbon black coating on its surface and the carbon coated resin had a density of 0.9371 gm/cc. The carbon black content of the resin was 3.29%. The produced carbon black filled resin was uniformly black, indicating a good coating by incorporation of carbon black onto the resin particles. Unlike the carbon black resin particles of Examples 1 and 2 the carbon black resin particles of the invention were coated on the outer surface of the resin and not distributed throughout the resin. The resin did not smear on handling. On extrusion of the granular material, the carbon coated resin of the instant invention was found to be similar in mixing qualities as the resins produced by Examples 1 and 2. Advantageously, no smearing of the product resin was evident.
EXAMPLE 4
The procedure of Example 3 was repeated except that the carbon black utilized was in pelleted form as in Examples 1 and 2.
The amount of carbon black utilized was about 4.1% by weight. The produced resin had a carbon black coating on its surface and a density of 0.9330. The carbon black content of the resin was 4.1% based on the total weight of the resin. The product extruded well and had no smearing of the carbon black. | A process for producing polyethylene resins containing carbon black in a gas fluidized bed reactor which comprises introducing into said reactor, polymerizable monomers capable of producing polyethylene resins at polymerizable reaction temperatures in the presence of a catalyst while directly introducing into said reactor during said polymerization, carbon black, in an amount to produce said polyethylene resins containing carbon black. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a brake fluid pressure control apparatus in a skid control system for a vehicle having at least one wheel and a brake for the wheel in which the brake fluid pressure to the wheel cylinder of the brake for the wheel is controlled in accordance with the rotational condition or skid condition of the wheel, and more particularly to a brake fluid pressure control apparatus of the type in which, when the brake for the wheel is relieved, brake fluid discharged through a fluid pressure control valve device from the wheel cylinder of the brake is returned to a pressure fluid supply conduit connected to a master cylinder by a fluid pump.
2. Description of the Prior Art
Recently, various kinds of skid control systems have been developed for a vehicle having at least one wheel and a brake for the wheel, by which skid control operation for the wheel is performed to avoid a locked wheel condition and obtain good braking performance on any road. In any of the skid control systems, the rotational condition or skid condition of the wheel such as deceleration, slip and acceleration is measured by the control unit which receives the detecting signal of the wheel speed sensor which is associated with the wheel for detecting the rotational speed of the wheel. The brake fluid pressure to the brake for the wheel is controlled on the basis of the measurement of the control unit.
Methods for measuring the rotational condition or skid condition of the wheel can be roughly classified into three. In the first method, slip of the wheel is obtained from the vehicle speed and the wheel speed, and the obtained slip of the wheel is compared with a predetermined slip. In the second method, acceleration or deceleration of the wheel is obtained, and the obtained acceleration or deceleration of the wheel is compared with a predetermined acceleration or decleration. And in the third method, slip and acceleration or deceleration of the wheel are obtained from the vehicle speed and wheel speed, and the obtained slip and acceleration or deceleration of the wheel are compared with the predetermined slip and acceleration or deceleration.
A brake fluid pressure control apparatus is arranged between a master cylinder as a brake pressure generating member and the brake for the wheel. Control signals from the control unit as the measurement result are supplied to the brake fluid pressure control apparatus for increasing and decreasing, or increasing, maintaining at constant, and decreasing the brake pressure to the brake for the wheel.
One example of the brake fluid pressure control apparatus includes a brake fluid pressure control valve device to which the control signals from the control unit are supplied, to control the brake fluid pressure to the wheel cylinder of the brake for the wheel, a hydraulic reservoir for reserving the brake fluid discharged through the brake fluid pressure control valve device from the wheel cylinder of the brake, when relieved, and a fluid pump for returning the brake fluid from the hydraulic reservoir into the pressure fluid supply conduit connecting the master cylinder and the brake fluid pressure control valve device.
In the example of the brake fluid pressure control apparatus, the brake fluid from the wheel cylinder of the brake is discharged into the hydraulic reservoir to relieve the brake for the wheel, and it is returned to the pressure fluid supply conduit by the fluid pump. When the brake for the wheel is relieved, the brake fluid pressure control valve device takes the position to reduce the brake pressure, and therefore to cut off the communication between the master cylinder and the wheel cylinder of the brake for the wheel. Accordingly, the fluid pressure of the brake fluid returned by the fluid pump is applied to the piston of the master cylinder connected to the brake pedal which is treaded by the foot of the drive. The brake pedal is pushed against the tread of the driver. Thus, whenever the brake fluid pressure to the wheel cylinder of the brake changes, the piston of the master cylinder is displaced backwards and forwards. The driver feels disagreeable. The pedal feeling is bad.
SUMMARY OF THE INVENTION
An object of this invention is to provide a brake fluid pressure control apparatus in a skid control system in which, the pedal feeling of the driver, when the driver treads the brake pedal, is good.
An accordance with an aspect of this invention, a brake fluid pressure control apparatus in a skid control system for a vehicle having at least one wheel and a brake for the wheel includes: (A) a fluid pressure control valve device arranged between a master cylinder and a wheel cylinder of a brake for the wheel, the fluid pressure control valve device receiving control signals of a control unit measuring the skid condition of the wheel to control the brake fluid pressure to the wheel cylinder; (B) a hydraulic reservoir which, when the brake fluid pressure to the wheel cylinder is decreased with control of the fluid pressure control valve device, reserves the brake fluid discharged through the fluid pressure control valve device from the wheel cylinder; (C) a pressure fluid supply conduit connecting the master cylinder with the fluid pressure control valve device; (D) a fluid pump for returning the brake fluid from the hydraulic reservoir into the pressure fluid supply conduit, (E) a first check valve arranged in the pressure fluid supply conduit, the first check valve being opened when the brake fluid flows from the master cylinder toward the fluid pressure control valve device, and the outlet of the fluid pump being connected to the pressure fluid supply conduit between the first check valve and the fluid pressure control valve device; (F) a pressure fluid return conduit connecting the master cylinder with the wheel cylinder; (G) a second check valve arranged in the pressure fluid return conduit, the second check valve being opened when the brake fluid flows from the wheel cylinder toward the master cylinder; and (H) means for receiving the brake fluid discharged from the fluid pump.
The foregoing and other objects, features, and advantages of the present invention will be more readily understood upon consideration of the following detailed description of the preferred embodiment of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a fluid pressure control apparatus in a skid control system according to a first embodiment of this invention;
FIG. 2 is a schematic view of a fluid pressure control apparatus in a skid control system according to a second embodiment of this invention;
FIG. 3 is a cross-sectional view of a fluid pressure adjusting valve in the apparatus of FIG. 2; and
FIG. 4 is a cross-sectional view of a modification of the fluid pressure adjusting valve of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Next, fluid pressure control apparatus in skid control systems according to embodiments of this invention will be described with reference to the drawings.
FIG. 1 shows a fluid pressure control apparatus in a skid control system according to a first embodiment of this invention. It is applied to rear wheels of the vehicle. In FIG. 1, a tandem master cylinder 1 has the well-known structure, and it includes first and second pistons connected through a spring with each other. The first piston is connected to a brake pedal 2 to be treaded by the driver. The cylinder body and, the first and second pistons define first and second brake fluid pressure generating chambers, although not shown. The first brake fluid pressure generating chamber is connected through a conduit 3 to wheel cylinders of the brakes for the front wheels. The second fluid pressure generating chamber communicates with a conduit 4. The conduit 4 is divided into a pressure fluid supply conduit 4a and a pressure fluid return conduit 4b.
The pressure fluid supply conduit 4a is connected through a first check valve 12, a conduit 4d, an electromagnetic inlet valve 7, a conduit 4e, an electromagnetic outlet valve 8, conduits 4f, 4h and 4i to wheel cylinders 5 and 6 of brakes for rear wheels W 1 and W 2 which are schematically shown. A brake fluid pressure control valve device is constituted by the electromagnetic inlet valve 7 and the electromagnetic outlet valve 8.
On the other hand, the pressure fluid return conduit 4b is connected through a second check valve 13 and the conduits 4f, 4h and 4i to the wheel cylinders 5 and 6 of the brakes for the rear wheels W 1 and W 2 . The direction from the side of the master cylinder 1 to the side of the electromagnetic inlet valve 7 is the forward direction of the first check valve 12. Thus, the fluid from the master cylinder 1 can pass through the first check valve 12 to the electromagnetic inlet valve 7, while the fluid from the electromagnetic inlet valve 7 cannot pass through the first check valve 12. On the other hand, the direction from the side of the wheel cylinders 5 and 6 to the side of the master clinder 1 is the forward direction of the second check valve 13. Thus, the fluid from the wheel cylinders 5 and 6 can pass through the second check valve 13, while the fluid from the master cylinder 1 cannot pass through the second check valve 13.
A supply opening 8b of the electromagnetic outlet valve 8 is connected through the conduits 4f, 4h and 4i to the wheel cylinders 5 and 6. A discharge opening 8c of the electromagnetic outlet valve 8 is connected through a conduit 4g to a hydraulic reservoir 9. In the hydraulic reservoir 9, a piston 9a is supported by a relatively weak spring 9b, and a seal ring 9c is fitted to the piston 9c. The hydraulic reservoir 9 is connected through a conduit 4j to an inlet of a fluid pump 10. An outlet of the fluid pump 10 is connected through a conduit 4k to a hydraulic accumulator 11. In the hydraulic accumulator 11, a piston 11a is supported by a relatively strong spring 11b, and a seal ring 11c is fitted to the piston 11a. The conduit 4k communicates with a conduit 4c which branches from the pressure fluid supply conduit 4a.
Wheel speed sensors 14 and 15 are associated with the rear wheels W 1 and W 2 , and they generate pulse signals having frequencies proportional to the rotational speeds of the rear wheels W 1 and W 2 . The pulse signals of the wheel speed sensors 14 and 15 are supplied to a control unit 16 which has the well-known circuits. On the basis of the detecting outputs of the wheel speed sensors 15 and 16, the skid condition or rotational condition of the rear wheels 5 and 6, namely wheel speeds of the rear wheels 5 and 6, slips thereof, and accelerations or decelerations thereof are calculated or measured by the control unit 16. Control signals S 1 and S 2 as the calculation or measurement results are generated from the control unit 16, and are supplied to solenoid portions 7a and 8a of the electromagnetic inlet and outlet valves 7 and 8.
Although schematically shown, the electromagnetic inlet and outlet valves 7 and 8 have well-known constructions, and they are called also "cut-off valve", and "discharge valve", respectively. When the control signals S 1 and S 2 of the control unit 16 are at higher levels "1", the electromagnetic inlet and outlet valves 7 and 8 are energized to take lower positions B and D, respectively. And when the control signals S 1 and S 2 of the control unit 16 are at lower levels "0", the electromagnetic inlet and outlet valves 7 and 8 are deenergized to take upper positions A and C, respectively.
When the solenoid portions 7a and 8a of the inlet and outlet valves 7 and 8 are not energized, the master cylinder 1 communicates with the wheel cylinders 5 and 6 of the wheels W 1 and W 2 so that the brake pressure to the wheels W 1 and W 2 are increased. When both of the solenoid portions 7a and 8a of the inlet and outlet valves 7 and 8 are energized, the communication between the master cylinder 1 and the wheel cylinders 5 and 6 is cut off, and the discharge opening 8c of the outlet valve 8 is connected to the wheel cylinders 5 and 6 to discharge brake fluid into the reservoir 9, so that the brake pressures to the wheels W 1 and W 2 are lowered. The brake fluid is returned through the conduits 4j and 4k to the conduit 4c by the pump 10. And when only the solenoid portion 7a of the inlet valve 7 is energized, the communication between the master cylinder 1 and the wheel cylinders 5 and 6 is cut off, and however, the supply opening 8b of the outlet valve 8 remains connected with the wheel cylinders 5 and 6, so that the brake pressure to the wheels W 1 and W 2 are maintained at constant.
Next, there will be described operation of the above-described apparatus.
The driver starts to tread the brake pedal 2 in order to brake the vehicle running at constant speed. It is judged by the control unit 16 receiving the detecting signals of the wheel speed sensors 14 and 15 that the deceleration and slip of the wheels W 1 and W 2 do not still reach the the predetermined slip and deceleration at the braking start. The control signals S 1 and S 2 of the control unit 16 are at the lower levels "0". The solenoid portions 7a and 8a of the inlet and outlet valves 7 and 8 are deenergized. The conduits 4d and 4f are made to communicate with each other. The brake fluid from the master cylinder 1 flows through the pressure fluid supply conduit 4a, the first check valve 12, the conduit 4d, the inlet and outlet valves 7 and 8, and the conduits 4f, 4h and 4i into the wheel cylinders 5 and 6 to brake the wheels W 1 and W 2 . On the other hand, the brake fluid from the master cylinder 1 is checked by the second check valve 13. Accordingly, it cannot flow through the pressure fluid return conduit 4b.
With the increase of the brake fluid pressure to the wheel cylinders 5 and 6, the slip or deceleration of the wheels W 1 and W 2 meanwhile reaches the predetermined slip or deceleration. The levels of the control signals S 1 and S 2 becomes higher "1". The solenoid portions 7a and 8a of the inlet and outlet valves 7 and 8 are energized to cut off the communication between the conduits 4a and 4f, and to make the communication between the conduits 4f and 4g. Accordingly, the brake fluid from the wheel cylinders 5 and 6 flows through the conduits 4h, 4i, 4f and 4g into the reservoir 9. The fluid pump 10 is so designed as to start at the time when any one of the control signals S 1 and S 2 becomes higher "1", and it continues to be driven during the skid control operation. The brake fluid in the reservoir 9 is pumped by the fluid pump 10, and it is led through the conduit 4k in to the pressure fluid supply conduit 4a and the accumulator 11. However, since the first check valve 12 is arranged in the pressure fluid supply conduit 4a, the brake fluid cannot flow to the master cylinder 1, and it is accumulated in the accumulator 11. No "kick-back" is imparted to the brake pedal 2. The pedal feeling of the driver is good.
When the deceleration of the wheels W 1 and W 2 becomes lower than the predetermined deceleration level by function of the inlet and outlet valves 7 and 8, or when the acceleration of the wheels W 1 and W 2 becomes higher than the predetermined acceleration level, the control signal S 2 becomes lower "0", while the control signal S 1 remains higher "1", according to the control unit 16 of this embodiment. Accordingly, the solenoid portion 7a of the inlet valve 7 remains energized, while the solenoid portion 8a of the outlet valve 8 is deenergized. The communication between the conduits 4a and 4f is cut off, and the communication between the conduits 4f and 4g are cut off. Thus, the brake fluid pressure to the wheel cylinders 5 and 6 is maintained at constant, or at the reduced value. Although the fluid pump 10 continues to be driven to lead the brake fluid from the reservoir 9 into the conduit 4k, no "kick-back" is imparted to the brake pedal 2.
When the skid condition of the wheels W 1 and W 2 comes within the permissible range, both of the control signals S 1 and S 2 become lower "0" to make the communication between the conduits 4a and 4f, and to increase the brake to the wheels W 1 and W 2 .
The above-described control operations are repeated. Meanwhile, the vehicle speed reaches the desired speed, or the vehicle stops. The brake pedal is released from treading. The fluid pressure at the side of the master cylinder 1 with respect to the second check valve 13 becomes lower than the fluid pressure at the side of the wheel cylinders 5 and 6 with respect to it, with the release of the brake pedal 2, in the pressure fluid return conduit 4b. The brake fluid flows back through the conduits 4h, 4i, 4f and 4b, and the second check valve 13 into the master cylinder 1 from the wheel cylinders 5 and 6. Thus, the wheels W 1 and W 2 are released from braking.
When the first check valve 12 is closed, some fluid pressure remains at the side of the conduit 4d, and therefore at the wheel cylinders 5 and 6. In order to reduce the influence of the remaining fluid pressure as much as possible, a throttling pipe 20 may be connected between the master cylinder side portion of the conduit 4a and the conduit 4c, as shown in FIG. 1. Since the diameter of the throttling pipe 20 is further smaller than the diameters of the conduits 4a to 4k, the throttling pipe 20 has little influence on the above-described control operation. After the brake pedal 2 is released from treading, the remaining fluid pressure is gradually dissipated in the wheel cylinders 5 and 6 by function of the throttling pipe 20. Of course, the throttling pipe 20 is not always required.
FIG. 2 shows a fluid pressure control apparatus in a skid control system according to a second embodiment of this invention. Parts in this embodiment which correspond to those in FIG. 1, are denoted by the same reference numerals, the description of which will be omitted.
In this embodiment, a fluid pressure adjusting valve 21 is arranged instead of the hydraulic accumulator 11 of the first embodiment. The details of the fluid pressure adjusting valve 21 are shown in FIG. 3. Referring to FIG. 2, a conduit 4m branches from the conduit 4 connected to the master cylinder 1, and it is connected to a first opening 21a of the fluid pressure adjusting valve 21. The conduit 4k connected to the outlet of the fluid pump 10 is further connected to a second opening of the fluid pressure adjusting valve 21. A third opening 21c of the fluid pressure adjusting valve 21 is connected through a conduit 4n to the reservoir 9. Next, there will be described the details of the fluid pressure adjusting valve 21 with reference to FIG. 3.
In the fluid pressure adjusting valve 21, the above described first and second openings 21a and 21b are formed in a cylindrical body 60. A piston 61 is slidably fitted to the cylindrical bore of the body 60. The piston 61 and the cylindrical body 60 define a first chamber 65 at the left side and a second chamber 66 at the right side. The fluid pressure of the master cylinder 1 is transmitted through the conduit 4m and the first opening 21a to the first chamber 65. A cover 64 is screwed to the opening of the cylindrical body 60. The second chamber 66 communicates through the second opening 21b and the conduit 4k with the outlet of the fluid pump 10. The discharging pressure of the fluid pump 10 is transmitted to the second chamber 66. A coil spring 62 is arranged in the compressed condition between the bottom of the cylindrical body 60 and the piston 61. The piston 61 is urged rightwards by the coil spring 62.
The above-described third opening 21c is formed in the cover 64. The third opening 21c includes a path 64a. A ball valve element 63 is fixed on a recess formed on the right end of the piston 61. A valve member is constituted by the ball valve element 63 and the opening of the path 64a. The opening of the path 64a functions as the seat of the ball valve element 63. The valve member is closed in FIG. 3.
As described with reference to FIG. 1, the fluid pump 10 is driven during the skid control operation. When the discharging pressure of the fluid pump 10 is higher than the urging force of the coil spring 62 plus the fluid pressure of the master cylinder 1, the piston 61 is moved leftwards to separate the ball valve element 63 from the opening of the path 64a. The brake fluid discharged by the fluid pump 10 is returned through the path 64a, the third opening 21c and the conduit 4n into the reservoir 9. Accordingly, no excessive load is applied to the fluid pump 10.
FIG. 4 shows a modification 31 of the fluid pressure adjusting valve 21 of FIG. 3. In this modification 31, a first cover 74 is screwed to a left opening of a cylindrical body 70. A first opening 31a is formed in the first cover 74, and it communicates through the conduit 4m with the master cylinder 1. A second cover 77 is screwed to a right opening of the cylindrical body 70. A ball valve element 73 is fixed in a recess formed on the inner end of the second cover 64. A stepped piston 71 is slidably fitted to a stepped cylindrical bore of the body 70. A T-shaped path 71a is formed in the right reduced portion of the stepped piston 71. A valve member is constituted by the right opening of the T-shaped path 71a and the ball valve element 73. A first chamber 75 is defined by the first cover 74 and the stepped piston 71. The fluid pressure of the master cylinder 1 is transmitted through the conduit 4m and the first opening 31a to the first chamber 75. A second chamber is defined by the stepped piston 71 and the inward projection of the cylindrical body 70. The outlet of the fluid pump 10 communicates through the conduit 4k with the second chamber 76. A third chamber 78 is defined by the second cover 77 and the inward projection of the cylindrical body 70. The reservoir 9 communicates through the conduit 4n and a third opening 31c formed in the body 70 with the third chamber 78. The stepped piston 71 is urged rightwards by a coil spring 72.
In the skid control operation, when the fluid pressure of the second chamber 76 becomes higher than [A 1 /(A 1 -A 2 )]× fluid pressure of the master cylinder 1, where A 1 represents diameter of the larger portion of the stepped piston 71, and A 2 represents diameter of the right smaller portion of the stepped piston 71, the latter is moved leftwards to separate the right opening of the T-shaped path 71a from the ball valve element 73. The second and third chambers 76 and 78 communicate with each other. The brake fluid in the second chamber 76 is returned through the T-shaped path 71a, the third chamber 78, the third opening 31c and the conduit into the reservoir 9. No excessive load is applied to the fluid pump 10, as in the fluid pressure adjusting valve 21 of FIG. 3.
While the preferred embodiments have been described, variations thereto will occur to those skilled in the art within the scope of the present inventive concepts which are delineated by the following claims.
The example, in the above embodiments, the brake fluid pressure to the wheel cylinders 5 and 6 is decreased, maintained at constant and increased in accordance with the skid condition of the wheels W 1 and W 2 . However, this invention may be applied to the skid control operation that the brake fluid pressure to the wheel cylinders 5 and 6 is alternately decreased and increased in accordance with the skid condition of the wheels W 1 and W 2 . In that case, the inlet valve 7 may be omitted.
Further, in the above embodiment, the skid control system is applied to the rear wheels W 1 and W 2 . However, the apparatus of FIG. 1 or FIG. 2 may be applied also to the front wheels of the vehicle. Or the apparatus of FIG. 1 or FIG. 2 may be applied to each of the wheels of the vehicle.
Further, the above embodiments are applied to the four-wheeled vehicle. However, this invention may be applied to a two-wheeled vehicle or a motor-cycle. | A brake fluid pressure control apparatus in a skid control system for a vehicle includes a brake fluid pressure control valve device arranged between a master cylinder and wheel cylinders. The device receives control signals from a control unit that measures the skid condition of wheels. The device controls the brake fluid pressure to the wheel cylinders in response to the control signals. A hydraulic reservoir stores the fluid discharged through the device from the wheel cylinders when the pressure to the wheel cylinders is decreased under the control of the device. A fluid pump returns fluid from the reservoir into a pressure fluid supply conduit connecting the master cylinder and the device. A check valve arranged in the supply conduit opens when the fluid flows from the master cylinder towards the device, the outlet of the pump being connected to the conduit between the check valve and the device. A pressure fluid return conduit connects the master cylinder and the wheel cylinders. A check valve arranged in the return conduit opens when the fluid flows from the wheel cylinders towards the master cylinder. A fluid pressure adjusting valve receives fluid discharged from the pump. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to European patent application No. EP 15 400002.0 filed on Jan. 14, 2015, the disclosure of which is incorporated in its entirety by reference herein.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The present invention relates to an arrangement for moving a door which allows the door to move in sliding and swinging motions.
[0004] (2) Description of Related Art
[0005] Several types of mechanisms for opening doors, particularly doors for aircrafts, are known in the prior art.
[0006] A type of mechanism is that characterizing sliding doors. The door is mounted on rails that guide it along the fuselage or other structure from a closed to an open position. This requires, normally, at least three guiding rails arranged in a particular manner, which limits the particular surface geometry of the fuselage or structure on which the arrangement can be mounted and the geometry of the door opening. U.S. Pat. No. 8,146,864 describes a sliding door for helicopters.
[0007] A further type of mechanism, intended for swinging doors, comprises two or more hinges that define an axis around which the door opens. Although the arrangement is simple and adaptable to several geometries, the door may protrude far from the fuselage or structure, which requires a wide area to open the door.
[0008] A different mechanism has a supporting arm which moves the door outward and then alongside the fuselage or structure in a circular motion. The door is kept parallel to the fuselage or structure by one or more guide arms. Due to the fact that the full weight of the door must be lifted by the supporting arm up to a significant distance from the door opening, which entails a large load moment on the supporting arm, this arrangement is usually heavy and bulky. An example can be found in US20020139897.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention aims at providing an arrangement for advantageously moving a door, in both a swinging and a sliding manner, suitable for being installed on fuselages or structures with different, complex geometries and without the need for large or heavy components.
[0010] This inventive arrangement comprises:
[0011] pivoting means attachable to the structure and to a first attachment point of the door, the pivoting means being suitable for allowing a rotation of the door around a plurality of axes of rotation of the pivoting means, said plurality of axes of rotation comprising a slide axis and at least one swing axis,
[0012] a guiding rail attachable to the structure,
[0013] guiding means attachable to a second attachment point of the door and comprising a slider for moving along the guiding rail, the guiding means being suitable for allowing the door to slide over the guiding rail while pivoting around the slide axis, and for allowing the door to swing about the at least one swing axis, said at least one swing axis passing through a swing point of the guiding means.
[0014] The pivoting means is one of the at least two connections for attaching the arrangement to the door. Such means allows the pivoting of the door about a plurality of axes referred to in this application as slide axis and at least one swing axis.
[0015] The at least one swing axis is the axis around which the door rotates when in a swinging motion. This motion is possible because the guiding means comprises a swing point, playing the role of a hinge, through which the swing axis passes.
[0016] The guiding means is intended for being another of the at least two connections between the arrangement and the door, and, besides, it comprises a slider for moving along a guiding rail which is in turn attachable to the structure. The swing point may be located at different positions of the guiding means. In an embodiment, the swing point is located at the slider, so that the door swings about a swinging axis passing through the slider and through at least a point of the pivoting means, and the remaining part of the guiding means remains integral with the door during the swinging motion. Alternatively, the swing point may be located at the point of the guiding means suitable for the attachment to the door.
[0017] Since the at least one swing axis passes through a swing point of the guiding means, and the guiding means comprises a slider for moving along the guiding rail, which causes that the swing point varies its position during the sliding motion, the at least one swing axis also moves during such sliding motion.
[0018] The arrangement is suitable for allowing the door to slide over the structure since the pivoting means further comprise a slide axis around which the door can pivot when the guiding means moves along the guiding rail.
[0019] The provision of the pivoting means that permit the rotation of the door around a plurality of axes of rotation can be achieved by means of different embodiments.
[0020] In an embodiment, the pivoting means comprises a spherical bearing suitable for allowing a free rotation of the door around the center of rotation of such spherical bearing. Accordingly, the slide axis and the at least one swing axis pass through the center of rotation of the spherical bearing. This configuration is advantageous in that one structural element, which, moreover, is simple, light and cheap, is sufficient to allow the rotation of the door in both the swinging and the sliding movements.
[0021] In an alternative embodiment, the pivoting means comprise an articulated joint in turn comprising at least a first and a second joint extensions, the first joint extension extending along the slide axis and the second joint extension extending along the at least one swing axis. Differently to the example of the spherical bearing, the rotation takes place around two axes articulately connected, and not around a single point. In a particular example of this embodiment, a longitudinal axis is provided so that the articulated joint is suitable for allowing a movement around three axes. In any case, this embodiment's mechanism is also a simple, cheap and light alternative to allow the rotation of the door in both the swinging and the sliding movements.
[0022] The plurality of axes of rotations of the pivoting means permits the rotation of the door around such plurality of axes when attached to the arrangement by the first attachment point. This rotation in turn makes it possible that the sliding motion of the door can be achieved using only one guiding rail attachable to the structure. Thus, the inventive arrangement can be used on complex structure geometries.
[0023] As has been explained, the arrangement is further advantageous in that it is formed by light, simple components. This is a consequence of the fact that the way of functioning of the arrangement does not exert excessive loads on the components of the arrangement, and that the moments generated by, for instance, the weight of the components are small, since the lever arms are configured for being small as well.
[0024] In spite of the simplicity of its parts, the arrangement does present the advantages of both the swinging doors and the sliding doors of the prior art, that is, the access from the outside of a vehicle or of another structure is easy and fast, as the arrangement allows the door to open conventionally in a swinging manner. However, once the door has been swung out, it can be slid away from the opening of the structure and then folded back to a position closer to the structure, therefore making it appropriate for working around the structure without obstacles and for cases wherein the structure, for example that of a vehicle, is stored in a reduced space.
[0025] In an embodiment, the guiding means comprises an arm extending between a first and a second extremities, the first extremity being attachable to the second attachment point of the door, and the second extremity comprising the slider. In the embodiment wherein the swing point is located at the slider, the door, the first extremity and the arm of the guiding means are suitable for moving integrally. In an alternative embodiment, the swing point is located at the first extremity of the arm.
[0026] In another embodiment, the guiding rail is a curve on a sphere. This geometry of the rail is suitable for the movement of the door around the slide axis. In the embodiment where the pivoting means comprises a spherical bearing, the center of the sphere is normally the center of the spherical bearing, whereas in the embodiment where the pivoting means comprises an articulated joint, the center of the sphere is usually located at a point of the slide axis of the articulated joint.
[0027] In yet another embodiment, the arrangement further comprises a guiding rod articulately attachable both to the structure and to a third attachment point of the door. This guiding rod is suitable for providing guidance of the door such that the door can follow a predetermined path.
[0028] In an example of this embodiment, the guiding rod extends between a first end and a second end, the first end being articulately attachable to the structure by means of a first pivoting link, and the second end being articulately attachable to the third attachment point of the door by means of a second pivoting link. The pivoting links in the articulations enable the relative rotation of the guiding rod with respect to the structure and to the door, which permits the adequate movement of the guiding rod when the door swings or slides. In yet a more particular example of this embodiment, the first and second pivoting links comprise auxiliary spherical bearings so as to allow the relative rotation of the guiding rod with respect to the structure and to the door.
[0029] In another embodiment, at least one stopper is provided at least at one point of the guiding rail for impeding a further movement of the slider along the guiding rail. For instance, two stoppers can be provided, one at each end of the guiding rail, for avoiding that the slider gets out of the guiding rail.
[0030] In a further embodiment, locking means are provided for fixing the position of the door at any specific position.
[0031] It is also an object of the invention to provide a door assembly comprising a door and any of the above described arrangements.
[0032] The arrangement of the inventive door assembly comprises:
[0033] pivoting means attachable to the structure and attached to a first attachment point of the door, the pivoting means being suitable for allowing a rotation of the door around a plurality of axes of rotation of the pivoting means, said plurality of axes of rotation comprising a slide axis and at least one swing axis,
[0034] a guiding rail attachable to the structure,
[0035] guiding means attached to a second attachment point of the door and comprising a slider for moving along the guiding rail, the guiding means being suitable for allowing the door to slide over the guiding rail while pivoting around the slide axis, and for allowing the door to swing about the at least one swing axis, said at least one swing axis passing through a swing point of the guiding means.
[0036] Since the inventive door assembly comprises the inventive door arrangement, all the explained technical advantages are also relevant to the assembly.
[0037] In a particular embodiment of the door assembly, the door comprises a door edge having at least a first and a second corners, the first attachment point of the door being located at said first corner and the second attachment point of the door being located at said second corner. This way, the swinging movement of the door can be carried out in a simple manner, as the points acting as hinges are attached to consecutive corners of the door.
[0038] In an example of this embodiment, the door assembly further comprises a guiding rod articulately attachable to the structure and articulately attached to a third attachment point of the door, the guiding rod being suitable for providing guidance of the door, wherein the third attachment point of the door is located at the inside of an area defined by the door edge.
[0039] It is an additional object of the invention to provide a vehicle comprising the disclosed inventive door assembly.
[0040] This vehicle comprises a door assembly in turn comprising a door configured to close an opening of a structure of the vehicle and an arrangement which comprises:
[0041] pivoting means attached to the structure and attached to a first attachment point of the door, the pivoting means being suitable for allowing a rotation of the door around a plurality of axes of rotation of the pivoting means, said plurality of axes of rotation comprising a slide axis and at least one swing axis,
[0042] a guiding rail attached to the structure,
[0043] guiding means attached to a second attachment point of the door and comprising a slider for moving along the guiding rail, the guiding means being suitable for allowing the door to slide over the guiding rail while pivoting around the slide axis, and for allowing the door to swing about the at least one swing axis, said at least one swing axis passing through a swing point of the guiding means.
[0044] Again, the inventive vehicle presents all the advantages of the inventive door assembly and of the inventive arrangement.
[0045] In a particular example, the vehicle is an aircraft and the structure of the vehicle is the fuselage of the aircraft.
[0046] The above detailed advantages make the invention especially appropriate for aircrafts, and more particularly for rotorcrafts. Aircrafts are in need of lightweight door systems in order to minimize their overall weight, and therefore the power and fuel needed for flight, and also in order to maximize the payload. This invention achieves this purpose and, besides, the folded position of the door once opened reduces the inconveniencies that many conventional doors cause regarding the movement around the aircraft.
[0047] In an even more particular example, the aircraft is a rotorcraft, and in yet a further example the door of the rotorcraft is the back door.
[0048] In an example of this embodiment, the pivoting means comprises a main body extending between a first edge and a second edge, the first edge being attached to the first attachment point of the door and the second edge being attached to the fuselage. A spherical bearing is located at the second edge so as to allow the free rotation of the door around its center of rotation, through which the slide axis and the at least one swing axis pass. In this embodiment, the second edge is a fixed point of rotation and the main body and the first edge moves integrally with the door. Due to the provision of a main body of sufficient length between the attachments of the pivoting means to the door and to the fuselage, a door that is flush with the fuselage when closed can perform the described sliding and swinging movements, by allowing for a clearance between a door edge and the door opening when the door swings out around the swing axis.
[0049] This clearance between the door edge and the door opening—and, therefore, the fuselage—can also be achieved thanks to the form of the guiding means or to the form of the guiding rail, following the same line of reasoning as for the main body of the pivoting means.
[0050] The guiding means may have a form suitable for linking the second attachment point to the guiding rail attached to the fuselage when the door is flush with the fuselage. In an example, the form of the guiding means is also configured so as to allow for the clearance when the swinging motion takes place. Alternatively, the guiding rail may have a curvature such that the door separates from the fuselage when there is a sliding motion, starting from the flush position.
[0051] The pivoting means can also comprise an auxiliary guiding rail along which the spherical bearing is able to move, so that the first attachment point of the door, moving integrally with the spherical bearing, can be led towards an offset position. The auxiliary guiding rail is in turn attached to the structure. This embodiment is also intended for providing a clearance between the door edge and the door opening that permits carrying out the defined swinging and pivoting movements.
[0052] In an embodiment, the clearance and the movements can be enhanced by placing the swing point at the slider, and by allowing a rotation at the swing point around multiple axes.
[0053] It is yet another purpose of the invention to provide a method for operating a door of the disclosed inventive vehicle, the method at least comprising the steps of:
[0054] swinging the door about an at least one swing axis passing through a swing point of a guiding means and through a point of a pivoting means, so that the door is suitable for opening and closing an opening of a structure and for folding and unfolding with respect to the structure,
[0055] sliding the door over a guiding rail by means of the pivoting of the door around a slide axis which passes through the pivoting means and by means of the movement along the guiding rail of a slider of the guiding means, the guiding means being attached to the door.
[0056] This method presents all the advantages of the inventive arrangement, door assembly and vehicle.
[0057] The method allows that once the door is opened and led to a swung out position, it can be folded, by means of a swinging motion around the swing axis, to a position closer to the structure of the vehicle, which makes the method advantageous for working around the vehicle when there are space constraints. The step of the folding—or of a subsequent unfolding—of the door can be carried out at any moment before, during or after the sliding of the door, no matter the position of the slider along the guiding rail. The movement of the slider along the guiding rail implies a corresponding movement of the swing axis, since the swing axis passes through a swing point of the guiding means. The versatility of the door for folding and unfolding leads to the commented advantage of the lack of obstacles when working around the vehicle. The method also permits that the door can be swung back to close the opening of the structure, when the slider is located at an end of the guiding rail.
[0058] These and other features and advantages of the invention will become more evident from the following detailed description of preferred embodiments, given only by way of illustrative and non-limiting example, in reference to the attached figures:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0059] FIG. 1 is a perspective view of the rear part of a rotorcraft comprising the inventive arrangement and a door in a closed, flush position.
[0060] FIG. 2 is a perspective view of the rear part of the rotorcraft comprising the inventive arrangement and the door in a swung out, slid position.
[0061] FIG. 3 is a detailed view of an attachment between a pivoting means of the arrangement and a fuselage of the rotorcraft by means of a spherical bearing.
[0062] FIG. 4 is a detailed view of an attachment between the pivoting means of the arrangement and the fuselage of the rotorcraft by means of an articulated joint.
[0063] FIG. 5 is a detailed view of a guiding means attached to the door and to the fuselage of the rotorcraft.
[0064] FIG. 6 is a detailed view of an attachment between a guiding rod and the fuselage of the rotorcraft by means of an auxiliary spherical bearing.
[0065] FIG. 7 is a detailed view of an auxiliary guiding rail suitable for guiding a spherical bearing of the pivoting means.
DETAILED DESCRIPTION OF THE INVENTION
[0066] FIG. 1 shows the rear part of a rotorcraft 30 , whose back door 2 is connected to the fuselage 1 of the rotorcraft 30 by means of the inventive arrangement. In the embodiment depicted in this figure, the door 2 is flush with the fuselage 1 , in a closed position.
[0067] The arrangement of this embodiment comprises a pivoting means 3 attached to a first attachment point 9 located on a first corner of the door 2 and guiding means 4 attached to a second attachment point 10 located on an adjacent second corner of the door 2 .
[0068] The pivoting means 3 of this example comprises a main body 3 . 1 extending between a first edge 3 . 3 and a second edge 3 . 2 . The first edge 3 . 3 is attached to the first attachment point 9 of the door, and the second edge 3 . 2 , attached to the fuselage 1 , comprises a spherical bearing 19 that allows the free rotation SW, SL of the door, with the second edge 3 . 2 as a fixed point and the main body 3 . 1 and the first edge 3 . 3 being able to move integrally with the door 2 . The separation between the first 3 . 3 and second 3 . 2 edges by means of the main body 3 . 1 of the pivoting means 3 makes this arrangement suitable for doors 2 which can be flush with the fuselage 1 . This configuration of the pivoting means 3 permits its attachment to the fuselage 1 and to a closed, flush door 2 .
[0069] The attachment between the pivoting means 3 and the fuselage 1 is depicted in greater detail in FIG. 3 . The spherical bearing 19 is located, in this embodiment, in the middle of the first edge 3 . 2 in order to make the integral rotation of remaining part of the pivoting means 3 and the door 2 possible.
[0070] The embodiment of FIG. 7 is also intended for allowing a door 2 which is flush with the fuselage 1 in a closed position to be in an offset position when open. To achieve this, an auxiliary guiding rail 18 is provided, along which the spherical bearing 19 can move, thus leading the first attachment point 9 of the door 2 , integral with the spherical bearing 19 , from the flush position to the offset, cleared position.
[0071] FIG. 4 represents an alternative embodiment of the pivoting means 3 , whose second end 3 . 2 comprises an articulated joint 25 instead of a spherical bearing 19 . The articulated joint 25 in turn comprises at least a first 26 and a second 27 joint extensions, the first joint extension 26 extending along the slide axis 23 and the second joint extension 27 extending along the at least one swing axis 22 . A longitudinal axis 28 is provided to confer the articulated joint with movement around three axes. It should be noted that a configuration with two axes, namely the at least one swing axis 22 and the slide axis 23 , is perfectly possible. The door 2 and the remaining part of the pivoting means 3 pivot integrally around the slide axis 23 associated to the first joint extension 26 and rotate about the at least one swing axis 22 associated to the second joint extension 26 , the swing axis changing its position as the door 2 and the remaining part of the pivoting means 3 pivot around the slide axis 23 .
[0072] In the embodiment of FIG. 1 , the guiding means 4 comprises an arm 12 extending between a first 17 and a second 16 extremities, the first extremity 17 being attached to the second attachment point 10 of the door 2 , and the second extremity 16 comprising a slider 11 . This embodiment is further shown, in detail, in FIG. 5 . The slider 11 is intended for sliding along a guiding rail 5 which, in FIG. 1 , is attached to the fuselage 1 and has the shape of an arc of circumference, as a particular example of a curve on a sphere, whose center is the center of the spherical bearing 19 . Such configuration facilitates the sliding motion of the door 2 when pivoting around the slide axis 23 that passes through the center of the spherical bearing 19 .
[0073] The arrangement of this embodiment further comprises a guiding rod 7 articulately attached to the fuselage 1 and to a third attachment 13 point of the door 2 . The guiding rod 7 is suitable for providing guidance of the door 2 during both the swinging and the sliding motions.
[0074] The guiding rod 7 of this example extends between a first end 14 and a second end 15 , the first end 14 being articulately attached to the fuselage 1 by means of a first pivoting link 8 , and the second end 15 being articulately attached to the third attachment point 13 of the door 2 by means of a second pivoting link 21 , the first 8 and second 21 pivoting links allowing the relative rotation of the guiding rod 7 with regard to the fuselage 1 and to the door 2 , respectively. The first 8 and second 21 pivoting links comprise first and second auxiliary spherical bearings, in an embodiment. A detail of this embodiment is shown in FIG. 6 —the guiding rod 7 is linked to the internal wall of the fuselage 1 through the first end 14 , which comprises, in its center, the first auxiliary spherical bearing that allows the relative rotation of the guiding rod 7 .
[0075] In the embodiment of FIG. 1 , a stopper 6 is provided at an end point of the guiding rail 5 for impeding a further movement of the slider 11 along the guiding rail 5 .
[0076] The door 2 of FIG. 2 is in a swung out position, after a swinging motion resulting from a swing rotation SW around the swing axis 22 . Besides, the slider 11 has slid along a slide distance SD along the guiding rail 5 , after a sliding motion of the door consequence of a slide rotation SL around the slide axis 23 .
[0077] In the embodiment of this figure, the swing axis 22 passes through the center of the spherical bearing 19 and through the second extremity 16 of the arm 12 of the guiding means 4 . Thus, such second extremity 16 of the arm 12 is the swing point of the guiding means 4 of the present embodiment, and the door 2 swings integrally with the arm 12 and with the first extremity 17 of the guiding means 4 .
REFERENCE LIST
[0000]
1 .—Structure/Fuselage
2 .—Door
3 .—Pivoting means
3 . 1 —Main body
3 . 2 —Second edge
3 . 3 —First edge
4 .—Guiding means
5 .—Guiding rail
6 .—Stopper
7 .—Guiding rod
8 .—First pivoting link
9 .—First attachment point
10 .—Second attachment point
11 .—Slider
12 .—Arm
13 .—Third attachment point
14 .—First end
15 .—Second end
16 .—Second extremity
17 .—First extremity
18 .—Auxiliary guiding rail
19 .—Spherical bearing
21 .—Second pivoting link
22 .—Swing axis
23 .—Slide axis
25 .—Articulated joint
26 .—First joint extension
27 .—Second joint extension
28 .—Longitudinal axis
30 .—Rotorcraft
SW.—Swing rotation
SL.—Slide rotation
SD.—Slide distance | The present invention aims at providing an arrangement for moving a door in both a swinging and a sliding manner, in which a pivoting means allows the rotation of the door around at least two axes of rotation—a slide axis around which the pivoting that allows the sliding motion takes place, and a swing axis, further passing through a swing point of a guiding means intended for allowing the door to slide over a guiding rail, around which the door swings. | 4 |
CROSS REFERENCE AND PRIORITY CLAIM TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. §119(e) of provisional patent application Ser. No. 60/444,105 entitled “Automatic Detection of Radioactive Seeds for CT Based Post-Planning for Prostate Seed Implantation Based on the Hough Transform”, filed Jan. 30, 2003, the disclosure of which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention is directed toward automated detection of seeds within CT images.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] With the introduction of the Prostate Specific Antigen (PSA) test, many more patients are presenting with early stage prostate cancer. For these early stage diseases for which the cancer is totally isolated to the prostate gland one treatment option that has been gaining in popularity is radioactive seed implantation. Radioactive seed implants offer the possibility of excellent local control as well as minimal morbidity. Due to the excellent clinical results of seed implantation there has been much attention paid by the medical community toward improving the seed implantation process either by improving the specific technique itself or improving the cost effectiveness so that the procedure can be offered to a wider geographical range of patients.
[0004] One area where the seed implantation process can be improved is in the development of a fast and accurate CT or MR based post-plan dosimetry system. While it is true that once the seeds have been implanted, the determination of the quality of the implant after the fact can not alter the physical implant. However, much can be learned from a properly performed post-plan. The post-plan can indicate hastily dropped seeds resulting in inferior gland coverage or too much dose to the rectum or urethra. These quantitative results of the post-plan can be used by the physician to indicate that more care during the procedure must be taken. In addition, a properly performed post-plan that indicates inadequate dosimetric coverage of the gland indicates that a postoperative procedure may be considered to correct the situation. In some cases the patient can be reseeded to boost under dosed regions, or more radically, a salvage prostectomy may be performed.
[0005] There have been many algorithms developed over the past two years, which claim to automatically find seed centers on post operative CT studies. However, most of these algorithms require a significant amount of user intervention and expertise to achieve an adequate result. Additionally, most, if not all, of these algorithms begin with a simple thresholding of the CT data to reduce the CT images to binary images. Some algorithms end here. The thresholding results in groups of contiguous voxels which represent single or multiple seeds. If seeds are grouped together in physical space so that they are within the resolution of the CT scan, or more precisely, within the resolution of the artifacts created by each individual seed, then the resultant contiguous set of voxels will contain many more voxels than if the seeds were distinct within the CT scan. The difficult and most creative part of any automatic seed finder is in the reduction of these multiple seed voxel sets to individual seed center coordinates. In addition to determining the center of the seeds, determination of the seed direction is also of value. If an anisotropic dose calculation is to be performed, the seed center and direction must be determined.
[0006] Against this backdrop, the inventors herein have developed an improved seed detection algorithm. The seed detection algorithm comprises the steps of (1) thresholding a 3D CT data set on a voxel basis; and (2) using the Hough transform to identify shapes within the thresholded data that match a predefined 3D shape corresponding to an implanted seed. The 3D CT data set is reconstructed from the CT slice data. Further, the predefined shape used during the Hough transform process is preferably an ellipsoid with a major axis and a minor axis with dimensions corresponding to the implanted seed. The algorithm may implemented on an apparatus such as a programmed computer.
[0007] The algorithm of the present invention's use of the Hough transform with a 3D ellipsoidal template to determine seed centers and orientations represents a vast improvement in the seed detection art. The present invention's ability to determine seed orientation and split multiple seed centers is particularly advantageous. Further, the algorithm of the present invention is preferably fully automatic and determines the seed centers and directions as seen on post-operative CT scans of the prostate. The algorithm can be verified using a unique CT based phantom that incorporates an array of contiguous seeds so that they appear as one contiguous set of voxels on CT. In addition a quality assurance procedure is described to verify the accuracy of the seed finder both in phantom as well as in the clinical setting.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 ( a ) illustrates an exemplary voxel representation of the Amersham 6711 125 I seed;
[0009] FIG. 1 ( b ) illustrates the ellipsoidal representation of the seed depicted in FIG. 1 ( a );
[0010] FIG. 2 is a parametric representation of a two-dimensional line;
[0011] FIG. 3 ( a ) depicts a binary image containing seven lines;
[0012] FIG. 3 ( b ) depicts the Hough transform of the binary image of FIG. 3 ( a );
[0013] FIG. 3 ( c ) depicts the Hough transform of FIG. 3 ( b ) with the contrast adjusted to display the underlying structure;
[0014] FIG. 4 ( a ) illustrate a distribution of measured best-fit ellipsoidal parameters for the ellipsoid minor axis;
[0015] FIG. 4 ( b ) illustrate a distribution of measured best-fit ellipsoidal parameters for the ellipsoid major axis;
[0016] FIG. 5 illustrates a multi-seed CT phantom;
[0017] FIGS. 6 ( a )-( d ) illustrate DRRs and projections of the calculated seed positions;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
METHODS AND MATERIALS
[heading-0018] Three-Dimensional Images
[0019] A three dimensional image is specified by a collection of voxels and their corresponding pixel values where I ijk is the pixel value of the voxel located at index i, j, k. Further, 0≦i≦N x , 0≦j≦N y , and 0≦k<N z , where N x , N y , and N z are the width, height, and length of the image in units of voxels. The pixel values are usually bounded such that 0≦I ijk <2 n where n is the number of bits per pixel. If there is a coordinate system associated with the image space then each voxel index (i,j,k) has an associated vector position, {right arrow over (r)} ijk . To simplify notational text let I({right arrow over (r)})=I({right arrow over (r)} ijk )=I ijk . Let {right arrow over (r)} ijk correspond to the spatial center of the voxel.
[0020] The algorithm presented here begins with the reduction of the CT image data to binary image data through a simple thresholding filter. The thresholding filter is given by
J ( r _ ) = { 0 I ( r _ ) < λ 1 I ( r _ ) ≥ λ , where , 0 ≤ λ ≤ 2 n - 1 , 1.0
where λ is the thresholding limit. Sets of super thresholded voxels (the voxels thresholded to “1” that are contiguous) will be referred to as “blobs”. Decreasing the value of λ will generally lead to more blobs as well blobs of greater size (i.e., number of voxels per blob). Preferably, λ is set near the white end of the grayscale, near the 80-90 percentile mark, depending upon the total bandwidth of the CT scanner.
[0022] There are now many different manufactures of radioactive seeds for prostate permanent seed implants. The possible isotope types include 125 I and 103 Pd. For the most part the seeds are all approximately the same in physical size and shape, that is small stainless steel cylinders of approximate dimensions 5 mm in length and 1 mm in diameter. However, they tend to have different characteristics under CT imaging. In the algorithm presented here, there are adequate parameters to model any commercially available seed.
[0023] The seeds tend to create artifacts in the CT images due to their approximate singular physical nature. While the number and size of the subsequent blobs are strongly dependent on the CT acquisition parameters, assume for the subsequent analysis that the CT acquisition parameter results in a slice spacing of 1 mm . Slice spacing should be in the range of 1-5 mm, with the range 2-3 mm being preferable. After the thresholding filter described in equation 1 is applied, single seeds are represented by blobs of approximately 15 to 25 voxels in size. These single seed blobs can be fit to an ellipsoidal surface. The ellipsoid is a regular ellipsoid whose major axis is approximately 1.0 cm and minor axis is approximately 0.3 cm. The blobs that correspond to the actual seeds are larger on the CT images. This is due to the CT artifact associated with each seed. This artifact depends on the direction the longitudinal axis of the seed makes with respect to the scan direction as well as other CT acquisition parameters. FIG. 1 ( a ) displays the resulting multivoxel blob for a single seed while FIG. 1 ( b ) displays the fit ellipsoidal surface for the same multivoxel blob. If two or more seeds are within 1 mm of each other the resultant blob will be larger and in fact usually multidirectional. These proximal seeds will be represented by a large, single blob. It is exactly this situation that tests the true effectiveness and robustness of any automatic seed finder. While there exist academic and commercial automatic seed finders, they either tend to require much user intervention or do not accurately break these multi-seed blobs into their component seeds. In fact the authors have found no evidence in the literature of studies which attempt to quantitatively determine the accuracy of the breaking of multi-seed blobs or for that matter, no quality assurance of post-algorithm seed breaking in a clinical setting or in phantom.
[0024] Once the image has been thresholded, the resultant binary image is analyzed to determine the seed centers and directions. In order to achieve this a specialized Hough transform is applied.
[heading-0025] The Hough Transform
[0026] The Hough transform was first applied to determine lines in an image. It is instructive to describe the line finding procedure for the purpose of clearly illustrating the concept of the Hough transform. Consider a two dimensional image containing a number of lines. A two dimensional line may be represented in a number of ways. For the description of the Hough transform considered here, the representation of the line will be given in terms of its angle, Ø, and the perpendicular distance, r. FIG. 2 displays the relationship of r and Ø to the line. FIG. 3 ( a ) displays a binary image that contains a number of line segments. A line in an image is mathematically described as the collection of voxel indices (i,j) such that
j = tan θ · i + r sin θ . 1.1
The first step in the Hough transform is to collect all binary voxels indices whose value is one, that is the set S such that,
S={ ( i,j ):∀ v ij =1}. 1 . 2
Now consider all possible pairs of such voxel indices {(i 1 ,j 1 ),(i 2 ,j 2 )}. From this pair it is possible to calculate a perpendicular distance r and angle Ø which describes the line which passes through them. The parameter Ø and r are given by,
tan θ = j 2 - j 1 i 2 - i 1 , and , r = j 1 · cos θ - i 1 · sin θ . 1.3
The Hough transform of the image is simply the set of all possible Ø and r values determined from the original binary image. FIG. 3 ( b ) displays the Hough transform of the image displayed in FIG. 3 ( a ). The axes of the Hough transform are the parameters Ø and r. The Hough transform contains a number of bright spots. These bright pixels correspond to the true Ø and r values of the lines in the original image. This is because the true lines in the image will contribute the most pixel pairs to the Hough Transformed Image. FIG. 3 ( c ) displays the Hough transform of the image displayed in FIG. 3 ( a ) except the contrast has been adjusted so as to display the underlying structure.
[0030] In the final step in determining the actual line parameters in the original image, the Hough transform must be thresholded to select only the bright pixels. Thresholding of FIG. 3 ( b ) results in the determination of the true line parameters of image in FIG. 2 ( a ).
[heading-0031] The Ellipsoidal Hough Transform
[0032] The Hough transform is a generalized algorithm which can be applied to any three-dimensional object which can quantitatively be described. The ellipsoid is such an object. A general ellipsoid can be described as,
( x - x 0 ) 2 a 2 + ( y - y 0 ) 2 b 2 + ( z - z 0 ) 2 c 2 = 1 , 1.4
where,
{right arrow over (r)} 0 =(x 0 ,y 0 ,z 0 ), 1.5
describes the center of the ellipsoid and,
{right arrow over (ζ)}=(a,b,c), 1.6
describes the length and direction of the major and minor axes. As with the two-dimensional line finding algorithm, the algorithm which determines the ellipsoids contained within an image begins with a thresholding of the three-dimensional image. The thresholding parameter, λ, can be adjusted to improve the accuracy of the seed finder. Once the image is thresholded, all superthresholded voxels are collected into contiguous groups, or blobs. The traditional Hough transform operates on the entire image, whereas in the algorithm presented here, the Hough transform is applied to the subimage of each blob. This dramatically reduces the computation time required for the Hough transform. After all blobs have been collected, all possible triplets of voxels are generated for each blob. This results in a set of voxels indices represented by the set S E given by,
S E ={( i 1 ,j 1 ,k 1 ),( i 2 , j 2 ,k 2 ),( i 3 ,j 3 ,k 3 ):∀ v ijk ∈blob}. 1.7
Assume that the point (i 1 , j 1 , k 1 ) represents a surface voxel on the ellipsoid and that the other two points, (i 2 , j 2 , k 2 ) and (i 3 , j 3 , k 3 ) represent the two foci of the ellipsoid, then if they are indeed surface and foci points their distances must satisfy the condition,
d 12 +d 13 +d 23 =2· a, 1.8
where d 12 is the distance between point one and two, d 13 the distance between one and three, and d 23 the distance between two and three. If equation 1.8 is true for the triplet then they are part of an ellipsoid whose axes are (a,b,c). Otherwise the triplet is rejected. The criterion for acceptance is dependent on the voxel size. That is the equation of invariance must be satisfied with in the uncertainly of the size of the voxel. If they do satisfy the equation of geometric invariance, equation 1.8, then the center and direction of the ellipsoid are recorded and the next triplet is inspected for invariance. The center is given by,
r → center = 1 2 ( r → 2 + r → 3 ) , 1.9
and the direction relative to {right arrow over (r)} 2 is given by,
r → direction = r → 2 - r → 3 r → 2 - r → 3 . 1.10
It is assumed that the values for a, b, and c are known a priori so that the search for geometric invariance can be performed.
Determination of the Ellipsoidal Axes Dimensions
[0041] To determine the values of a, b, and c for Amersham Nycomed's 125 I model 6711, 100 patients who were treated with interstitial seed implantation using this model seed were analyzed. The post-operative CT scans were thresholded and the contiguous blobs collected. Each blob was then fit to an ellipse of the form given in equation 1.4 where b=c. The results of the best fit values were histogramed and appear in FIG. 4 ( a ). Seeds which were too close and coalesced into a single blob were included in the analysis and would not represent the true values of the ellipsoid dimensions. However, this coalescence is the exception rather than the rule and would represent weak, distance peaks in the resultant histogram. Ignoring these exceptions, the average value for the length of the major and minor axes of the best fit ellipsoid for the model 6711 seed are a=1.0 and b=0.35. The best fit value for the axes show a minor dependence on the threshold parameter λ. FIG. 4 ( b ) displays the best fit value for the axes as a function of λ, again for the model 6711 seed. The same techniques can be used to determine the a, b, and c parameters for other types of seed implants.
[heading-0042] Phantom Test
[0043] A phantom consisting of eight dummy (zero activity) 6711 seeds was constructed. FIG. 5 displays the phantom geometry along with the seed coordinates relative to the geometric center of the seeds. The phantom was constructed such that the seeds were in physical contact such that they described a square shape. The seeds were embedded in between to one inch thick sheets of superflab material. The seed phantom was scanned at 1 mm slice spacing throughout the entire phantom for a total of 64 CT slices. The resultant CT image set for this phantom displayed the seeds as one contiguous blob which contains the eight individual seeds. The automatic seed finding algorithm presented here was applied to the CT images of the phantom. A threshold value of λ=210 was applied to create the binary image and resultant, single, multi-voxel blob which contained 823 voxels.
[heading-0044] Quality Assurance Digitally Reconstructed Radiograph (DRR)
[0045] In order to attempt to quality assure the results of the automatic seed finder a quality assurance tool based on a digitally reconstructed radiograph was developed by the authors. The tool is based on the construction of a DRR for any orientation and direction. The tool is very robust in this regard. It is not limited to the simple three orthogonal directions. The user simply chooses an initial direction for the DRR, usually the anterior to posterior (AP) direction. On this DRR the bony anatomy and the seeds can be easily seen. FIG. 6 ( a ) displays the results of an AP DRR for an actual patient study. The software then projects the calculated position of the seeds in this DRR projection as colored crosses. FIG. 6 ( b ) displays the DRR along with the project calculated seed positions. The display of the calculated seed positions can be toggled on and off so that the user can inspect whether or not a high density region appears under the colored cross. It is in this manner that the user can get an estimate of whether the calculated seed position is correct or not. If a cross is draw with no corresponding, underlying high density region, then the calculated position of that particular seed is in question. If there exists an ambiguity in the DRR such as one seed lying behind another seed and along the ray from the DDR source to the DRR projection plane then the user simply calculates another DRR and a different angle. These processes of multiple DRR reconstructions can be repeated until the user is confident in the results of the automatic seed finder are correct or incorrect.
[heading-0046] Patient Results
[0047] The commercial algorithm has been used for 850 patients at this and associated clinics. The software has never failed to properly identify the number and subsequent position of all implanted seeds for all of these patients. The accuracy in the number of implanted seeds was simply evaluated by comparing the actual number of seeds implanted to that number which the algorithm found. The accuracy of the determined spatial seed coordinates were more difficult to quantitatively assess, however, each patient was reviewed using the qualitative DRR QA tool previously described. Using this tool it was determined that the algorithm corrected determined the position of each seed for all 850 patients.
[0048] While the present invention has been described above in relation to its preferred embodiment, various modifications may be made thereto that still fall within the invention's scope, as would be recognized by those of ordinary skill in the art. Such modifications to the invention will be recognizable upon review of the teachings herein. Accordingly, the full scope of the present invention is to be defined solely by the appended claims and their legal equivalents. | A technique for detecting implanted seeds automatically from CT image data. Various features of the inventive technique include (1) thresholding a 3D CT data set on a voxel basis; and (2) using the Hough transform to identify shapes within the thresholded data that match a predefined 3D shape corresponding to an implanted seed. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates generally to a refrigeration apparatus for home refrigerator-freezer units and more particularly to a refrigeration system for the carbonator apparatus of a post-mix beverage dispenser mountable in a conventional home refrigerator.
In recent years, home refrigerators have been designed to dispense chilled products such as ice, water and beverages through the front door of the refrigerator when the door is closed. Not only is this a convenience to the homeowner, but it also acts to save energy by reducing the number of times that the refrigerator door must be opened and closed. Home refrigerator dispensing systems accessible by opening the door are also useful to the homeowner if adequate product cooling can be maintained.
Both types of systems have a need for easily and efficiently cooling a carbonator used within the refrigerator dispensing system which will time-share the refrigerator's existing cooling system so that additional auxiliary refrigeration systems will not be required. The use of the existing refrigeration system for cooling the carbonator should, further, be effective regardless of the location of the carbonator within the refrigerator door or the interior of the refrigerator.
To be effective and useful, any beverage dispensing system for use in a home refrigerator should be simple so that it can be easily built into or retrofitted into the refrigerator.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the invention to provide an improvement in liquid dispensing systems for conventional home refrigerators.
It is another object of the present invention to provide a carbonated liquid dispenser integral with a conventional home refrigerator.
It is a further object of the present invention to provide a system for dispensing a chilled carbonated liquid from a door on the front of the refrigerator.
It is a still further object of the present invention to cool the carbonator used in the dispensing system by time-sharing the existing refrigeration system.
These and other objects of the present invention are fulfilled by providing an apparatus in a home refrigerator for dispensing a chilled carbonated liquid, said refrigerator having a mechanical refrigeration system including a compressor an evaporator and a condenser, the improvement comprising:
(a) a source of cooling fluid flowing across the evaporator;
(b) a carbonator device disposed in said cabinet;
(c) heat exchange means, provided in association with said carbonator device, for cooling said carbonator device;
(d) conduit means for connecting said source of cooling fluid in fluid communication with said heat exchange means;
(e) sensor means for detecting temperature related parameters of the carbonator device;
(f) valve means for selectively regulating the flow of said cooling fluid to said heat exchange means; and
(g) control means for operating said valve means in response to the temperature related parameters detected by said sensor means.
The cooling fluid may be either chilled air passing over the evaporator, or a high pressure refrigerant passing through the evaporator in route to the carbonator.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects of the present invention and the attendant advantages thereof will become more readily apparent by reference to the accompanying drawings, wherein:
FIG. 1 is a front perspective view generally illustrative of a conventional refrigerator having an upper freezer compartment and a lower refrigeration compartment;
FIG. 2 is a top plan view taken along lines II--II of FIG. 1 with the refrigerator door in an opened position and is illustrative of one embodiment of the present invention;
FIG. 3 is a top plan view taken along lines II--II of FIG. 1 with the refrigerator door in a closed position;
FIG. 4 is a front cross-sectional view taken along lines IV--IV of FIG. 3;
FIG. 5 is a front cross-sectional view of a second preferred embodiment of the present invention with a carbonator by-pass valve in a closed position;
FIG. 6 is a partial cross-sectional view of the embodiment shown in FIG. 5 with the carbonator by-pass valve in an opened position;
FIG. 7 is a schematic view of a third embodiment of a refrigeration system the present invention; and
FIG. 8 is a block diagram showing only the essential control components for the carbonator refrigeration system in each of the embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference numerals refer to like parts throughout, attention is directed first to FIG. 1 where reference numeral 10 denotes a conventional home refrigerator of the type which is comprised of an upper freezer compartment 12 and a lower refrigeration compartment 14, which includes respective handles 20 and 22 for opening the doors.
The present invention has the capability of dispensing carbonated water or a post-mix carbonated beverage including a mixture of flavor concentrate 28 and carbonated water from one of the front doors of a home refrigerator. This may be done through the lower door 14 which includes a generally rectangular access opening or recess 24 wherein a liquid receptacle (not shown) can be inserted therein and pressed against an actuation lever 26 coupled to a liquid dispenser having a discharge port (not shown).
Referring now to FIG. 2, there is shown the details of the first embodiment of the present invention wherein an entire dispensing system including the carbonator 30 located in the refrigerator door which is in an opened position.
FIG. 3 is a view similar to that of FIG. 2, but with the refrigerator door 18 in a closed position.
With respect to FIGS. 2 and 3, there is shown, in addition to the carbonator 30 in the refrigerator door 18, a CO 2 cylinder 48 and a control section 46 positioned adjacent each other in the refrigerator door 18. The syrup package 28 is centrally located in the refrigerator door 18 above a dispensing outlet in an opening or recess 24. Door seals 60 assist in sealing the interior of the refrigerator 14 from external atmosphere and, although shown in cross-section, run the entire vertical length of the door 18 between the door and the refrigerator.
The carbonator 30 is surrounded by a band of heat transfer fins 62 which are enclosed within a torroidal plenum 64 (see FIG. 4).
An insulated duct 32 within the refrigerator compartment 14 includes a carbonator by-pass valve 34 and a duct seal 58.
Referring now to FIG. 4 which is a front cross-sectional view taken along lines IV--IV in FIG. 3, it can be seen that within the freezer compartment 12 there is positioned a freezer fan 36 and an evaporator 38 adjacent the rear of freezer compartment 12.
The arrangement described enables a unique ability to cool the carbonator 30 with the use of the existing refrigeration elements, including the evaporator 38 (more clearly shown in FIG. 5), and a compressor and condenser disposed below the cabinet.
In order to cool the carbonator, cold air from the evaporator 38 flows past a closed carbonator by-pass valve 34 through the insulated duct 32, through a booster or carbonator fan 50, through the heat transfer fins 62 surrounding the carbonator 30, and then through a short exhaust duct 40 into the interior of the refrigerator 14.
Thus the carbonator by-pass valve 34 is in the closed position, the cold air from evaporator 38 is directed to the carbonator 30. When the by-pass valve 34 is in an open position, the cold air generated by evaporator 38 is directed straight into the refrigerator compartment 14, as it would be in a conventional refrigerator. An ice bank detector (see FIG. 8) located in controls 46 determines the position of the by-pass valve 34 such that when the ice bank detector senses a lack of an adequate ice bank surrounding the carbonator, a control system 46 will switch closed the bypass in order to direct evaporator-cooled air directly at the carbonator 30 as shown in FIG. 4. A conventional ice bank detector is disclosed, for example, in U.S. Pat. No. 4,008,832 to Rodth entitled "Three Drink Gravity Dispenser for Cool Beverages " and is incorporated herein by reference. Whether or not the compressor 44 is running is determined by the set point of the interior of the refrigerator as detected by a temperature sensor associated with controls 46. The temperature sensor may be located in any suitable location within the refrigerator.
Water and electricity are routed to the refrigerator door 18 by flexible connectors in the hinge area (not shown). When the refrigerator door 18 is opened (see FIG. 2), the carbonator 30 and its related assembly swings awaY from the insulated duct 32. When the refrigerator door 18 is closed (see FIG. 3), the carbonator 30 and its related assembly reconnects to the insulated duct 32.
FIG. 5 is a front cross-sectional view of a second preferred embodiment of the present invention, showing the carbonator by-pass valve 34 in a closed position. FIG. 7 is a partial cross-sectional view of FIG. 6 showing the carbonator by-pass valve 34 in an opened position.
Similar to the first embodiment shown, the second embodiment uses the refrigerator's main refrigeration system with no additional auxilliary refrigeration systems.
The carbonator 30 is likewise surrounded by a band of heat transfer fins 62 which are enclosed within a torroidal plenum 64.
In a carbonator cooling operation, cold air from the evaporator 38 is ducted past a closed carbonator by-pass valve 34, into the plenum inlet 63, over the carbonator's heat transfer fins 64 and then through the plenum outlet 65 into the refrigeration compartment 14. If the heat transfer fins 62 cause too much resistance to the air flow, an exhaust fan 51 for the carbonator 30 can be added to the plenum outlet 65.
Thus, when the by-pass valve 34 is in the closed position, the cold air from the evaporator 38 is directed to the carbonator 30 prior to passing into the refrigerator compartment 14. When the by-pass valve 34 is in the open position, the cold a-r is directed straight into the refrigeration compartment 14, as it would be in a conventional refrigerator. The ice bank detector (see FIG. 8) determines the position of the by-pass valve 34 such that when the ice bank detector senses a lack of an adequate ice bank surrounding the carbonator, a control system 46 will switch closed the bypass valve 34 in order to direct evaporator-cooled air directly at the carbonator 30 as shown in FIG. 5. Whether or not compressor under the refrigerator (not shown in FIGS. 6 and 7) is running is determined by the set point of a temperature sensor in the interior of the refrigerator.
Similar to the first embodiment, carbonated water from the carbonator 30 is directed to a dispensing mechanism in door 18 by way of a flexible tube routed through the hinge area (not shown).
Referring now to FIG. 7, there is shown a schematic view for a substitute refrigeration system for use as a third embodiment of the present invention. The system schematically shown provides an evaporator 38 which cools the interior of both the freezer 12 and the refrigerator 14. When the ice bank detector senses the presence of an adequate ice bank of more than a predetermined thickness on the carbonator 30, a three-way valve 56 will always direct a high pressure refrigerant to the evaporator 38, by-passing the carbonator 30. When the ice bank detector senses a lack of an adequate ice bank on the carbonator 30, a control system 46 will oscillate the three-way valve 56 back and forth, sending high pressure refrigerant to the carbonator's cooling coils 62 for an appropriate percentage of the compressor 44 run cycle, and send high pressure refrigerant to the evaporator 38 for the remainder of the run cycle in the compressor 44.
It should be understood that the mechanical refrigeration system used with the first and second embodiments of FIGS. 4 and 5 of FIG. 7 includes evaporator 38, condenser 42 and compressor 44. However, valve 56 and coil 62 would not be included in those embodiments.
Referring now to FIG. 8, there is shown a block diagram of the essential control components for the carbonator refrigeration system in each of the embodiments of the present invention.
In particular, it can be seen that a temperature sensor 70 is primarily responsible for detecting the temperature within the interior of the refrigerator. The interior temperature of the refrigerator is to be maintained at a predetermined set point, such that when the temperature falls below the predetermined set point, the compressor 44 is activated to initiate cooling by evaporator 38 (see FIG. 7).
Power source 72 can be any suitable power means available for running a standard refrigerator.
The ice bank detector 74 detects the lack of an adequate ice bank (below a predetermined thickness) surrounding the carbonator 30 such that detection of an adequate ice bank will operate to open switch 34 and allow chilled air to pass directed into the refrigerator compartment 14. Conversely, if an inadequate ice bank is detected, the switch 34 will close allowing chilled air to cool the carbonator 30.
If high pressure refrigerant is being utilized to cool the carbonator, the three-way valve 56 operates as described in connection with FIG. 7 whereby when the ice bank detector senses the presence of an adequate ice bank on carbonator 30, the three-way valve 56 will always direct the high pressure refrigerant to the evaporator 38, by-passing the carbonator 30. When the ice bank detector 74 senses a lack of an adequate ice bank on the carbonator 30, the three-way valve 56 will oscillate to direct high pressure refrigerant to the carbonator cooling coils 62 for an appropriate percentage of the compressor 44 run cycle, and send high pressure refrigerant to the evaporator 38 for the remainder of the compressor 44 run cycle.
It should be understood that the foregoing detailed description has been made by way of illustration and not limitation. Accordingly, all such modifications, alterations and changes coming within the spirit and scope of the invention are herein meant to be included. | A carbonator refrigeration system for use in a conventional refrigerator for dispensing a chilled carbonated liquid such as water or a beverage from the front door of the refrigerator. The system includes a compressor, an evaporator, a condenser, a carbonator and a valve member wherein the valve member is responsive to conditions detected within the refrigerator for selectively directing a source of cooling fluid to or away from a heat exchange device provided in connection with the carbonator. The carbonator refrigeration system enables cooling of the carbonator for home dispensing use in a time-share manner with the remaining mechanical refrigeration components. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to fluorescent lamp operating circuits and, more particularly, to an electronic fluorescent lamp operating circuit for starting and operating a fluorescent lamp load at a controllable output level.
2. Description of the Prior Art
Presently, fluorescent lamp operating circuits for providing variable illumination levels from fluorescent lamps have involved the use of chopping circuitry to limit the overall electrical power delivered to the fluorescent lamp. Such circuits employ high frequency signals during a portion of the a-c power wave, which create electromagnetic interference having a deleterious effect upon the operation of electronic equipment located in the vicinity of the ballast circuit or lamps and low power factor. The prior art fluorescent lamp control circuits provided dimming of the level of illumination by dissipating the energy within the power supply circuitry. This created heat which had to be dissipated from the system and resulted in substantial inefficiencies in terms of light output versus electrical power input.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a fluorescent lamp operating circuit which allows reliable starting of fluorescent lamps and controllable operation of the fluorescent lamps at a variety of illumination levels without reducing the overall lighting system efficiency. A more specific object of the present invention is to provide an electronic ballast circuit including control signal detection circuitry for receiving control signals transmitted over the power line and adjusting the light output according to the information contained in the control signal.
Accordingly, the present invention includes a bridge circuit for converting a standard frequency power signal into a d-c input, an inverter circuit for converting the output of the d-c signal to a high frequency a-c wave for providing power to a fluorescent lamp load, an electrode heating control circuit for controlling the application of heating current to the lamp electrodes, an input control circuit for controlling the switching frequency of the transitors of the inverter circuit, a receiver circuit for receiving high frequency control signals from the power line and decoding binary messages from the control signals for providing control of the switching frequency, and a power transformer for supplying high frequency lamp operating power to the fluorescent lamp load including an auxiliary starting circuit for applying a starting voltalge to the load after preheat of the fluorescent lamp filament by an auxiliary power circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the present invention together with its organization, method of operation and best mode contemplated may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic circuit diagram illustrating the fluorescent lamp operating circuit of the present invention; and
FIGS. 2a and 2b are schematic timing diagrams illustrating the input control signals of the circuit diagram of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The fluorescent lamp operating circuit 10 of the present invention, as shown in FIG. 1, includes input terminals 12 and 14 for connection to a power supply system having a signal generating and transmitting means attached to it for providing control signals to the operating circuit 10. Such a signal generating and transmitting system is disclosed in U.S. patent application Ser. No. (LD 9607) filed concurrently herewith by William M. Rucki and assigned to the present assignee which discloses and claims a system for providing to a power line carrier control signals of the character utilized by the fluorescent lamp operating circuit of the present invention. The circuit 10 of the present invention includes a notch-filler 16 including capacitor C16, inductor L2 and capacitor C15 connected as shown in the FIG. 1. The output of the notch filter is provided to a bridge rectifier circuit 18 including the four diodes D27, D28, D29 and D30. The bridge rectifier 18 supplies via capacitor C1 a rectified d-c signal to the power factor correction circuit 20 which includes diodes D1, D2, D3, zener diode D27, resistors R8 and R15, SCR1, inductor L1 and capacitor C2 a shown in the FIG. 1 connected to ground. The output of the power factor correction circuit 20 is supplied to an inverter switch circuit 22 which includes transistor Q1 supplied from transformer T2 connected to a d-c power supply at the terminal 24 via resistor R1 and capacitor C4 and connected to the transistor Q1 via diodes D4 and D5 and resistor R3 connected as shown with diode D8 connected across the output of transistor Q1; and transistor Q2 supplied from transformer T3 having its primary winding supplied from the d-c source 24 via resistor R2 and capacitor C3 and having a second winding connected via diodes D6 and D7 and resistor R4 to the base of transistor Q2 as shown, with diode D9 connected across the output of the transistor Q2. The inputs to the transformers T2 and T3 are controlled by the outputs of IC3 connected respectively at points A and B to be described hereinafter. The transistors Q1 and Q2 are connected in a half bridge arrangement with capacitors C6 and C7 as shown. The output from the junction 26 between capacitors C6 and C7 is supplied to the primary winding of transformer T1 whose secondary winding supplies power to the lamp load 28 across capacitor C10. Also connected to the junction point 26 is a primary winding of the transformer T4 whose secondary windings are connected to the respective terminals of the lamps of the lamp load 28 to provide preheating current to the lamp electrodes to assist in starting the lamps. The numerals shown on the drawing at the respective ends of the transformer windings are pin numbers for the electronic components comprising the elements shown schematically in FIG. 1. The input from the notch filter 16 is also connected to a bootstrap circuit 30 including diode D15 resistors R5, R6, and R12, capacitor C8 and transistor Q4 connected as shown in FIG. 1. The output of the bootstrap circuit 30 is connected to a power supply circuit 32 which includes a transformer winding on the transformer T1 to operate as a secondary and includes diodes D17, D18, D23, D24, D25 and D26; and capacitors C9 and C14 connected as shown in FIG. 1 to provide a reference voltage at output terminal 34 for the control circuit to be described hereinafter. A receiver circuit 36 is also connected to the input terminals 12 and 14 via blocking capacitor C26 and transformer T6 having capacitor C27 connected across its output terminals. Integrated circuit IC4 is connected to transformer T6 via resistor R16 at pin 10 and to capacitors C18, C19, C20, C21 and C25, resistors R17, R18, R19 and R20 and zener diode D16 at the respective pins as shown in FIG. 1. Integrated circuit IC4 is connected to pin 2 of IC6 with filter capacitor C28 connected thereto and IC6 is connected at pin 1 to the reference voltage output 34 of the power supply circuit 32. Integrated circuit IC5 is connected to pin 12 of IC4 and has resistors R21, R22, R23, and capacitors C22, C23, C24 and C29 connected to respective pins thereof as shown in FIG. 1. The outputs from pins IC5 at 12, 13, 14 and 15 of IC5 are provided to the respective pins 1, 2, 4, 5, 9, 10, 12 and 13 on integrated circuit IC7, for the respective gates connected thereto having respective resistors R25, R26, R27 and R28 connected to the output pins 3, 6, 8 and 11, respesctively, thereof with filter capacitor C17 connected to the opposite side of each of the respective resistors R25-R28. A control circuit 38 includes integrated circuit IC3 for providing the control signals A and B for the inverter switch circuits and has resistors R7, R9 and R11, potentiometer P1 and capacitors C11 and C13 connected thereto as shown in FIG. 1. The control circuit 38 also includes logic gates 40, 42, 44 and 46 disposed on an additional integrated circuit IC2 resistors R10, R12, capacitors C5, C12, didoes D10, D11, D12, D13, D14, transistor Q3 and diodes D19, D20, D21 and D22 connected to the primary winding of transformer T7 whose secondary winding is connected in series with the primary winding of the preheat transformer T4 to provide a control signal to the preheat circuits for controlling the application of preheating current to the lamp electrodes. The secondary winding of transformer T5 is connected electrically in series with the primary winding of transformer T1 and has a center tapped primary winding connected to the diodes D11 and D12 as shown in the figure to provide a control signal to turn on electrode heat when the lamps are started.
The fluorescent lamp operating circuit illustrated in FIG. 1 operates as follows. Upon application of a-c power, for example 277 volt a-c input at the terminals 12 and 14, the bootstrap circuit 30 provides a power signal to the power supply circuit 32 which generates a d-c reference voltage signal which is applied to the receiver circuit at IC6. This then generates pluses at A and B of 38 firing Q1 and Q2 of 22 which generates a voltage on power supply 32 from transformer T1. The bridge rectifier provides a d-c signal to circuit 20 and the power factor correction circuit 20 supplies a d-c power signal to the inverter switch circuit 22 when the 277 volt a-c signal is near zero voltage. The output of the inverter switch circuit 22 at terminal 26 feeds the primary winding of the transformer T1 and the primary of transformer T4. The transformer T4 which has a plurality of secondary windings connected to the respective filaments at the ends of the respective fluorescent lamps to preheat the windings to emissive temperatures. The output at terminal 26 also feeds the primary windings of transformers T1 and T5. The secondary windings of transformers T5 provides an output signal via diodes D11 and D13 to gate 40 which forces A and B to go to a high frequency (65 KHz) when there is an overload condition on Q1 and Q2. With either input of gate 44 going low, the output of 46 goes high which turns on transistor Q3 to apply a voltage to the primary winding of transformer T7 to allow current flow through the primary winding of transformer T4. The output of the transistors Q1 and Q2 is at a frequency of approximately 65 kilohertz and the component values of capacitors C10 and the inductances of the secondary winding of the transformer T1 and the auxilary winding L7-12 are selected so that at resonance C10 applies a high voltage across the series connected lamps to initiate the arc and therefore start the lamps. To initiate the arc, the frequency is reduced to 40 KHz which is the resonant frequency of the combination of C10 and the secondary winding and auxiliary winding of transformer T1.
A multi-bit binary control signal shown in FIG. 2a is transmitted over the power line as a high frequency, e.g. 125 KHz center frequency, signal and is received at the input transformer T6. The secondary winding of transformer T6 and capacitor C27 form a tuned circuit at the data transmission frequency so that the data signal is transmitted to the integrated circuit IC4 which detects the binary signal and provides the series multi-bit data signal shown in FIG. 2b to the decoder IC5. IC5 decodes the input signal, stores the decoded data in memory and decodes the next data signal and compares the two data values. If two consecutive data values are equal IC5 translates the data into a multi-bit parallel binary output signal which is supplied via the gates on IC7 to IC3 to cause integrated circuit IC3 to provide output frequency control signals A and B to the windings of transformers T2 and T3 to control the switching frequency of transistors Q1 and Q2. In a sample circuit constructed as shown in FIG. 1, IC4 was a LM1983 frequency shift key transciever sold by National Semiconductor and IC3 was a PWM Controller UC 3525 of Unitrode. Capacitor C18 is a 60 Hz filter, and capacitors C19 and C20 are filter capacitors. Resistor R17 and capacitor C25 set the center frequency of the voltage controlled oscillator on IC 4. Resistor R18 and capacitor C21 comprise a phase locked loop filter and set the system a-c gain. Resistor R19 ia a pull-up resistor on an open collector and resistor R20 is a bias resistor for a transistor on IC4. When a data signal is received by IC4, the frequency modulated data shown in FIG. 2a is decoded into a serial binary data word and outputted at pin 12 of IC4 to serial input decoder IC5, e.g. a MC145027 sold by Motorola. IC5 has resistors R21, R22 and capacitors C23 and C22 connected as shown to set the detection characteristics of IC5. IC5 detects a five bit address code and if the address is correct, the four data bits are decoded and stored in a data register on IC5 for comparison with the successive data word. It two successive data words agree, a control signal of four parallel bits is transmitted to IC7, e.g. a nand chip 74LS03 sold by Texas Instruments. Binary zeroes in the parallel data word cause a current increase through resistor R9 to cause the frequency outputs of IC3 to vary at A and B. The frequency shift at A and B on transformers T2 and T3 shifts the switching frequency of transistors Q1 and Q2 to vary the voltage across capacitor C10 and therefore the intensity of light output from lamps in the load 28. | A fluorescent lamp operating circuit includes a high frequency electronic ballast circuit for providing a controlled output to a fluorescent lamp load. A control signal is detected from the power line carrier which includes binary data indicative of the illumination level desired. The control signal comprises a multi-bit binary signal which is detected by the control circuit and used to control the frequency of the power supply circuit so that the fluorescent light illumination level may be dimmed over a wide range. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to substituted diphenyls of formulae I and II: ##STR2## which can be additionally mixed with substituted diphenyls of formulae III and IV ##STR3## and their use as heat transfer fluids. In the formulae R 1 stands for hydrogen or ethyl, R 2 for ethyl, R 3 for methyl and R 4 for the benzyl radical.
DESCRIPTION OF THE BACKGROUND
Heat transfer fluids (herein also referred to as heat carriers), are used to transfer heat energy between thermodynamic systems of different temperature. Heat carriers are to be understood, in the sense of the present invention, to be fluids which are able to supply heat energy to a medium or to remove heat energy from a medium via a heat exchange unit.
In a narrower sense, the invention relates to heat carriers which can be utilized over a wide temperature range, i.e. from about -25° C. to about 390° C. In order for heat carriers to be employable under operational conditions over the above wide temperature range, they must possess a number of specific properties, including:
1. high boiling point at normal pressure;
2. liquid state of aggregation at the required low temperatures;
3. marked thermal stability;
4. low sensitivity to oxidation;
5. good heat transport and heat transfer characteristics;
6. low corrosive action on equipment materials;
7. low flammability;
8. favorable physiological properties (low toxicity);
9. environmental acceptability;
10. capacity for regeneration; and
11. economy
The heat carrier used most frequently in industry is water; but this can only be used, for known reasons, over a narrow temperature range. Mineral oils and synthetic heat carriers are also widely used in industry. In general, mineral oils can be used in a high temperature range only up to temperatures of about 250° C. Above about 250° C. mineral oils increasingly undergo cracking with the formation of gaseous products, manifested by sludge formation. Above 250° C. synthetic heat carriers are used. The following are known as synthetic heat carriers: biphenyl/diphenyl oxide mixtures, partially hydrogenated terphenyls, benzyltoluenes, ditolyl ethers, aryl silicates and phenylsilicones. However, the majority of these products have attained only little practical significance, because they are used mainly in the regions where water or mineral oils are more commonly used, which are per se more reasonably priced. Furthermore, they usually commence to decompose at high temperatures and can then no longer be regenerated, others are too costly and again others make severe demands on work safety. A need therefore continues to exist for materials which possess improved thermal stability as a heat transfer medium.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a heat transfer medium which exhibits improved stability at high temperatures.
Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by one or more compounds of formula I and/or II, ##STR4## in which R 1 stands for ethyl or hydrogen, R 2 for ethyl, R 3 for methyl and R 4 for a benzyl radical, as a heat transfer fluid. The fluid may additionally contain one or more compounds of formulae III and/or IV, wherein R 1 to R 4 are as defined above:
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The heat transfer fluid of the invention has favorable viscosity characteristics at lower temperature ranges and has excellent thermal stability in the upper temperature range up to an initial cot temperature of about 370° C.
The heat transfer fluid of the invention is particularly characterized by an exceptionally low tendency to form low-boiling and in particular high-boiling fractions. Under the effect of high-boiling fractions the heat transfer characteristics of the heat carrier are adversely altered. In extreme cases the high-boiling fractions separate out on the walls of the heat exchanger tubing from a certain concentration because of their poor solubility. These fractions carbonize and drastically impair heat transfer. This drawback is overcome by the fluid of the present invention.
A further advantage of the present heat transfer medium is ease of regeneration. A particularly advantageous characteristic of the fluid according to the invention is the wide range of temperatures over which it remains in liquid form, the lower limit being -26° C.
In a preferred embodiment of the invention, the heat transfer fluid consists of benzylethyldiphenyl, benzylethylmethyldiphenyl, benyldiethyldiphenyl, benzyldiethylmethyldiphenyl, benzylmethyldiphenyl, and mixtures thereof and can be used up to an initial temperature of 370° C. and a film temperature of 390° C. These properties represent a significant advantage over the properties of known synthetic heat transfer media.
The heat transfer fluid of the invention can be prepared by a known process such as, for example, successive ethylation and benzylation of diphenyl in the presence of a Friedel-Crafts catalyst.
The industrial advantages of the fluid of the present invention become clear by comparison with two examples of heat carriers already used in industry, i.e. the partially hydrogenated terphenyls (comparison fluid A) and dibenzylated toluene (comparison fluid B). Table 1 provides a summary of the physical properties which do not point to any particular advantages of the fluids according to the invention except for certain advantages of comparison fluid B in the low temperature range (lower viscosity) and certain drawbacks of the comparison fluid B in the high temperature range (higher proportion of low-boiling fractions).
The significant and industrially crucial advantages of the fluid of the present invention are apparent from Table 2. This table contains boiling analyses of the heat carriers in their virgin state (original products before use) and after heat exposure tests carried out in each case over 500 hours in steel pressure vessels at 350°, 360° and 370° C. The boiling analyses were carried out according to ASTM 1078.
It is apparent that the comparison fluids change when subjected to heat to a considerably greater extent than the fluid according to the present invention. Thus the tendency to form low-boiling fractions (thermal degradation, cracking) of the comparison fluid A is greater than that of the fluid of the present invention, while the proportion of high-boiling fractions in the comparison fluid B increases to a much greater extent.
Decomposition of the comparison fluids A and B increases with increasing temperature (350° C./370° C.) to a much greater extent than is the case with the fluid of the present invention. This becomes especially clear when the boiling characteristics of the virgin, original fluids are compared with their boiling characteristics after a heat exposure at 370° C. over 500 hours (see Table 2). On the one hand, the original fluids are completely (fluid according to the invention and comparison fluid B) or almost completely (comparison fluid A) distillable up to the ASTM 1078 limit temperature of 400° C. On the other hand, only 80% of the comparison fluid A is (after heat exposure at 370° C.) distillable up to 400° C. and as little as 60% of the comparison fluid B is distillable, while not less than 95% of the fluid according to the invention remains distillable. From this boiling analysis, standardized according to ASTM 1078, it is obvious that in the comparison fluid A about 20% and in the comparison fluid B as much as about 40% of undesirable high-boiling compounds have formed when subjected to heat at 370° C. over 500 hours, while in the fluid according to the invention the formation of such high-boiling fractions takes place only to a comparatively small extent of about 5%.
This indicates that the fluid according to the invention can be industrially utilized as a heat transfer fluid even at 370° C., while the comparison fluids A and B do not withstand a prolonged heat exposure at 370° C. The advantages of higher thermal stability of the fluid according to the invention are also valid for a long-term heat exposure temperature lower by 10° C. of 360° C. and, when the fluid B is included in the comparison, even for a longterm heat exposure temperature of 350° C., as shown by the test data of Table 2.
TABLE 1______________________________________Physical properties Fluid of the Comparison ComparisonProperty invention fluid A fluid B______________________________________Boilingrange in °C.at 10% 360 340 37090% 380 390 380according toASTM 1078Flash point (°C.) 196 178 190according toDIN 51376Ignition temp. (°C.) 415 374 >500according toDIN 51794Viscosity at 20° C. 110 100 40(mm.sup.2 /s) accordingto DIN 51562Solidification point -26 -28 -35(°C.) according toDIN 51597Specific heat at 1.62 1.60 1.5820° C. (J/g · grd.)______________________________________ Comparison Fluid A: partially hydrogenated terphenyl Comparison Fluid B: dibenzylated toluene Composition of the fluid of the present invention tested: 54% benzylethyldiphenyl, 28% ethylmethylbenzyldiphenyl, 3% benzylmethyldiphenyl, 15% diethylbenzyldiphenyl.
TABLE 2__________________________________________________________________________Boiling analysesAll heat carriers were heat treated in a pressure vessel at thetemperatures stated over 500 hours.The evaluation is carried out according to ASTM 1078. Fluid of the present invention Comparison fluid A Comparison fluid B% by vol. Orig. 350° C. 360° C. 370° C. Orig. 350° C. 360° C. 370° C. Orig. 350° C. 360° C. 370° C.__________________________________________________________________________1st drops 342 114 110 115 338 100 95 95 348 102 102 102(start of boiling) 5 352 300 220 134 339 146 135 120 368 244 150 14810 357 345 337 348 340 314 230 210 372 302 250 25020 361 352 351 355 342 335 315 310 373 366 360 36030 361 360 357 356 343 340 332 325 374 374 369 37540 366 362 363 357 344 342 345 340 375 376 373 38550 368 364 368 358 345 345 347 346 376 377 375 39060 370 366 371 368 346 347 349 348 377 379 380 up to 40070 372 368 375 379 350 352 355 355 378 380 38880 374 371 380 382 359 361 365 up to 379 390 up to 400 40090 378 376 390 395 383 385 up to 380 up to 400 40095 382 380 395 up to up to up to 381 400 400 40098 391 387 up to 383 400__________________________________________________________________________
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein. | Heat is transferred in a thermodynamic system with a heat transfer medium which is at least one fluid of formula I and/or II, ##STR1## wherein R 1 is ethyl or hydrogen, R 2 is ethyl, R 3 is methyl and R 4 is a benzyl radical. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional application No. 60/857,249, filed Nov. 6, 2006, which is incorporated by reference.
BACKGROUND
The amount of data transferred between devices in computer systems has been increasing at a tremendous pace that shows no signs of abating. In particular, the amount of data transferred between memory devices and other devices, such as devices implemented using field programmable gate arrays (FPGAs), has grown prodigiously. Unfortunately, the rate at which these devices can process data has increased faster than the memory device's capacity to provide it. For this reason, faster memory interface protocols are being developed.
One such faster protocol is the Double-Data Rate 3 (DDR3) interface standard. In this standard, several memory devices communicate with a memory interface circuit on an FPGA or other device. Each memory device communicates using a number of data or DQ signals and a strobe or DQS signal. While the FPGA receives data, the FPGA provides a system clock signal to the memory devices, each of which provide a DQS and a number of DQ signals to the memory interface circuit. The memory devices use the system clock to adjust the frequency of the DQS and DQ signals. However, the system clock is routed to the memory devices using a fly-by topology. Accordingly, the DQ and DQS signals are provided asynchronously to the memory interface, that is, each memory device may provide DQS and DQ signals having any phase relationship to the system clock.
The DQ signals received by the memory interface are retimed using a phase-shifted version of the corresponding DQS signals. These retimed signals need to be retimed once again to an internal clock, which may be the system clock or a second clock signal, to transfer the signals to the core of the device. Unfortunately, if the timing between the phase-shifted DQS signal and the system clock is not optimal, data recovery errors may result. Conventional techniques have included using first-in-first-out memories, but these are comparatively large, complex circuits.
Thus, what is needed are circuits, methods, and apparatus that provide for the efficient transfer of data from a device's inputs to its core circuitry.
SUMMARY
Accordingly, embodiments of the present invention provide circuits, methods, and apparatus that provide for the transfer of data from an input clock domain to a device's core clock domain. An exemplary embodiment of the present invention achieves this by using a leveling element between a device's input and core circuits. One embodiment calibrates the leveling element by incrementally sweeping a delay and receiving data at each increment. Minimum and maximum delays where data is received without errors are recorded and averaged to generate a delay setting. This delay can then be used to adjust the leveling element inserted in an input path between an input register that is clocked by an input strobe signal and an output register that is clocked by a core clock signal. In various embodiments of the present invention, the delay may be used directly, that is, an input signal may be delayed by an amount corresponding to the delay setting. In other embodiments of the present invention, the leveling element is an intermediate register placed between the input register and the output register, where each input signal is retimed using an intermediate register, and where a clock signal for the intermediate register is delayed by an amount corresponding to the delay setting. In one such embodiment of the present invention, a number of clocks are provided to the intermediate registers, each to one group of data inputs, where the delay or phase of each clock signal is independently adjusted. In another embodiment of the present invention, a number of clocks are provided to each group of data inputs, where one of the number of clocks is selected and used to clock the intermediate registers in the group. In other embodiments of the present invention, other circuits, such as latches, may be used as the leveling element.
Another exemplary embodiment of the present invention provides a memory interface circuit that interfaces with a plurality of memory devices arranged, for example, on a dual inline memory module (DIMM). Each memory device communicates with the memory interface circuit using a strobe signal, referred to as a DQS signal, and several data lines, which are referred to as DQ signals. The memory interface provides a system clock to each of the memory devices. The memory devices use the system clock such that the DQS and DQ signals have the correct fundamental frequency and the strobe and data signals provided by each memory device are aligned with each other. However, newer memory interface standards, such as DDR3 route the system clock using a fly-by topology. This topology results in the reception of the system clock by the memory devices at different times. Accordingly, the memory devices each provide DQ and DQS signals at times that are skewed relative to each other. As a result, the received DQS strobe signals are out of phase with the system clock.
The memory interface receives data signals from the memory devices and retimes them using an input register clocked by a corresponding strobe signal. However, since the strobe signal is out of phase with the system clock in the memory controller, the input data signals are re-registered using an output register clocked by the system clock, or a second clock derived from the system clock for use by core circuitry connected to the memory interface. Unfortunately, if the strobe signal is improperly aligned with the system clock, data may not transfer from the input register to the output register properly, and errors in data reception may occur.
Accordingly, a specific embodiment of the present invention provides leveling elements implemented as delay elements between the input and output registers such that data is properly transferred to the core circuitry. To calibrate the delay elements, the delay provided by the delay element is incremented over a range of values. In this specific embodiment, the range of values is approximately covers one clock cycle period, though in other embodiments, the range of values may be greater or less than one clock cycle. At each increment, a known data pattern is provided by each memory device to the memory interface. The received data is checked for errors for each DQ signal in a group. Minimum and maximum delays where error-free reception occurs for the DQ signals in the group are noted. These delays may be averaged and the average delay used to delay the input signal. Each DQ/DQS group typically is delayed an independently determined delay, though each DQ signal in the group is typically delayed the same amount. In other embodiments, each DQ in a DQ/DQS group may be delayed an independent amount.
Another embodiment of the present invention provides leveling elements implemented as an intermediate register between the input and output registers. The intermediate register is clocked by a delayed version of the system clock, where the delay is calibrated for error-free data reception. In this embodiment, a phase-locked loop (PLL) generates the system clock and several delayed versions of the system clock. Each of the delayed versions of the system clock is provided to the intermediate registers for one group of DQ inputs. Again, the delays of these versions of the system clock are incrementally increased (or decreased) and a known data pattern is received at each increment. For each DQ group, minimum and maximum delays where error-free reception occurs for the DQ signals in the group are averaged and a clock delayed by this amount provided to intermediate registers for the DQ group. Typically, one clock line having one delay is used for each intermediate register in a DQ group, while each DQ group has a different delayed clock that has an independently calibrated delay.
Another embodiment of the present invention also provides leveling elements implemented as intermediate registers between the input and output registers. These intermediate registers are clocked by a delayed version of the system clock, where the delay is calibrated for error-free data reception. In this embodiment, a number of delay elements are used to generate a number of delayed clocks, which are in turn multiplexed using a clock multiplexer. Specifically, one clock, such as the synchronization clock that clocks the output synchronization registers or a second clock derived from the system clock, is received by the number of delay elements that generate a number of delayed clock signals. The delayed clock signals are routed to each DQ group. A clock multiplexer is associated with each DQ group, where the clock multiplexer selects one of the delayed clock signals and provides it to the intermediate registers in the DQ group. During calibration, the clock multiplexer incrementally adjusts the delay of its output clock signal by selecting different input clock signals. Again, a known data pattern is received at each increment. For each DQ group, minimum and maximum delays where error-free reception occurs for the DQ signals in the group are averaged and a clock delayed by this amount is selected by the clock multiplexer and provided to intermediate registers for the DQ group. Typically, the selected multiplexer input is chosen independently for each DQ group.
Various embodiments of the present invention may incorporate one or more of these or the other features described herein. A better understanding of the nature and advantages of the present invention may be gained with reference to the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram of a programmable logic device that is improved by incorporating embodiments of the present invention;
FIG. 2 is a block diagram of an electronic system that is improved by incorporating embodiments of the present invention;
FIG. 3 is a block diagram of a memory interface that is improved by the incorporation of embodiments of the present invention;
FIG. 4 is a block diagram illustrating a portion of the memory interface of FIG. 3 in greater detail;
FIG. 5 is a simplified block diagram of a portion of an input path of a memory interface that is improved by the incorporation of an embodiment of the present invention;
FIG. 6 illustrates a possible timing for the circuitry of FIG. 5 that may lead to metastates and other instabilities during data reception;
FIG. 7 is a block diagram illustrating a portion of a memory interface circuit that includes a leveling element consistent with an embodiment of the present invention;
FIG. 8 illustrates the timing of the circuitry shown in FIG. 7 ;
FIG. 9 is a block diagram of a portion of a memory interface where a leveling element is implemented as a delay line according to an embodiment of the present invention;
FIG. 10 illustrates a delay line that may be used as the delay lines 940 and 942 in FIG. 9 or other embodiments of the present invention;
FIG. 11 is a flowchart illustrating the calibration routine for setting a delay through the delays 940 and 942 in FIG. 9 ;
FIG. 12 is a block diagram of a portion of a memory interface consistent with an embodiment of the present invention where the leveling element is a register;
FIG. 13 is a flowchart illustrating a method of adjusting a phase of a leveling clock according to an embodiment of the present invention;
FIG. 14 is a block diagram of a portion of a memory interface circuit according to an embodiment of the present invention;
FIG. 15 is a flowchart illustrating the operation of calibration logic employed by an embodiment of the present invention;
FIG. 16 is a block diagram of a delay-locked loop, a delay element, a number of delay elements, and a clock multiplexer that may be used to implement the delay-locked loop 1460 , delay 1420 , and delays 1440 in FIG. 14 , or in other embodiments of the present invention; and
FIG. 17 illustrates one possible simplification of the circuitry of FIG. 16 .
DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 is a simplified partial block diagram of an exemplary high-density programmable logic device or FPGA 100 wherein techniques according to the present invention can be utilized. PLD 100 includes a two-dimensional array of programmable logic array blocks (or LABs) 102 that are interconnected by a network of column and row interconnections of varying length and speed. LABs 102 include multiple (e.g., 10) logic elements (or LEs), an LE being a small unit of logic that provides for efficient implementation of user defined logic functions.
PLD 100 also includes a distributed memory structure including RAM blocks of varying sizes provided throughout the array. The RAM blocks include, for example, 512 bit blocks 104 , 4 K blocks 106 , and an M-Block 108 providing 512 bits of RAM. These memory blocks may also include shift registers and FIFO buffers. PLD 100 further includes digital signal processing (DSP) blocks 110 that can implement, for example, multipliers with addition or subtraction features.
It is to be understood that PLD 100 is described herein for illustrative purposes only and that the present invention can be implemented in many different types of PLDs, FPGAs, and the other types of digital integrated circuits.
While PLDs or FPGAs of the type shown in FIG. 1 provide many of the resources required to implement system level solutions, the present invention can also benefit systems wherein a PLD is one of several components.
FIG. 2 shows a block diagram of an exemplary digital system 200 , within which the present invention may be embodied. System 200 can be a programmed digital computer system, digital signal processing system, specialized digital switching network, or other processing system. Moreover, such systems may be designed for a wide variety of applications, such as telecommunications systems, automotive systems, control systems, consumer electronics, personal computers, Internet communications and networking, and others. Further, system 200 may be provided on a single board, on multiple boards, or within multiple enclosures.
System 200 includes a processing unit 202 , a memory unit 204 and an input/output unit 206 interconnected together by one or more buses. According to this exemplary embodiment, a programmable logic device (PLD) 208 is embedded in processing unit 202 . PLD 208 may serve many different purposes within the system in FIG. 2 . PLD 208 can, for example, be a logical building block of processing unit 202 , supporting its internal and external operations. PLD 208 is programmed to implement the logical functions necessary to carry on its particular role in system operation. PLD 208 may be specially coupled to memory 204 through connection 210 and to input/output unit 206 through connection 212 .
Processing unit 202 may direct data to an appropriate system component for processing or storage, execute a program stored in memory 204 , or receive and transmit data via input/output unit 206 , or other similar function. Processing unit 202 can be a central processing unit (CPU), microprocessor, floating point coprocessor, graphics coprocessor, hardware controller, microcontroller, programmable logic device programmed for use as a controller, network controller, and the like. Furthermore, in many embodiments, there is often no need for a CPU.
For example, instead of a CPU, one or more PLDs 208 can control the logical operations of the system. In an embodiment, PLD 208 acts as a reconfigurable processor, which can be reprogrammed as needed to handle a particular computing task. Alternately, programmable logic device 208 may itself include an embedded microprocessor. Memory unit 204 may be a random access memory (RAM), read only memory (ROM), fixed or flexible disk media, PC card flash disk memory, tape, or any other storage means, or any combination of these storage means.
FIG. 3 is a block diagram of a memory interface that is improved by the incorporation of embodiments of the present invention. This figure includes a number of memories, in this example arranged in a dual in-line memory module (DIMM) 300 , and an integrated circuit, in this example an FPGA 340 . The DIMM 300 includes a number of memory devices 310 , 320 , through 330 . The FPGA 340 includes a memory controller 350 and core circuitry 360 . The memory controller 350 reads and writes data using a number of DQS/DQ groups 312 , 322 , and 332 , and receives data from and provides data to the core circuits 360 . Timing for the DQS and DQ signals is derived from a system clock 352 , which is provided from the memory controller 350 to the memory devices 310 , 320 , and 330 .
In DDR3 systems, the system clock 352 is routed using a fly-by topology. That is, the memory devices 310 through 330 receive the system clock 352 in a serial fashion. Other signals, such as control signals (not shown) may also be routed this way. This topology provides a greater signal integrity as compared to more conventional routing. The result of using this topology is that memory device 310 receives the system clock 352 first, and the other memory devices receive the system clock some time later, with memory device 330 receiving it last. The skew between the arrival of the system clock 352 at the memory devices can be on the order of a clock cycle. Since the timing for the DQ and DQS signals provided by the memory devices is based on the system clock 352 , the DQ and DQS signals received by the memory controller 350 may also be skewed by as much as a clock cycle.
Accordingly, the DDQS and DQ signal groups from the memory devices each operate at the same frequency but have phase relationships that are uncorrelated to each other. Without more, these phase shifts may lead to errors in the reception of data by the memory controller 350 due to timing errors that occur during the transfer of data from the capture registers to the synchronization registers, as shown below. Accordingly, embodiments of the present invention provide circuits, methods, and apparatus that provide for consistent and accurate data reception by memory controllers, such as the memory controller 350 .
FIG. 4 is a block diagram illustrating a portion of the memory interface of FIG. 3 in greater detail. This figure includes a memory device 400 that further includes a memory core 402 , multipurpose registers 404 , and a memory input and output interface 406 , as well as an integrated circuit 460 , such as an FPGA, which includes a delay element 410 , capture registers 420 through 424 , synchronizing registers 430 through 434 , phase-locked loop 440 , and core circuits 450 .
In this example embodiment, a phase-locked loop 440 provides a system clock to the memory device 400 . The memory device in turn provides a data strobe DQS signal and data signals DQ 1 , DQ 2 , and DQN. The data strobe signal is phase shifted by delay circuit 410 to produce a delayed DQS signal, DDQS. The delayed strobe signaled DDQS clocks capture registers 420 , 422 , and 424 , which capture input data signals DQ 1 , DQ 2 , and DQN, respectively. The outputs of the capture registers are provided to synchronization registers 430 , 432 , and 434 , which are clocked by the system clock. The outputs the synchronization registers are provided to core circuits 450 .
In a typical system, the data strobe signal DQS is aligned with the data signals DQ 1 , DQ 2 , and DQN when provided by the memory interface 406 . Once received by the FPGA 460 , the DQS signal is delayed, typically by approximately 90 degrees (though other phase shifts may be required), so that the edges of the delayed DQS signal DDQS are centered to the bits of the incoming DQ data. This enables the capture registers to clock the incoming DQ data.
Again, the DQS signal may have any phase relationship with the system clock. Thus, the DDQS signal may also have any possible phase relationship with the system clock. This means that as data is passed from a capture register to a synchronization register, metastates or other instabilities may occur. This is shown further in the following figures.
FIG. 5 is a simplified block diagram of a portion of an input path of a memory interface that is improved by the incorporation of an embodiment of the present invention. This figure includes a delay element 510 , capture register 520 , and synchronization register 530 . Data is received on the DQ line by capture register 520 . The DQS signal is received from the memory devices and delayed or phase shifted by delay circuit 510 to generate a delayed DQS signal DDQS. The DDQS signal clocks the capture register, which provides a retimed data output CQ to the synchronization register 530 . The synchronization register 530 is clocked by the synchronization clock, and provides an output DATAOUT to core or other circuits.
If data transitions of the signal CQ occur near active edges of the system clock, metastates or other instabilities in the synchronization register may occur, leading to errors in the received data at DATAOUT. In the following examples, the active edges of the synchronization register 530 are shown as rising edges, though in other embodiments of the present invention, the active edges of the synchronization register 530 may be falling edges.
FIG. 6 illustrates a possible timing for the circuitry of FIG. 5 that may lead to metastates and other instabilities during data reception. These metastates or other instabilities typically lead to errors in data reception. In this example, the timing diagram illustrates timing for a data signal DQ 610 , data strobe signal DQS 620 , delayed DQS signal DDQS 630 , retimed data signal CQ 640 , synchronization clock SYNC CLOCK 650 , and data output signal DATAOUT 660 .
Signals DQ 610 and DQS 620 are received from a memory device by an integrated circuit, such as an FPGA. The data strobe signal DQS 620 is phase shifted an amount 632 to generate DDQS 630 . DDQS 630 clocks the DQ 610 signal to generate CQ 640 . Edges of CQ 640 follow DQS rising edges by a clock-to-Q delay 642 . Again, the SYNC CLOCK 650 may have any timing relationship to DDQS 630 . If rising edges of the SYNC CLOCK 650 approach the data edges 644 by an amount less than the setup time 652 , metastates or data instabilities may occur. Similarly, if rising edges of SYNC CLOCK 650 are near data edge 646 , hold time 656 may be violated. If one of these conditions occurs, that is, the setup time 652 or the hold time 656 are violated, instabilities in the output signal DATAOUT 660 may occur. Accordingly, embodiments of the present invention provide leveling elements such that the signal CQ 640 maintains a relationship with the SYNC CLOCK 650 such that these registers do not become metastable and that instabilities do not occur. Examples are shown in the following figures.
FIG. 7 is a block diagram illustrating a portion of a memory interface circuit that includes a leveling element consistent with an embodiment of the present invention. This figure includes a capture register 720 , leveling element 725 , synchronization register 730 , delay 710 , delay-locked loop 740 , and phase-locked loop 750 . Data signal DQ is received by the capture register 720 . A data strobe signal DQS is received by the delay 710 and phase shifted to generate a delayed DQS signal DDQS that clocks the capture registers 720 . The output of the capture registers 720 is received by the leveling element 725 , which in turn provides an output to the synchronization register 730 . The synchronization register 730 is clocked by a synchronization clock provided by phase-locked loop 750 . The synchronization register 730 provides an output DATAOUT to other circuitry (not shown), for example core circuitry of an FPGA. The delay-locked loop 740 synchronizes to a local clock generated by phase-locked loop 750 and provides a control signal COUNT to delay 710 , such that the DDQS signal is properly phase shifted to clock the incoming data DQ.
Without the presence of the leveling element 725 , the data CQ provided by the capture register 720 may be provided to the synchronization register 730 near an active edge of the synchronization clock. Under such a condition, the synchronization register may become unstable and provide incorrect data on the DATAOUT line. Accordingly, the leveling element 725 retimes the output CQ from the capture register 720 as signal LQ, which has a more desirable timing relationship with the synchronization clock. In various embodiments of the present invention, the leveling element 725 may include various circuits. In a specific embodiment of the present invention, the leveling element is a delay line whose delay is varied to avoid meta-stabilities in the synchronization registers 730 . In other embodiments of the present invention, the leveling element 720 includes a register timed by a clock whose phase can be varied. In still other embodiments of the present invention, other circuits, such as a latch, may be used. A timing diagram illustrating the timing of the circuitry of FIG. 7 is shown in the following figure.
FIG. 8 illustrates the timing of the circuitry shown in FIG. 7 . This figure includes timing for signals DQ 810 , DQS 820 , DDQS 830 , CQ 840 , LQ 850 , synchronization (SYNC) CLOCK 860 , and DATAOUT 870 . The data strobe signal DQS 820 is phase shifted an amount 832 to generate the DDQS signal 830 . The DDQS signal is used to capture the data signal DQ. The output of the capture registers, CQ 840 , follows the clock edges by a clock-to-Q delay 842 . The leveling element 725 phase shifts the data signal CQ 840 an amount 846 to generate LQ 850 , such that the data edge 852 of LQ 850 is away from the rising edges 862 and 864 of the SYNC CLOCK 860 . The DATAOUT signal 870 changes state following a rising edge 864 of the SYNC CLOCK 860 by a clock-to-Q delay 872 . Again, in various embodiments of the present invention, the leveling element may be implemented using various types of circuits. In a specific embodiment of present invention, the leveling element 725 is a delay line. An example is shown in the following figure.
FIG. 9 is a block diagram of a portion of a memory interface where a leveling element is implemented as a delay line according to an embodiment of the present invention. This figure includes a capture register, which is implemented as flip-flops FF 1 , FF 2 , and FF 3 , leveling elements, implemented here as delays 940 and 942 , and synchronization register flip-flops FF 4 and FF 5 . Also included are delay 920 , a delay-locked loop 960 , phase-locked loop 970 , and calibration logic 980 .
Data DQ is received by capture register flip-flops FF 1 and FF 3 on alternating edges of the DDQS signal. The output of FF 1 is retimed by flip-flop FF 2 , such that the data outputs CQ and CQ 1 are provided by the capture register on rising edges of DDQS. The data strobe signal DQS is delayed to generate the DDQS signal. The outputs of the capture register CQ and CQ 1 are delayed by delay elements 940 and 942 to generate signals LQ and LQ 1 . Signals LQ and LQ 1 are retimed by resynchronization registers FF 4 and FF 5 , which provide data outputs DATAOUT and DATAOUT 1 . The delays provided by delay lines 940 and 942 are adjusted such that instabilities are avoided at resynchronization registers FF 4 and FF 5 .
A system clock is received from a crystal oscillator or other period source by phase-locked loop 970 , which in turn generates a local clock and a synchronizing clock. The synchronization clock is tracked by the delay-locked loop 960 , which provides a control signal COUNT to the delays 920 , 940 , 942 . This sets the delay through individual delay elements in the delay lines. In this way, as temperature, processing, and voltage vary, the value of the COUNT can be adjusted, thereby keeping the delays at least relatively constant.
Accordingly, the COUNT signal is incremented or decremented with changing temperature, voltage, and processing, such that the delays through the delays 940 and 942 remain fairly constant. Again, if data edges of the LQ and LQ 1 signals are near active edges of the synchronizing clock, there may be metastable conditions in the synchronizing registers. Accordingly, the delays of delay elements 940 and 942 are adjusted to avoid these conditions. Specifically, the delays through delay 940 and delay 942 are adjusted by one or more SELECT signals provided by the calibration logic 980 . In this way, the delays provided by the delays 940 and 942 are controlled by the COUNT signal, which adjusts to compensate for temperate and voltage supply changes, and the SELECT signal, which adjusts the delay so data is properly transferred. An example of a delay element that is adjusted in this way is shown the following figure.
FIG. 10 illustrates a delay line that may be used as the delay lines 940 and 942 in FIG. 9 , or as delay lines in other embodiments of the present invention. This figure includes a number of delay elements DE 1 , DE 2 , DE 3 , and DE 4 , the outputs of which are selected by a multiplexer 1020 under the control of one or more select signals provided by a calibration logic circuit. In other embodiments of the present invention, other numbers of delay elements may be used. For example, where finer resolution is needed, more delay elements can used. A delay line having “N” elements will provide a resolution of 360/N.
Specifically, a control signal COUNT is provided on line 1004 to the delay elements DE 1 , DE 2 , DE 3 , and DE 4 . This controls the delay through each delay element, such that the delay provided by them has a reduced variability with temperature, processing, and voltage. Specifically, each delay element may be implemented as one or more individual delay circuits, where the delay is dependent on the value of the COUNT signal. For example, each delay element may be one or more circuits having a current discharging a voltage across a capacitor. Alternately, each delay element may include one or more a current starved inverters, where a current starved inverter is implemented as a current source that provides a variable current to an inverter stage. The value of the current can be dependent on the value of the COUNT signal, such that a lower COUNT value provides less current to the inverters, increasing the delay through the inverter. In other embodiments of the present invention, other types of delay elements may be implemented.
The signal selected by multiplexer 1020 is provided as a data signal to one of the synchronization registers. The select signal or signals 1006 are generated by a calibration logic circuit, such that metastates or instabilities in the synchronization registers are avoided. An example of how the calibration logic accomplishes this task is shown in the following figure.
FIG. 11 is a flowchart illustrating the calibration routine for setting a delay through the delays 940 and 942 in FIG. 9 or other delays in other embodiments of the present invention. In this method, data is received at a number of possible delay settings. The validity of the data reception at each delay setting is determined, and from this an optimal delay setting is found.
Specifically, in act 1110 , an initial delay is set. In act 1120 a test pattern is received. In a typical embodiment of the present invention, this test pattern is received from onboard test registers located on the memory devices, for example, multipurpose registers 404 .
In act 1130 , it is determined whether the test pattern has been received correctly. In a typical embodiment of the present invention, data from only one side of each double-data-rate path is checked to determine whether data has been correctly received. For example, in FIG. 9 , data at the DATAOUT output is checked, while data at the DATAOUT 1 is redundant and is therefore not checked to speed up the calibration routine. In other embodiments of the present invention, only the DATAOUT 1 output is checked, while in others, both outputs are checked. Further, in various embodiments of the present invention, data received by each DQ path in a DQ/DQS group is checked in determining whether data was correctly received, that is, data needs to be correctly received by each DQ path to be considered correctly received. In other embodiments, only one DQ path is checked, again to speed up the calibration routine. In other embodiments, these and other techniques may be mixed. For example, an initial calibration may be performed using each DQ path in a DQ/DQS group, while later adjustments are made using only one DQ path.
In act 1140 , the delay is changed. For example, a new multiplexer input may be selected by multiplexer 1020 in FIG. 10 . In act 1150 , the test pattern is received again, while in act 1160 , it is determined whether the pattern is received correctly. In act 1170 , it is determined whether the last delay has been tested. If not, the delay is changed again in act 1140 . If the last delay has been tested, the minimum and maximum delays where the pattern was received correctly are averaged in act 1180 , and that delay is used as the delay for delay elements 940 and 942 . In an embodiment of the present invention where the delay is incremented or decremented monotonically, the delay is set to the average of the first and last delays where the pattern was received correctly.
FIG. 12 is a block diagram of a portion of a memory interface consistent with an embodiment of the present invention. In this embodiment, the leveling element is a register. This figure includes a double-data-rate capture register that is implemented using flip-flops FF 1 , FF 2 , and FF 3 , leveling elements implemented using flip-flops FF 4 and FF 5 , synchronization registers FF 6 and FF 7 , delay element 1220 , delay-locked loop 1260 , and phase-locked loop 1270 .
Data is received on the DQ line by flip-flops FF 1 and FF 3 on alternating edges of the delayed DQS signal DDQS. The outputs of the capture register are provided as CQ and CQ 1 on rising edges of the DDQS signal to the leveling elements FF 4 and FF 5 . The leveling elements retime the data and provide outputs LQ and LQ 1 to synchronization registers FF 6 and FF 7 . These registers then provide data outputs DATAOUT and DATAOUT 1 to the core or other circuits.
A data strobe signal DQS is received by the delay element 1220 , which phase shifts it to generate the delayed DQS signal, DDQS. A system clock, for example, generated by a crystal oscillator or other source, is received by the phase-locked loop 1270 . The phase-locked loop 1270 generates a local clock for the delay-locked loop 1260 , leveling clocks for the leveling elements FF 4 and FF 5 , and a synchronization clock for the synchronization registers FF 6 and FF 7 . The delay-locked loop 1260 synchronizes to the local clock and generates a digital control signal COUNT, which it provides to the delay element 1220 .
In these circuits, data is transferred from capture register flip-flops FF 2 and FF 3 to leveling elements FF 4 and FF 5 , and again from leveling elements FF 4 and FF 5 to synchronization registers FF 6 and FF 7 . Accordingly, the leveling clock should be timed such that metastates and instability are avoided as leveling elements FF 4 and FF 5 receive data from the capture register flip-flops FF 2 and FF 3 , and again as leveling elements FF 4 and FF 5 provide data to the synchronization registers FF 6 and FF 7 . Accordingly, in this embodiment of the present invention, the delay of the leveling clock relative to the synchronization clock is adjusted by the phase-locked loop 1270 , such that data is correctly received and provided to the core circuits.
In one embodiment of the present invention, phase-locked loop 1270 provides one leveling clock signal for each DQ/DQS group of signals received by the memory interface. In other embodiments of the present invention, other numbers of leveling clocks may be provided to other groups of signal paths. One method of adjusting a leveling clock timing is shown in the following figure.
FIG. 13 is a flowchart illustrating a method of adjusting a phase of a leveling clock according to an embodiment of the present invention. In this method, the phase relationship between a leveling clock signal and a synchronization clock signal is adjusted to optimize data reception by a memory interface. In other embodiments of the present invention, the phase of the leveling clock may be adjusted relative to other clock signals.
Specifically, in act 1310 , a phase of a clock generated by a phase-locked loop is set to an initial value. In act 1320 , a test pattern is received. In act 1330 , it is determined whether the pattern was received correctly. In act 1340 , the phase of the clock provided by the phase-locked loop is changed. Again, in act 1350 , a test pattern is received. It is determined whether this pattern was received correctly in act 1360 . In act 1370 , it is determined whether the last phase has been tested. If not, the phase of the clock provided by the phase-locked loop is changed again in act 1340 . If the last phase has been tested, the phase of the leveling clock provided by the phase-locked loop delay is set to the average of the minimum and maximum delays where the pattern was received correctly in act 1380 . In a situation where the delays are incremented or decremented monotonically, the phase-locked loop is set to the average of the first and last delays where the pattern was received correctly.
FIG. 14 is a block diagram of a portion of a memory interface circuit according to an embodiment of the present invention. This figure includes a capture register that is implemented using flip-flops FF 1 , FF 2 , FF 3 , leveling registers implemented as flip-flops FF 4 and FF 5 , synchronization registers FF 6 and FF 7 , delay element 1420 , clock multiplexer 1430 , delay element 1440 , calibration logic 1450 , delay-locked loop 1460 , and phase-locked loop 1470 . The data signal DQ is received by capture register flip-flops FF 1 and FF 3 , which are clocked by alternating edges of the DDQS signal. The output of flip-flop FF 1 is retimed by flip-flop FF 2 , such that the capture register provides outputs CQ and CQ 1 on rising edges of the DDQS signal. These output signals are received at rising edges of the leveling clock by leveling element registers FF 4 and FF 5 , which provide outputs LQ and LQ 1 on rising edges of the leveling clock. The synchronization registers FF 6 and FF 7 receive this data on rising edges of the synchronization clock, and in turn provide outputs DATAOUT and DATAOUT 1 to other circuitry, such as core circuits (not shown) on an FPGA. The delay element 1420 delays the DQS signal to generate the delayed the delayed DQS signal DDQS. The phase-locked loop 1470 receives a system clock signal from a crystal oscillator or other periodic signal source, generates a local clock, and provides it to the delay-locked loop 1460 . The delay-locked loop 1460 provides a control signal COUNT to delay elements 1420 and 1440 . The phase-locked loop 1470 also provides the synchronization clock to the synchronization registers FF 6 and FF 7 .
The synchronization clock is delayed by delay elements 1440 , which generate a number of clock signals CLK[1:n]. These clock signals are separated in phase from each other, such that the clock multiplexer may select one of a number of clocks having different phases. In a specific embodiment of the present invention, eight clock signals having different phases are provided to the clock multiplexer, one of which is selected and provided as the leveling clock, though in other embodiments of the present invention, other number of clocks may be provided and selected from. These clock signals are multiplexed by the clock multiplexer 1430 to provide the leveling clock signal to the leveling registers FF 4 and FF 5 . The clock multiplexer selection is controlled by calibration logic 1450 .
In a specific embodiment of the present invention, a number of clock signals CLK[1:n] are provided to each DQ/DQS group. Each DQ/DQS group includes a clock multiplexer 1430 that selects one of these clocks as the leveling clock for the group. This arrangement limits the number of delay elements 1440 that are needed, but consumes routing resources in delivering clock signals CLK[1:n] to each DQ/DQS group. In other embodiments, the synchronization clock is routed to each DQ/DQS group, each of which has a delay element 1440 and clock multiplexer 1430 . These embodiments reduce the consumed routing resources, but require a larger number of delay elements 1440 .
Again, the leveling clock should be timed to avoid metastates and instabilities when the leveling element registers FF 4 and FF 5 receive data from the capture register, and when the synchronization registers FF 6 and FF 7 receive data from the leveling registers FF 4 and FF 5 . Again, at each signal transfer, the provided data should be provided such that register setup and hold times are not violated. Typically this means that the leveling clock should be adjusted such that its edges are away from edges of the data signals CQ and CQ 1 , and that the data signals LQ and LQ 1 , which follow the leveling clock signal by a clock-to-Q delay, should be adjusted such that their edges are away from active edges of the synchronization clock. This adjustment is controlled by selecting one of the clock signals CLK[1:n] using the calibration logic 1450 . An example of how this is done is shown in the following figure. Further safeguards can be implemented to aid in data transfer from register to register as well. For example, delay elements can be selectively inserted. Further, negative-edge triggered registers can be selectively inserted in the signal path, where the negative-edge triggered registers are inserted when needed to provide proper set-up and hold times. Also, since the skews caused by the fly-by topology used for the system clock, additional registers can be selectively inserted or removed such that each group of DQ signals received from the memory devices are transferred from the memory controller to the core circuitry on the same clock cycle. These and other circuit techniques that may be incorporated in embodiments of the present invention are illustrated in co-pending co-owned patent application Ser. No. 11/935,347, filed Nov. 5, 2007, titled “I/O BLOCK FOR HIGH PERFORMANCE MEMORY INTERFACES,” by Bellis et al., which is incorporated by reference.
FIG. 15 is a flowchart illustrating the operation of the calibration logic employed by an embodiment of the present invention. In this method, a number of clock signals having different phases are provided to a multiplexer. Test pattern data is received using each of these phases as a leveling clock. At each phase, it is determined whether the data is received correctly, and from this, an optimal phase for the leveling clock is determined.
Specifically, in act 1510 , a number of clock signals having different phases are provided as inputs to a clock multiplexer. An initial multiplexer input is selected. In act 1520 , a test pattern is received, for example, from multipurpose registers 404 . In act 1530 , it is determined whether the pattern was received correctly. In act 1540 , a new clock multiplexer input is selected. Again, the test pattern is received in act 1550 , while in act 1560 it is determined whether the pattern was received correctly. In act 1570 , it is determined whether the last clock multiplexer input has been checked. If not, a new clock multiplexer input is selected in act 1540 .
If the last multiplexer input has been checked in act 1570 , then the clock phase having a phase equal to the average of the minimum and maximum phases where the test pattern was received correctly is selected as a leveling clock in act 1580 . In various embodiments of the present invention, the clock multiplexer inputs are selected such that the clock phase is monotonically incremented or decremented. In this case, the clock phase having a phase equal to the average of the phases for the first and last clock inputs where test pattern data was received correctly can be used as the leveling clock.
Again, in a typical embodiment of the present invention such as the examples shown here, data from only one data path is checked to determine whether data has been correctly received. For example, in FIG. 14 , data at the DATAOUT output is checked, while data at the DATAOUT 1 is redundant and is therefore not checked to speed up the calibration routine. In other embodiments of the present invention, only the DATAOUT 1 output is checked, while in others, both outputs are checked. Further, in various embodiments of the present invention, data received by each DQ path in a DQ/DQS group is checked in determining whether data was correctly received, that is, data needs to be correctly received by each DQ path to be considered correctly received. In other embodiments, only one DQ path is checked, again to speed up the calibration routine. In other embodiments, these and other techniques may be mixed. For example, an initial calibration may be performed using each DQ path in a DQ/DQS group, while later adjustments are made using only one DQ path.
In the above examples, a delay-locked loop generates a control signal COUNT that is used to control the delay provided by various delay elements. For example, in FIG. 15 a delay-locked loop 1560 generates a COUNT signal that is used by delay element 1420 to generate a phase-shifted DQS signal, and by delay elements 1440 to generate a number of clock signals. An example circuit that may be used is shown in the following figure.
FIG. 16 is a block diagram of a delay-locked loop, a delay element, a number of delay elements, and clock multiplexer that may be used to implement the delay-locked loop 1460 , delay 1420 , and delays 1440 in FIG. 14 or in other embodiments of the present invention. This figure includes a delay-locked loop made up of delay elements DE 1 , DE 2 , DE 3 , and DE 4 , phase detector 1640 , counter 1650 , delay elements DE 5 , DE 6 , and DE 7 , the outputs of which are selected by clock multiplexer 1610 to provide a leveling clock, and delay element DE 8 , which is used to phase shift the data strobe DQS signal to generate a DDQS signal that clocks the input data capture registers.
In this example, each of the delay elements DE 1 through DE 8 provide a phase shift that is equal to 90 degrees of the local clock period. In other embodiments of the present invention, other numbers of delay elements can be used, and each delay element may provide a phase shift different than 90 degrees. The local clock is received by delay element DE 1 which phase shifts it and provides it to DE 2 , DE 3 , and DE 4 in succession. The output of this chain is provided to the phase detector 1640 , which also receives the local clock signal. The phase detector 1640 provides a signal that either increments or decrements the COUNT provided by counter 1650 , which provides the control signal COUNT to the delay elements DE 1 through DE 4 . When the delay-locked loop is locked, the local clock and the output of delay element DE 4 are synchronized. At this point, each delay element DE 1 through DE 4 provides a 90 degree phase shift, for 360 phase shift, or one complete cycle in total. The same COUNT signal is used to adjust the delays provided by delay elements DE 5 , DE 6 , and DE 7 . The local clock and the outputs of the delay elements are multiplexed by clock multiplexer 1610 under control of the select signals provided by the calibration logic (not shown). The output of multiplexer 1610 is provided as a leveling clock to leveling registers (not shown). The same COUNT signal is also provided to delay element DE 8 , such that delay element provides a 90 degree phase shift to the DQS signal in order to generate DDQS.
This figure includes four delay elements DE 1 , DE 2 , DE 3 , and DE 4 in the delay-locked loop. In other embodiments, other numbers of delay elements may be used. Typically, the delay elements phase shift the clock signal by 360 degrees, or one clock cycle. However, the output of the delay line may be inverted, in which case the delay elements phase shift the clock cycle by 180 degrees, with an additional 180 degrees phase-shift being accomplished by the signal inversion. Where four delay elements are used to delay the clock one cycle, each delay element phase shifts the clock signal 90 degrees. Where “N” delay elements are used, each delay element phase shifts the clock signal by 360/N, or 180/N if a signal inversion is used. Also, for simplicity, only one delay element DE 8 is used to delay the DQS signal. In practical circuits, more delay elements may be used to provide greater flexibility to a user. Further, each delay element may be made up of a number of sub-elements where the number of sub-elements may be varied to provide even further flexibility. For example, one or more such sub-elements may be bypassed using a selection or multiplexer circuit.
FIG. 17 illustrates a possible simplification of the circuitry of FIG. 16 that may be desirable in some embodiments of the present invention. In FIG. 16 , it can be seen that the function of delay elements DE 1 , DE 2 , and DE 3 are repeated by delay elements DE 5 , DE 6 , and DE 7 . Accordingly, this circuitry may be simplified as shown in FIG. 17 , in some embodiments of the present invention. For example, in one embodiment of the present invention, delay elements DE 5 , DE 6 , and DE 7 are placed in the memory interface once, and their outputs are routed to a clock multiplexer located in each DQ/DQS group, while the delay elements DE 1 , DE 2 , and DE 3 are also placed once in the memory interface. In this embodiment, it may be desirable to merge the function of the delay elements DE 1 , DE 2 , and DE 3 with the function of delay elements DE 5 , DE 6 , and DE 7 . In other embodiments of the present invention, due to layout proximity or other reasons, such a simplification may be undesirable. For example, in one embodiment of the present invention, delay elements DE 5 , DE 6 , and DE 7 are repeated once and positioned, along with a clock multiplexer, near each DQ/DQS group, while the delay elements DE 1 , DE 2 , and DE 3 are implemented only once for the memory interface.
The above description of exemplary embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. | Circuits, methods, and apparatus for transferring data from a device's input clock domain to a core clock domain. One example achieves this by using a retiming element between input and core circuits. The retiming element is calibrated by incrementally sweeping a delay and receiving data at each increment. Minimum and maximum delays where data is received without errors are averaged. This average can then be used to adjust the timing of a circuit element inserted in an input path between an input register clocked by an input strobe signal and an output register clocked by a core clock signal. In one example, an input signal may be delayed by an amount corresponding to the delay setting. In other examples, each input signal is registered using an intermediate register between the input register and the output register, where a clock signal is delayed by an amount corresponding to the delay setting. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention herein pertains to a steam iron and, more particularly, to a novel feed water valve structure between the water tank and the soleplate steam generator to self clean itself of deposits in the water so that tap water in any reasonable locality may be used.
2. Description of the Prior Art
In steam irons a water tank is used above the soleplate and a water valve structure provides controlled water drippage into the steam generator where it is evaporated and directed out soleplate ports to steam the article. Additionally, the water tank may also supply a spray attachment at the front of the iron. Generally, the user is advised to use distilled water because of the fineness of various water passages and orifices which tend to clog due to mineral deposits from the water, which varies locally. Distilled water works well on steam irons since deposits are not plated out of the water onto the metal parts. In hard water localities, the tap water contains minerals which produce loose flakes and deposits that plate out easily onto hot iron components. These deposits varying in various areas of the country generally consist of lime or calcium carbonate as well as other chemicals in solution or in a colloidal suspension. Self-cleaning irons have appeared such as shown in U.S. Pat. No. 3,747,241 of common assignment, where the tank water is suddenly dumped onto the hot soleplate to purge and scrub out the iron prying out the loose deposits and other debris. Other designs blow an extra charge of high pressure steam through the soleplate ports cleaning them. Part of the new self-cleaning concept of applicant's assignee includes cleaning the valve structure per se by a constant scraping action to remove valve deposits which are then carried out of the iron by the self-cleaning action of the U.S. Pat. No. 3,747,241. The two together, purging the tank and passages plus the valve structure cleaning, have provided a self-cleaning iron with much longer life than previously obtainable. The scraping action concept of the metering rod and orifice of the valve structure is disclosed and claimed in U.S. Pat. No. 3,496,661 of common assignment. It is this particular structure that the present invention improves.
SUMMARY OF THE INVENTION
Briefly described, the present invention is directed to specific structural improvements on the U.S. Pat. No. 3,496,661 and is directed to a steam iron with an enclosed fillable water tank and a steam generating soleplate onto which water is dripped through an orifice to generate steam in a generator in the soleplate in normal fashion. There is provided a guided water valve with a stem and metering rod portion that is movable between an on-off position to start and stop water flow from the tank bottom to the soleplate and there is provided an outlet duct from the tank, the duct having a recess extending below the valve, to direct water to the soleplate for steam generation. The valve is designed to prevent the collection of flakes as well as clean the water deposits formed on the critical parts. Generally, the orifice is formed in the top of an upwardly domed plate which is disposed in the bottom of the tank to control and meter water to the steam generator. A tubular stem with a peripheral seal engages the dome of the plate around the orifice to close it and stop the water flow and the metering rod portion is supported pendulum-like in the lower end of the stem. The rod continuously protrudes through the orifice. To this structure, generally shown in the U.S. Pat. No. 3,496,661, the structural improvement comprises the use of a thin sheet metal cup-shaped plate with a flanged rim, the plate being formed with an upwardly-domed bottom with an orifice in the dome. The flange provides a stop for fixedly nesting the plate in the duct above the bottom of the recess so that a separate floating centrally-apertured thin sheet metal scraper plate is disposed in the recess below the cup-shaped plate. While any suitable sheet metal formed to the shape described is satisfactory, stainless steel has been found to be the best and the description proceeds on this basis. The metering rod has dual diameters with the small diameter adapted to scrape in the plate aperture while the large diameter scrapes the orifice on each valve operation. The parts are designed so that the distance between the orifice and scraper plate is less than the total valve travel resulting in a clean scraped stem always being disposed in a clean scraped orifice when the valve is "on" to remove all deposits and provide for continuous accurate water control greatly extending the life of the iron. Additionally, the guided valve is spring-biased in the usual manner and the domed bottom is curved to snugly locate the spring in a fixed position in the cup-shaped plate. Finally, the parts are dimensioned so that the orifice in the dome is preferably no higher than the rim flange to provide short travel of the small diameter rod in the orifice reducing the overall height necessary for valve travel. Thus, the main object of the invention is to provide an improved water valve structure that is self-cleaning, self-guiding, acts as a wick, and inherently tends to repel accumulation of flakes in the valve orifice and does it all in an improved manner over the U.S. Pat. No. 3,496,661 whereby the same structure thereby performs four important functions of metering, guiding, cleaning and flow assisting and greatly improves the life of the iron.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view, partially in section and broken away, showing general parts of an iron and illustrating the invention; and
FIG. 2 is a partial cross-sectional view of the water valve structure shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown an electric steam iron that may include a spray attachment if desired. The iron includes a soleplate 10 with a plurality of steam ports 12 and an outer shell 14 suitably connected to handle 16 in known fashion. Soleplate 10 conventionally may be cast from aluminum with an electric heating element 18 cast in position and disposed so uniform heat distribution is provided when the iron is plugged in and activated.
The iron includes means for generating steam by providing water tank 20 positioned by bracket 22 and other suitable mechanism in conventional fashion. For steam, soleplate 10 has a steam generator 24 into which, under control of button 26 and guided valve stem 28 movable between an on-off position, water controllably drips from tank 20 onto hot soleplate 10, the resulting steam being distributed through passages 30 under cover 32 and out ports 12 onto the fabric being ironed. If desired, any spray attachment is operated by control button 34, temperature control 36 thermostatically controls the soleplate heat and fill opening 38 provides direct communication to fill the tank 20 all in a known manner.
Generally, such steam irons preferably use distilled water for best operation because of the purity of the water. However, many operators simply do not use distilled water but use tap water and, depending on the water hardness, in time the water passages become clogged. Some irons use a clean-out pin projecting through the metering orifice to remove scale that accumulates and the collection area around the orifice tends to collect flakes because of the cup-shaped structure employed. When the clean-out pin is removed, flakes funnel into the orifice and clog it affecting its operation. The present invention is designed to improve on the water valve structure heretofore used and is an improvement on the specific invention in the 3,496,661 patent by providing structural changes that greatly improve the life of the iron and its ability to steam at a constant rate for a long time.
Accumulation of deposits at the metering orifice of the water valve is prevented by providing a protruding element in the orifice at all times thus making the orifice an annular controlled orifice as well as using the protruding member as a wick to assist flow and as a pilot guide and to this end numerous modifications are shown in the U.S. Pat. No. 3,496,661. The preferred FIG. 2 modification of that patent is the one that is improved upon in the instant invention. To this end, there is provided in the bottom of the water tank 20 an opening with an outlet duct 40 provided with a recess 42 and extending below the water tank and the upper valve mechanism by extension 44 to direct water to soleplate generator 24 as shown in FIG. 2 of said U.S. Pat. No. 3,496,661.
In order to provide much longer iron life, nearly doubling the tap water life of the iron, the structural improvements in the present invention comprise the use of a thin stainless cup-shaped plate 46 having a flanged rim 48 that overlies the top of the duct as shown and has an upwardly domed bottom 50 with an orifice 52 in the apex of the dome. The particular shape and material of plate 46 is very significant for the much longer tap water life obtained. Prior constructions have used turned brass plates press-fitted into outlet duct 40 wherein the machine pressing the plate in position was relied upon to locate it properly. With the flanged construction, plate 46 is just pushed into positive stopped position to fixedly nest the plate in and overlapping the duct above the recess bottom and not rely on any friction fit in the duct for positioning. Thus, this always provides a positive dimensioned chamber 54 in the recess below the plate 46. The use of stainless also permits a sheet metal part of relatively thin dimensions -- about 0.50 mm -- and this is what is meant by "thin" as used in the claims. This sheet metal plate has several inherent advantages, to be fully explained, over the turned part previously used. For guiding and scraping, there is also provided a separate floating centrally-apertured thin stainless scraper plate 56 in the chamber portion 54 of the recess that, with the flanged construction, is formed below cup-shaped plate 46. Thus, plate 56 has freedom to float with no binding action in the chamber 54 since plate 46 is permanently stopped in the recess well above its bottom. This scraper plate is in the order of 0.38 mm and is also made of stainless steel.
In order to utilize the stainless plate structure effectively, stem portion 28 of the water valve carries the lower metering rod portion as in the U.S. Pat. No. 3,496,661 patent in a pendulum-like arrangement 58 for continuous alignment of rod 60 in orifice 52 and central aperture 62. For continuous accurate water control over a long life, the metering rod portion 60 carried by stem 28 has dual large and small diameters 64 and 66 with the rod always protruding through both orifice 52 and aperture 62. Thus, the metering rod is free to center and locate itself by its presence in aperture 62. For sealing in the off-position, the bottom of stem 28 has a sealing periphery 68 mating with the upper portion of domed plate 46 around the orifice to provide a good seal and is preferably formed with a bulbous portion for a ball joint seal.
For continuous cleaning, large diameter 64 is the same diameter as orifice 52 thus scraping the orifice on each valve operation. Similarly, the cross-section of aperture 62 is the same as small diameter 66 thus scraping it also on each valve operation. Thus, both water control structural parts of small diameter 66 and orifice 52 are continuously and simultaneously scraped on each valve operation to provide a constant annulus 70 for continuous accurate water metering. Further, in order to prevent any possibility of binding, the domed bottom of plate 46 is formed or curved at 72 to snugly locate the bottom of biasing spring 74 which biases stem 28 in the usual manner. This forming of the curved portion of the plate to positively seat and locate the spring in a fixed position prevents any riding or movement of the spring along the domed surface to possibly jam operation and this advantage is obtained by properly forming plate 46 to the shape noted.
For constant metering by cleanly scraped parts, the valve structure is dimensioned critically in that the distance D between orifice 52 and scraper plate 56 is always less than the total valve travel up and down so there is always a scraped orifice 52 operating in conjunction with a scraped rod 66 for accurate water control i.e. there is no danger that an unscraped portion 66 can enter orifice 52 if this distance D is always less than the total valve travel. Further, to reduce the overall height of the structure, while not necessary if the distance D is maintained, it is advantageous to maintain the orifice 52 in the dome at or below rim flange 48 so that there is a short travel of the small diameter 66 in the orifice.
The use of the preferred stainless steel plate 46 has several inherent advantages over a turned metal part in being of lower cost. More importantly, the length of the orifice 52 is reduced to the thickness of the sheet metal and this cannot be obtained practically with a turned part that would be as thin. The short length orifice possible provides a better scraping edge to cooperate with metering rod 62 to keep the orifice clean and allow chips and flakes to fall away with less chance of binding the metering rod in the orifice because of its short length. With a relatively long length orifice, small flakes can jam in the orifice but with the shorter length available there is provided a sharper orifice with cleaner scraping action. Further, stainless steel permits better wear resistance so that there is little or no distortion or elongation of the metering orifice such as making the orifice elliptical in which case the steam rate gets too high and the iron consequently will drip. Also, such elliptical wear permits the parts to get out of line with the bottom scraper. Then the entire valve structure can bind, bending the metering rod and resulting in shorter life. Still further, stainless steel, with its inherent lower thermal conductivity tends to reduce the build-up of tap water deposits since the minerals plate out faster at higher temperatures. Thus, the part runs cooler with no plating out of minerals and reduced possibility of jamming the orifice. Finally, the dimensioning of the parts as described avoids the disadvantage of not cleaning enough length of the small diameter 66 of the metering rod when the valve is fully open permitting any small uncleaned diameter to be still in the orifice so that an unscraped part is in the orifice to prevent good metering and restricting the flow. By reducing the travel so that D is always less than the valve travel it ensures having a cleaned rod part in a cleaned orifice at all times and thus a constant metering annulus. With the particular forming of plate 46 for the snug fit of the spring, it prevents the spring from riding up the dome of the valve seat preventing stem 28 from sealing to completely shut off the flow as opposed to a flat seat for the spring as in the prior art. This also helps during assembly of the iron in the manufacturing operation since the valve stem assembly is properly positioned. Finally, the flange portion on plate 46 positively positions the plate in the recess and does not rely on a friction fit so that the parts are more easily assembled by machine by just pressing down against the stop. This ensures that D is always the same and that plate 56 is always assured of centering and for always properly scraping small diameter 66.
While there has been described a preferred form of the invention, some equivalent variations may be possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described, and the claims are intended to cover such equivalent variations. | The invention discloses a steam iron water valve structure for feeding water into a steam generating chamber. The valve structure adapts the iron for use with any reasonable tap water available by using a scraping or cleaning arrangement of the various orifice and valve structure to remove deposits on each operation and to reduce the vertical extent of the valve travel. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an adjustable hydraulic damper with a damping piston which is secured on a hollow piston rod and divides the working cylinder into two chamber halves filled with damping fluid and has at least one throttle member, a constant oil passage being present through a transverse bore arranged above the damping piston and the interior of the piston rod, and for adjusting the damping force, an axially displaceable tension rod is arranged in the interior of the piston rod and is connected to an electro-magnet comprising a coil and an armature.
2. Description of the Prior Art
An hydraulic damper is disclosed in DE-OS No. 29 11 768, in which regulation is achieved by an electro-magnet and by which the adjustment of the damping force is possible at low piston speeds. A drawback in this arrangement is that no change in the damping force is possible at medium and high piston speeds. Moreover, no change in the valve force at medium piston speeds is possible since the piston rod simply acts to hold a corresponding by-pass open or closed.
In order to adjust damping forces at low and medium piston speeds, a variable oil pressure technique has been proposed in DE-PS No. 894 965. In such a construction, in additon to the change in the cross-section of the passage, the pre-loading of the valve spring is altered by means of oil pressure, for which, in a disadvantageous manner, throttle setting devices and corresponding pipe systems are necessary.
SUMMARY OF THE INVENTION
The invention provides an improved adjustable hydraulic apparatus of the type having a hollow piston rod operably associated with a damping piston means which divides the interior of a cylinder member into first and second halves filled with damping fluid. At least one throttle means is operably associated with the damping piston means. The hollow piston rod includes a traverse bore disposed above the damping piston means for the constant passage of damping fluid therethrough. An axially displaceable tension rod is disposed within the interior of the hollow piston rod and is operably associated with an adjusting device. The improvement to the damper apparatus, according to this invention, provides an annular gap defined by the tension rod in combination with the inner surface of the hollow piston rod, which functions as a throttle restriction. The tension rod includes a recessed portion adjacent the annular gap which provides an opening of increased cross-sectional dimension as the tension rod moves with respect to the hollow piston. The lower portion of the tension rod is also associated with a control piston means which is axially displaceable within a pot-like valve body disposed within the interior of the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention, by way of example, are illustrated diagrammatically in several drawings in which:
FIG. 1 is a section through an adjustable hydraulic damper;
FIG. 2 shows a further form of damper;
FIG. 3 is a section through a vibration damper with a hollow piston rod in the interior of which is shown an adjusting device, a switch device and the tension rod, the latter being shown in the right hand lower portion as in the extended position;
FIG. 4 shows a section through a housing of the switching device;
FIG. 5 shows a control rod in elevation; and
FIG. 6 shows a rotating portion, partially sectioned and partially in elevation.
DETAILED DESCRIPTION OF THE INVENTION
It is an object of this invention to provide a damper in which the damping forces can be adjusted electrically at different piston speed ranges. To solve this problem, it is provided that the tension rod forms, with the inner surface of the piston rod, directly or through a corresponding device, an annular gap acting as a throttle, at least one recess being provided on the outer surface of the tension rod in the region adjacent the annular gap, this recess providing over a corresponding working range of the armature an annular gap of greater cross-section, and that the end region of the tension rod receives a control piston which is guided to slide axially in the cylindrical inner surface of a pot-like valve body. As a further embodiment the valve body, acted on by a spring, has between its face and the region which is nearest the damping piston a permanent oil passage and has in the base of the valve body a further oil passage which can be closed off by the control piston.
In this arrangement, it is of advantage that the damping force, and with it the valve force, can be altered by means of the electro-magnet at medium piston speeds, in that simultaneously the damping force can be altered at low piston speeds by means of an additional constant passage and the damping force at higher piston speeds can be altered by altering the cross-section for flow. In this arrangement, the constant oil throttle passage and the surface of the valve disc which is acted on are made to be adjustable so that an electro-magnet of small construction is sufficient since the relatively high valve spring and damping forces do not themselves have to be varied.
According to a further important feature of the invention, it is provided that the recess on the outer surface of the tension rod is in the form of an annular groove. An advantage of this embodiment is that a simple machining of the tension rod is all that is needed because of the rotationally symmetrical nature of the groove. After the axial change in position of this recess through the action of the magnet, a greater throttling cross-section is uncovered. By means of the outside diameter of the tension rod, therefore, different throttle cross-sections can be achieved for the behavior in the extension stage at high piston speeds.
A relatively simple possibility for manufacture to form a corresponding annular gap for the extension phase at high postion speeds is to be seen in providing a disc in the interior of the piston rod or in the inner wall of a securing nut connected to the piston rod.
A further embodiment provides that the permanent oil passage is formed by a collar on the pot-like valve body and the face of a securing nut, the valve spring abutting, on the one hand, on the underside of the collar and, on the other hand, against an abutment surface on a threaded ring connected to the securing nut. The constant oil flow passage in this arrangement is formed with advantage on the circumferentially extending control edge and is effective at low piston speeds.
According to a further important feature, it is provided that the valve body has an inside diameter which increases progressively from the cylindrical inner surface towards the permanent oil passage. This diverging region is then effective when the tension rod and accordingly, the control piston is displaced upwards, when the electro-magnet is energized, into a predetermined position so that a passage between the control piston and the valve body is uncovered. This passage allows the oil pressure to act on the whole inner face of the valve body so that, by virtue of the resulting greater area which is acted on, lower damping forces arise at the same piston speed range. At the same time, the further constant oil passage present in the base of the valve body is also uncovered so that low damping forces are produced, even at low piston speeds.
In order to achieve trouble-free guiding of the tension rod and to protect the electro-magnet from the damping medium, the tension rod is guided and sealed in a bearing mounted in the interior of the piston rod. A preferred embodiment of this bearing has on its cylindrical outer surface and/or on its cylindrical inner surface an annular groove for receiving a seal.
In order to seal off the additional constant oil passage when the electro-magnet is de-energized, the outer surface of the control piston is provided with an annular groove for receiving a piston ring.
In a further embodiment, the electro-magnet cooperates with a control unit. In such an embodiment of the invention, the control unit can be acted on by desired value output of a computer or micro processor so that data, such as vehicle speed, road condition and load condition, can be evaluated and on the basis of this information, the necessary damping force can be provided to match the corresponding data, a corresponding energization of the electro-magnet being possible.
According to a further important embodiment, it is provided that the valve body has, in its base, an opening corresponding to the cross-section of the tension rod and that the tension rod has in the region of the valve body a longitudinal bore which is closed at the end of the rod, this bore being provided above and below the control piston with at least one respective radially extending opening for flow, the lower opening leading, in the upper working position of the tension rod, into the interior of the valve body and in the lower working position of the tension rod into the lower chamber half.
In this arrangement, it is of advantage that the damping force, and thereby the valve force, can be altered by means of the adjustment device at all piston speeds, in that the tension rod, with its recess and the openings for flow, can be brought into a corresponding working position. In this arrangement, according to the use to which it is put, it is possible, corresponding to the axial position of the control piston, to achieve low damping forces in the medium piston speed range and high damping forces in the low piston speed range. In the opposite position of the control piston, by contrast, high damping forces can be achieved in the medium piston speed range and low damping forces in the low piston speed range. Moreover, it is of advantage that only a small adjusting device matching the forces is sufficient in order to achieve control of the tension rod, since there is no need for high valve spring and damping forces to be controlled.
According to a further important feature, it is provided that holes are arranged, extending at right angles to the longitudinal axis of the tension rod, to form the radial openings for flow. These holes are easy to produce in manufacture at low cost and without difficulties.
A further embodiment provides that the end of the tension rod is closed by a closure disc, so that a simple manufacturing technique is possible for forming the blind bore. Furthermore, it is provided that the closure disc is force-fitted into the tension rod.
According to a further important feature of the invention, it is provided that an electric motor or an electro-magnet is employed as the adjusting means. By the constant oil throttling passages and the variable area of the valve body which is exposed, such small electro-magnets or electric motors achieve sufficient control of the tension rod, because the relatively high valve spring forces and damping forces do not themselves need to be controlled. A further variability is achieved by making the recess with at least two stepped shoulders and the adjusting means provide a number of working positions of the tension rod corresponding to the number of steps.
To achieve a short electrical switch-on time and/or the need for a minimum of force, it is provided, according to the invention, that a switch device is arranged between the adjusting means and the tension rod, the switch device having positions corresponding to at least two axially different positions on the tension rod, the tension rod being urged towards the adjusting device by a spring. In such a device it is of advantage that not only can it be mounted within the hollow piston rod but that by a switch device a force is only required for the actual period of the change in position, thus saving energy. This results in a short switch-on time so that electro-magnets of correspondingly small size can be employed.
According to a further important feature of the invention, it is provided that the switching device comprises a housing, a control rod and rotating portion. This results in a compact construction which, given a corresponding outside diameter, can be pressed or otherwise secured in the interior of the hollow piston rod. It has been found particularly advantageous for the adjusting means to take the form of an electro-magnet.
In a particularly preferred embodiment, it is provided that the control rod and the rotating portion are provided on their mutually opposed faces with respective toothed faces and axially extending grooves on the periphery, the grooves being axially movably guided in corresponding axially extending ribs in the housing. In this embodiment, it is of advantage that, by means of the toothed face, the rotating portion receives a movement in a peripheral direction during the switch movements and after clearing the guide ribs on the housing, so that thereby different axial positions are reached. To achieve trouble-free function and to allow manufacture from rotationally symmetrical components, the grooves and ribs are distributed uniformly around the periphery. It is furthermore provided that the rotating portion is kept in face-to-face contact with the tension rod by means of a coil spring so as to impart the displacements to the tension rod without problems. According to a further embodiment, it is provided that the armature spindle of the electro-magnet acts on the control rod.
The section through an adjustable hydraulic damper illustrated in FIG. 1 shows substantially the cylinder barrel 21, the hollow piston rod 1, on the end of which is secured the damping piston 11. The damping piston 11 divides the interior of the cylinder 21 into two chamber halves 24 and 25. On the upper end of the damping piston 11 is the contraction phase valve 20.
On the upper end of the hollow piston rod 1 and within it, there is arranged a fixed electro-magnet 2, into which extends the axially displaceable tension rod 4, acted on by a return spring 3. The hollow piston rod 1, under the action of the spring 3, abuts through a retaining ring 5 against the tension rod bearing 7. To seal the bearing 7 with respect to the tension rod 4 and the hollow piston rod 1, there are O-rings 6 and 26. The bearing 7 is held in its axial position by a helical spring 8 which abuts at its lower end against a disc 9 on the securing nut 10 of the damping piston 11. Formed between the tension rod 4 and the disc 9 is the annular gap 27 which acts as the throttle and which determines the behavior in the extension phase at high piston speeds.
When the tension rod 4 is pulled upwards by the electro-magnet 2, an increased annular gap 27 arises between the disc 9 and the recess 23 in the tension rod 4, resulting in lower forces in the extension phase at high piston speeds. Thus, with the electro-magnet 2 energized and accordingly with the tension rod 4 in its upper position, low damping forces are produced in the extension phase in all speed ranges of the damping piston 11.
The tension rod 4 has at its lower end a control piston 12 which is guided to be axially movable in the valve body 13. The control lip 14 which extends around the periphery of the valve body 13 defines a constant oil passage 16. Arranged in the base 15 of the valve body 13 is a further constant oil passage 28 which is open or closed according to the position of the control piston 12.
With the control piston 12 in the position illustrated, the inside diameter of the control lip 14 of the valve body 13, loaded by the spring 17, forms a small surface exposed to the outside diameter of the control piston 12 so that consequently high damping forces are produced in the medium speed range of the piston. At the same time, only the constant oil passage 16 in the valve body 13 is effective so that even at small piston speeds high damping forces are produced. In addition, a small constant oil passage is formed at the same time between the tension rod 4 and the disc 9, so that also at high piston speeds high damping forces are produced. When the tension rod 4 and accordingly, the control piston 12 are drawn to the upper position by the electro-magnet 2, pockets 18 which become free in the control piston 12 and, in connection with it the increasing diameter of the valve body 13, allow the oil pressure to act on the entire inner face of the valve body 13 so that the consequent increased area acted on in the medium piston speed range allows lower damping forces to arise. At the same time, the constant oil passage present in the base 15 of the valve body 13 is also additionally open so that even at small piston speeds low damping forces are produced. Furthermore, the recess 23 and the increased annular gap 27 produce lower damping forces at high piston speeds.
The valve spring 17 abuts at its underside against the threaded ring 19, the contraction phase valve 20 being provided on the upper side of the damping piston 11. In order to guide the damping medium from the upper chamber half 24 into the lower chamber half 25 in the extension phase transverse, bores 22 are provided in the hollow piston rod 1 distributed around the periphery.
The section through an adjustable hydraulic damper illustrated in FIG. 2 shows substantially the cylinder barrel 121, the hollow piston rod 101 on the end of which is secured the damping piston 111. The damping piston 111 divides the interior of the cylinder 121 into two chamber halves 124 and 125. On the upper end of the damping piston 111 is the contraction phase valve 120.
Mounted in a fixed position on the upper end of the hollow piston 101 and within its interior is an electro-magnet 102, into which projects the axially displaceable tension rod acted on by a return spring 103. The rod 104, pre-loaded by the spring 103, abuts through a retaining ring 105 against the tension rod bearing 107. To seal the bearing 107 with respect to the tension rod 104 and the hollow piston rod 101, there are O-rings 106 and 126. The bearing 107 is held in its axial position by a coil spring 108 which abuts at its lower end against a disc 109 on the securing nut 110 for the damping piston 111. Between the tension rod 104 and the disc 109, there is formed the annular gap 127 acting as a throttle and determining the behavior in the extension phase at high piston speeds.
The tension rod 104 has at its lower end a control piston 112 which is guided to be axially movable in the valve body 113. The control lip 114 extends around the periphery of the valve body 113. In the base 115 of the valve body 113, there is an opening 134 through which the rod 104 can move axially. In the lower region 133 of the tension rod 104, there is the blind hole 130 with its radial openings 129 and 131 for flow. According to the position of the control piston 112, the lower opening 131 leads into the lower chamber 125 or into the interior 116 of the valve body 113. In the lower position of the electro-magnet, a constant passage is available for oil through the upper opening 129, the blind bore 130 and the lower opening 131. In the upper position of the rod 104, the lower opening 131 is within the interior 116 of the valve body 113 and by virtue of the closure disc 132 arranged in the tension rod 104, the base 115 of the valve body is closed off with respect to the upper chamber 124 apart from the residual minimum annular cross-section of the opening 134. The control piston 112 is secured on the tension rod 104 by securing rings 118 and sealed by means of a sealing ring 128.
When the tension rod 104 is pulled upwards by the electro-magnet 102, an increased annular gap 127 arises between the disc 109 and the recess 123 in the rod 104. The constant oil passage between the openings 129 and 131 is closed off in this position apart from the annular cross-section of the opening 134.
In the lower position of the tension rod 104, on the other hand, there is a smaller annular gap 127 and, additionally, the constant cross-section oil passage through the upper opening 129, the blind bore 130 and the lower opening 131.
In the lower position of the rod 104, as illustrated, high damping forces are produced in the medium piston speed range by virtue of the smaller exposed area of the valve body 113. In the low piston speed range, the damper fluid flows from the upper opening 129, through the blind bore 130, to the lower opening 131 and then into the lower chamber half 125, producing low damping forces. A constant additional oil passage is still provided by the residual minimum annular cross-section of the opening 134 between the rod 104 and the base 115 of the valve body 113.
When the rod 104 is drawn upwards, the greater exposed area of the valve body 113 (oil can flow around the control piston 112) causes lower damping forces to be produced in the medium piston speed range. By virtue of the fact that then the lower opening 131 in the tension rod 104 comes to lie inside the interior 116 of the valve body 113, then at low piston speeds only still as a reduced constant oil passage does the residual minimum annular cross-section remaining in the opening 134 between the tension rod 104 and the base 115 of the valve body act, resulting in high damping forces.
The respective arrangement of the damping forces at high piston speeds can be achieved by altering the position and shape of the recess 123 on the tension rod 104.
The valve spring 117 abuts at its lower end against the threaded ring 119, the contraction phase valve 120 being provided on the upper end of the damping piston 111. In order to conduct the damping fluid from the upper chamber half 124 into the lower chamber half 125 in the extension phase, transverse bores 122 are arranged in the hollow piston rod 101, distributed around its periphery.
The section through an adjustable hydraulic damper illustrated in FIG. 3 shows substantially the hollow piston rod 201, in the interior of which there are provided an electro-magnet 202, the switch device 203 and the tension rod 204. Secured to the end of the hollow piston rod 201 is the damper piston 205. The piston 205 divides the interior of the cylinder barrel 206 into the upper chamber half 207 and the lower chamber half 208. The piston 205 is provided with valves for the contraction phase and adjustable valve devices for the extension phase.
A constant oil passage from the upper chamber half 207 to the lower chamber half 208 is provided by the bore 209, arranged above the damper piston 205, and the interior 210 of the hollow piston rod 201.
Arranged at the upper end of the hollow piston rod 201 and in its interior, there is the fixed electro-magnet 202 and the switch device 203 is present between it and the tension rod 204, acted on by a compression spring 211.
The switch device 203 comprises the housing 212, the control rod 213 and the rotating portion 214. The rotating portion 214 is in engagement with the tension rod 204 and the control rod 213 is acted on by the armature spindle 215 of the electro-magnet 202.
In the retracted position illustrated in FIG. 3, the armature spindle 215 of the electro-magnet 202 is in contact with the control rod 213 which is provided on its lower end with grooves 216 extending right through and on its face it is provided with teeth 217. The teeth 217 on the face engage corresponding teeth 218 on the face of the rotating portion 214. The rotating portion is provided on its outer periphery with grooves 219. The upper part of the rotating portion 214 is guided in a bore in the control rod 213 and its lower hollow part is guided on the tension rod 204 of the damper, the rotating portion 214 and the tension rod 204 being in axial and face contact through the compression spring 211 abutting against the tension rod 204. The control rod 213 and the rotating portion 214 are guided to prevent rotation by grooves 216, 219 engaging ribs 220 on the housing 212.
When the electro-magnet 202 receives a pulse of current, the control rod 213 is displaced downwards by the amount of the predetermined stroke of the armature spindle 215, as well as the rotating portion 214 and the tension rod 204. While the control rod 213 remains secured against rotation in the ribs 220 in the housing 212, the rotating portion 214 moves clear of the guide ribs 220 and by virtue of the teeth 217, 218 on their faces, both components perform a partial rotation. When the current ceases, the compression spring 211 pushes the face teeth 218 on the rotating portion 214 against the ends of the ribs 220 in the housing 212, so that the rotating portion 214 completes a further rotation and the ribs 220 abut axially and forcibly into the roots of the teeth 218 on the face of the rotating portion 214. In this way, the lower, extended switch position of the switch is attained.
On the arrival of a further current pulse, the previously mentioned components, engaging axially in contact, are again urged downwards by the armature spindle 215; and the rotating portion 214, after moving clear of the ribs 220 in the housing 212, again performs a partial rotation as a result of the engagement of the teeth on the face. When the current is now broken, the compression spring 211 urges the rotating portion 214 and its face teeth 218 against the lower ends of the ribs 220 in the housing, producing further rotation of the portion 214 and arriving at the starting or retracted position of the switch device 203. The grooves 219, on the rotating portion 214, are again guided and located against rotation by the ribs 220 on the housing 212.
In FIG. 4, the housing 212 is shown in section, ribs 220 being provided in the lower region and serving to guide the rotating portion 214 and the control rod 213. Provided in the upper part of the housing 212 is a screw thread 221 for receiving the electro-magnet 202. The control rod is guided in the cylindrical bore 222.
FIG. 5 shows the control rod 213 as an individual component, the upper cylindrical region 223 being received in the housing 212 and the lower region being provided with the teeth 217 on its face and with the grooves 216. These grooves 216 engage in the ribs 220 in the housing 212.
The face teeth 217 and the grooves 216 are distributed uniformly around the periphery.
In FIG. 6, the rotating portion 214 is illustrated partly in section and partially in elevation. The lower region 224 serves to receive the tension rod 204 and the upper cylindrical region 225 is received in a bore in the control rod 213. Also in the rotating portion 214, the face teeth 218 and the grooves 219 are distributed uniformly around the periphery.
The invention is not to be taken as limited to all the details that are described hereinabove, since modifications and variations thereof may be made without departing from the spirit or scope of the invention. | The invention provides an improved adjustable hydraulic apparatus of the type having a hollow piston rod operably associated with a damping piston means which divides the interior of a cylinder member into first and second halves filled with damping fluid. At least one throttle means is operably associated with the damping piston means. The hollow piston rod includes a traverse bore disposed above the damping piston means for the constant passage of damping fluid therethrough. An axially displaceable tension rod is disposed within the interior of the hollow piston rod and is operably associated with an adjusting device. The improvement to the damper apparatus, according to this invention, provides an annular gap defined by the tension rod in combination with the inner surface of the hollow piston rod, which functions as a throttle restriction. The tension rod includes a recessed portion adjacent the annular gap which provides an opening of increased cross-sectional dimension as the tension rod moves with respect to the hollow piston. The lower portion of the tension rod is also associated with a control piston means which is axially displaceable within valve body disposed within the interior of the cylinder. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to the drilling and production from offshore wells and particularly wells in water depths beyond those where conventional divers may operate. As the search for petroleum deposits in offshore waters continues, it has moved into deeper and deeper waters, beyond the depths at which divers can operate. The depths have increased to the point where the use of conventional bottom-supported production platforms is no longer practical. This has led to the use of floating production platforms which require the use of remotely operated subsea wellhead assemblies. The remotely operated equipment includes the installation of various wellhead assemblies during drilling and production such as conventional blowout preventer assemblies as well as lower marine riser assemblies. In addition, after the drilling is completed, other assemblies must be remotely attached to the wellhead, for example, marine risers and production flow lines. All of these assemblies require that they be remotely connected and removed from the subsea well.
The conventional approach to the attachment and removal of various subsea assemblies has relied upon the remote actuation of various latching means. For example, conventional dog-like members have been moved into and out of engagement with the permanently installed subsea well assembly by either mechanical or hydraulic means. For example, hydraulic fluid could be utilized to move a cam which would move the latching members into a latched position or, alternatively, into an unlatched position. Removal of the hydraulic pressure would allow a spring means to move the latches into an unlatched position or, alternatively, into a latched position. Similarly, weight on the tubing string used for running the assembly to the subsea wellhead could be either removed or applied to operate the latching mechanism.
While the various remotely operated latching means have a high degree of reliability, there is always the possibility that the latching mechanism will fail to operate or will become stuck in a latched position. In these circumstances, it would be impossible to remove the subsea assembly. These conditions will normally occur after the assembly has been in place for an extended period of time. Typically, only the production equipment is subject to these conditions since the drilling equipment is normally in place only a short period of time during the actual drilling of the well. Whenever the latching means fails to operate for any reason, some means must be provided for an emergency release of the subsea assembly to allow other operations to be performed.
In U.S. Pat. No. 4,086,776, there is disclosed a release means for releasing a cam-operated locking means used to lock the end of a guide line assembly to a subsea well assembly. The means shown comprise a "scissors" arrangement which is opened to force the locking means into an unlocked position. The scissors arrangement is shown as hydraulically operated by a submersible vessel.
The system disclosed in the '776 patent requires only a modest effort to move the locking means to an unlocked position and does not forcefully remove the guide line assembly from the subsea wellhead assembly. Even if the locking means is moved to an unlocked position, it is still possible that the locking dogs will remain in place and make it impossible to remove the guide line assembly from the subsea assembly.
SUMMARY OF THE INVENTION
The present invention solves the above problems by providing a remotely operated release tool which operates mechanically to forcefully release an assembly from the subsea wellhead assembly. The release tool has sufficient mechanical power to overcome the locking means and forcefully separate the assembly from the subsea equipment.
The release tool utilizes a frame member which can be inserted between two flanges on the members that are to be separated. The frame member includes an hydraulic means which can be powered from a remotely operated vehicle (ROV). In place of an ROV, an umbilical hydraulic line extending from the surface could be used to power the system. The hydraulic means is designed to provide sufficient mechanical force so that it can physically separate the member from the subsea equipment even in those instances where the locking means remains engaged.
While the emergency release tool is capable of generating sufficient mechanical force to overcome the locking means, it is still relatively light and compact and therefore, is easily handled by the ROV. This is accomplished by providing a relatively light frame for holding the hydraulic means and then positioning the hydraulic means between the two flanges of the embers that are to be separated. The only portion of the release means that must be capable of structurally resisting the forces required for separating the members are the hydraulic means while all the remaining structure is mere support means. This is important when the devices are to be transported and maneuvered by remotely operated vehicles since most ROV's have a limited lift capacity.
While it is preferred that the release tool be designed so that it may be handled by an ROV, other configurations are also possible. For example, the release tool could be incorporated as a component of the wellhead assembly and designed so that it can be replaced if it fails to operate. An additional variation would be a provision for releasing the ROV from the release tool after it is positioned on the wellhead.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of the emergency release mechanism positioned on the subsea wellhead assembly.
FIG. 2 is a top view of the assembly shown in FIG. 1 with a portion removed for clarity.
FIG. 3 is an enlarged view of the remotely operated vehicle with the emergency release tool secured thereto.
FIG. 4 is a top view of the assembly shown in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, there is shown a subsea well assembly 10 installed on the ocean floor. The well assembly includes a mud mat, marine wellhead, and several casing strings that are suspended from the wellhead. The casing terminates in a wellhead assembly that includes a funnel-shaped guide means and suitable surfaces so that equipment such as blowout preventers and lower marine riser assemblies can be attached to the casing during drilling operations. Also, production equipment such as the production riser 11 can be secured to the wellhead assembly during production operations. The production riser 11 is provided with a flange 12 at its lower end adjacent the top of the subsea well assembly. The flange 12 is securely fastened to the riser and provided with sufficient structural strength to resist bending when the emergency release tool is utilized to remove the riser from the subsea assembly. A similar flange 13 is secured to the top of the funnel-shaped guide means. In the alternative, the funnel-shaped guide means in itself may be used as the cooperating flange under certain conditions.
Shown positioned between the opposed flanges 12 and 13 is the emergency release tool 20. Release tool 20 is transported and positioned by means of a remotely operated vehicle (ROV) 21. The remotely operated vehicle is connected to the surface by a suitable umbilical cord 22 that contains both the conductors for sending control signals to the ROV as well as cables for supplying power to the ROV in those cases where the ROV is not self-contained. Various offshore oilfield service companies offer ROVs that are capable of lifting weights of 100 to 500 pounds and supplying hydraulic power to operate various wellhead equipment. These vehicles are all provided with freedom of motion to accurately position themselves or the equipment on the wellhead.
Referring now to FIGS. 3 and 4, there is shown the details of the emergency release tool 20. The tool consists of a C-shaped frame member 30 that is provided with an opening having dimension A which is sufficient to encircle the members that are to be separated. As explained above, the member 30 is not a structural member and must have only sufficient rigidity for installation and to support the hydraulic jack means that are used for forcing the two members apart. Hydraulic jack means 31 are positioned on the frame member and located so that when the frame member is inserted between the flanges 12 and 13 of FIG. 1, the jacks may be equally positioned around the periphery of the members to be separated. Normally, the members will be circular members and the jack members will be positioned at equal-degree angles or spacing with respect to each other and the center of the members that are to be separated. The frame member is provided with suitable attaching means 32 which can be gripped by the arm 33 of the ROV. The details of the attachment means 32 are not shown since they depend upon the type of gripping means that is utilized by the ROV. The normal ROVs used in the oil well servicing operations have an arm 33 that is provided with three degrees of motion in addition to being capable of extending or retracting from the position shown in FIG. 3. An alternate arrangement would be to attach the release tool directly to the arm of the ROV. This requires that the release tool be retrieved by the ROV and returned to the surface after use.
The hydraulic jacks are supplied with suitable pressurized hydraulic fluid from a source not shown in the drawings. The normal ROV contains pump means for connecting hydraulic lines to the subsea equipment and for supplying hydraulic pressure for operating various subsea equipment. This source can be used for powering the jacks shown in the Figures. In addition, it is possible to incorporate a mechanically-driven hydraulic system in the emergency release tool and utilize the ROV for operating the hydraulic system. For example, a mechanically-operated pump could be driven by the tool means normally carried by the ROV for opening or closing valves or performing other mechanical operations on a subsea assembly.
The emergency release tool is operated by first either securing the tool to the ROV at the surface or providing means to transport the tool to the subsea well assembly. After the tool is secured to the ROV, the ROV can be launched and lowered into the ocean to transport the emergency release tool to the subsea well assembly. The ROV can then position the emergency release tool between the opposing flanges 12 and 13 of the two members that are to be separated as shown in FIG. 1. After the positioning of the tool is confirmed by the camera mounted on the ROV, the hydraulic jacks may be supplied with pressurized hydraulic fluid. The jacks will then expand to physically force the two opposing flanges apart and release the latches securing marine riser 11 to the wellhead assembly. The riser may then be pulled to the surface and faulty latches replaced or repaired. After separation, the hydraulic jacks may be de-energized and the release tool withdrawn from the wellhead assembly by the ROV. The ROV can then return to the surface with the release tool.
From the above description it is appreciated that the jacks operate directly on the two flanges to supply the axial force required to separate the two members. The release tool does not depend upon the use of any scissors mechanism or other mechanical levers for effecting the emergency separation of the two members. This direct acting of the jacks simplifies the construction of the release tool and greatly reduces the overall weight of the mechanism. This is an important consideration where the tool must be transported and positioned by an ROV that has a limited lift capability and also a limited capability for positioning a member. | An emergency release tool for operation by a remotely operated vehicle (ROV) for forcefully releasing a riser from a subsea well assembly The tool includes hydraulic cylinders mounted on a frame that can be positioned by the remotely operated vehicle to surround the risers. The cylinders are pressurized to forcefully remove the riser from the wellhead assembly. | 4 |
BACKGROUND
[0001] The invention relates to the transportation of goods that are kept in climate controlled environments.
[0002] As refrigerated goods move through the transportation chain, each link in the chain must be configured to provide the proper environment for the goods. This requires an operator at each link to determine the proper environment and to program the storage area appropriately.
SUMMARY
[0003] In one embodiment, the invention provides an environmentally-controlled structure for storing good in a cold chain. The structure includes a sensor, an identification reader, an environment implementer, and a controller. The sensor senses a parameter indicative of an environmental condition in the environmentally-controlled structure. The identification reader is positioned relative to the environmentally-controlled structure and reads information about the goods from an identification device associated with the goods. The environment implementer modifies the environmental condition inside the environmentally-controlled structure. The controller receives the indication of the environmental condition inside the environmental control structure from the sensor, receives the information about the goods from the identification reader, and controls the environment implementer to maintain a desired environment inside the environmentally-controlled structure based on the information about the goods and the indication of the environmental condition.
[0004] In another embodiment, the invention provides an environmentally-controlled transportation and storage system. The system includes a plurality of identification elements and a plurality of environmentally-controlled containers. The identification elements are associated with particular goods in the system. Each of the plurality of environmentally-controlled containers includes an identification reader, a controller, and an environment implementation system. The identification reader is configured to read the plurality of identification elements. The controller is configured to receive information from the identification reader related to the identification element read by the identification reader and to determine the optimum environment for the environmentally-controlled container based on the information. The environment implementation system is configured to receive an indication of a desired environment for the container and to maintain the desired environment in the container.
[0005] In another embodiment, the invention provides a system for controlling an environment of an environmentally-controlled transportation or storage container. The system includes an identification reader, a controller, and an environment implementation system. The identification reader reads information related to the good from a plurality of identification elements, each identification element associated with a good to be stored in environmentally-controlled transportation or storage container. The controller receives the information from the identification reader and determines the optimum environment for the environmentally-controlled transportation or storage container based on the information. The environment implementation system receives an indication of a desired environment for the environmentally-controlled transportation or storage container and maintains the desired environment in the environmentally-controlled transportation or storage container. The environmentally-controlled transportation or storage container is part of a cold chain including a plurality of environmentally-controlled transportation or storage containers, each environmentally-controlled transportation or storage container including a system for controlling the environment of the environmentally-controlled transportation or storage containers.
[0006] In another embodiment, the invention provides a method of transporting and storing goods requiring environmentally-controlled conditions. The method includes providing an identification element with information related to an environment for storing a good, linking the identification element with the good, reading the identification element when the good enters an environmentally-controlled container, determining an optimum environment for the good based on the information read from the identification element, and controlling an environment of the container based on the optimum environment.
[0007] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagram of a cold chain.
[0009] FIG. 2 is a diagram of a construction of an environmentally-controlled structure.
[0010] FIG. 3 is an embodiment of an operation of the environmentally-controlled structure of FIG. 2 .
DETAILED DESCRIPTION
[0011] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
[0012] Many goods require climate controlled environments to preserve the goods (e.g., to prevent spoilage). Table 1 below shows typical storage temperatures for various goods.
[0000]
TABLE 1
Typical Storage Temperatures
Product
Temperature
Ice Cream, Frozen Bakery
−25° F.
to −10° F.
Frozen Foods
−15° F.
to 0° F.
Meats, Seafood
20° F.
to 30° F.
Dairy , Produce, Juice
25° F.
to 40° F.
Produce, Flowers
45° F.
to 60° F.
[0013] In addition, some goods require levels of humidity or other environmental factors to be maintained at certain levels. These goods typically need to have their environments controlled from the time they are created until they are used (e.g., from harvesting to consumption). FIG. 1 shows a typical cold chain 100 for an exemplary good. A good (e.g., a food product such as eggs) is harvested on a farm 105 . The farm 105 can include a refrigerated storage area where the good is moved after harvesting (e.g., for sorting, packaging etc.). Later, the good is moved to a refrigerated truck 115 for transportation to another facility, generally geographically near the farm 105 , such as a warehouse 120 or a factory 125 . Goods that are sent to the factory 125 will generally be sent to the warehouse 120 after being processed at the factory 125 . The warehouse 120 can be integrated with the factory 125 or separate (requiring transportation once again). The goods are provided with an identification element 130 (e.g., a radio frequency identification “RFID” tag) at the farm 105 , when loaded on or unloaded from the truck 115 , at the warehouse 120 , or at the factory 125 . In some constructions, the identification element 130 can be coupled to the good and/or modified at different points in the cold chain 100 .
[0014] From the warehouse 120 , the goods are transported to a remote location via a tractor trailer 135 , or by a first truck 140 to a plane 145 , a train 150 , or a boat 155 . A second truck 160 retrieves the goods at the remote location from the plane 145 , the train 150 , or the boat 155 and transports the goods to a second warehouse 165 . From the second warehouse 165 , the goods are transported to a store 170 via a third truck 175 .
[0015] Throughout the entire cold chain 100 , each container—the trucks 115 , 135 , 140 , 160 , and 175 , the plane 145 , the train 150 , the boat 155 , the warehouse 120 , 130 , and 165 , the factory 125 , and the store 170 —must provide the proper environment for the goods. The goods that each container receives can change on a regular basis (e.g., daily, seasonally, etc.), requiring that the containers constantly be reprogrammed to the correct environmental factors for the goods they are presently holding. If an error occurs, and a container is not programmed, or is programmed incorrectly, the goods can be damaged (e.g., spoiled or improperly frozen).
[0016] FIG. 2 shows a construction of an environmentally-controlled environment 200 . The environment 200 includes an environment containment structure 205 (e.g., a walk-in cooler, a refrigerated merchandiser, a marine container, another container, a warehouse, a refrigerated truck, etc.), an identification reader 210 (e.g., an RFID tag reader, a bar code scanner, etc.) positioned by an entranceway 215 (e.g., a door, a gate, an insulated barrier, etc.) of the structure 205 , an environment controller (EC) 220 , one or more sensors 225 , and an environment implementation system (EIS) 230 (e.g., a refrigeration unit, a humidor, a heater, etc.). As goods enter the environment containment structure 205 , the identification reader 210 reads the identification element 130 (e.g., an RFID tag, a bar code, etc.) provided with the goods. The identification reader 210 provides information obtained from the identification element 130 to the environment controller 220 . In some constructions, the information is provided to a computing device, which in turns provides information to the environment controller 220 indicating how to control the environment in the environment containment structure 205 .
[0017] The controller 220 includes a processor 235 (e.g., a microprocessor, microcontroller, ASIC, DSP, etc.) and memory 240 (e.g., flash, ROM, RAM, EEPROM, etc.), which can be internal to the processor 235 , external to the processor 235 , or a combination thereof. The controller 220 also includes other circuits, such as input/output circuits and communication circuits. The controller 220 provides signals to, receives signals from and/or communicates with the identification reader 210 , the environment controller 220 , the one or more sensors 225 , and the environment implementation system 230 via wires or wirelessly.
[0018] Based on the information obtained from the identification element 130 , the environment controller 220 controls the environment implementation system 230 to ensure the environment inside the environment containment structure 205 is correct for the goods entering the structure 205 . If multiple goods are stored in the structure 205 , the environment controller 220 determines the best environment for all of the goods combined (e.g., maintaining a temperature for the goods requiring the coldest temperature). In some constructions, multiple identification readers 210 are positioned around the structure 205 . This enables one or more environment controllers 220 to control one or more environment implementation systems 230 (e.g., refrigeration units, venting, etc.) to maintain different environments within the structure 205 . The different environments can be based on what goods are stored in the environmentally-controlled structure 205 , and where in the environmentally-controlled structure 205 the various goods are stored.
[0019] In some constructions, the environment containment structure 205 includes multiple chambers or sections, each section providing a different environment (e.g., a trailer having a frozen section and a refrigerated section). The sections can be controlled by a single environment controller 220 and the environment of each section can be maintained by a single environment implementation system 230 .
[0020] In some constructions, individual goods (e.g., a carton of ice cream) contain the identification element 130 . In other constructions, groups of goods (e.g., a pallet containing multiple cartons of ice cream) contain the identification element 130 . The identification element 130 includes data from which the environment controller 220 can determine how to best control the environment for the particular goods being stored. For example, the identification element 130 can include a proprietary environment identifier code that indicates to a proprietary system (e.g., a specific manufacturer's system) how to control the environment. In other constructions, an industry wide specification could be developed to create environment identifier codes which environment controllers 220 from different manufacturers would recognize. The identification element 130 can also contain actual environment information (e.g., temperature range, humidity range, etc.) for the particular goods. The identification element 130 can also include information on the type or class of goods, an owner of the goods, a serial number, etc., which the environment controller 220 can use to determine the optimum environment for the goods. The identification element 130 could also include various time/date stamps, for example indicating when produce was harvested at a farm. The environment controller 220 can determine if the goods have been in the cold chain 100 for a certain time period and could lower the temperature of the structure 205 to slow further ripening of the goods that have been in the cold chain 100 for an extended time period, thereby increasing the shelf life of the goods.
[0021] FIG. 3 shows an embodiment of the operation 300 of an environmentally-controlled environment 200 for goods entering and leaving the environment. The identification reader 210 detects and reads the identification element 130 of goods entering or leaving the environmentally-controlled structure 205 (step 305 ). The controller 220 then determines if the goods are entering or leaving the structure 205 (step 310 ). The controller 220 can determine whether goods are entering or leaving the structure by detecting a direction of movement of the goods or the controller 220 can request an operator input, into an operator interface, whether the goods are entering or leaving.
[0022] If the controller 220 determines the goods are entering the structure 205 (at step 310 ), the controller 220 compares the desired environment for the goods with the range of desired environments for goods presently stored in the structure 205 (step 315 ), and determines if the entering goods are compatible with goods presently in the structure 205 (step 320 ). If the desired environment for the new goods is not compatible (step 320 ) with the range of desired environments for goods presently stored in the structure 205 , the controller 220 issues an alarm or warning (step 325 ). The alarm can be an acoustic alarm or can be shown on a display or both. The display can show information on the desired environment for the goods, and can show information on the goods presently stored in the structure 205 . An operator makes a decision (step 330 ) to store the goods in the structure 205 in spite of the incompatibility or to move them to another structure 205 . If the goods are compatible with the goods presently stored in the structure 205 (step 320 ) or the operator chooses to store the incompatible goods in the structure anyway (step 330 ), the controller 220 determines the best environment based on all of the goods now stored in the structure 205 (step 335 ). If the goods are the only goods being stored in the structure 205 , the optimum environment is chosen. If the goods are all compatible, the controller 220 calculates the best environment for all of the goods. If the goods were not compatible (step 320 ), the operator may be given an opportunity to choose whether to let the controller 220 determine the best environment for all of the goods (e.g., reducing the temperature below freezing even if some of the goods should not be frozen) or to maintain the present environment and ignore the addition of the latest goods. Different algorithms can be used to determine the best environment including taking into account the quantity of the various goods stored, a value of the various goods stored, a length of time the goods are expected to be kept in the structure 205 , etc. (e.g., choosing the environment for the most valuable goods). If the operator decides to not store the incompatible goods in the structure 205 (step 330 ), the operation is exited (step 337 ).
[0023] Once the environment is determined, the controller 220 directs the environment implementation system 230 to maintain the desired environment (step 340 ). The controller 220 also updates its inventory records to account for the goods that are now stored in the structure 205 (step 345 ) and exits the operation (step 350 ) until another identification element 130 is detected (step 305 ).
[0024] If the controller 220 determines the goods are leaving the structure 205 (step 310 ), the controller 220 updates its inventory records to remove the goods from inventory (step 355 ). The controller 220 then recalculates the best environment for the goods remaining in the structure 205 (step 360 ) and directs the environment implementation system 230 to maintain the desired environment (step 365 ). The controller 220 then exits the operation (step 370 ) until another identification element 130 is detected (step 305 ).
[0025] In some constructions, the identification element is powered, enabling the element to transmit the information it contains over greater distances than a passive device. In some constructions, one or more identification readers are positioned within the environmentally-controlled structure and read the identification elements after the container is sealed. The controller then determines the optimum environment and controls the environmentally-controlled structure to maintain the optimum environment.
[0026] Various features and advantages of the invention are set forth in the following claims. | An environmentally-controlled structure for a cold chain. The structure includes a sensor, an identification reader, an environment implementer, and a controller. The sensor senses a parameter indicative of an environmental condition in the environmentally-controlled structure. The identification reader is positioned relative to the environmentally-controlled structure and reads information about the goods from an identification device associated with the goods. The environment implementer modifies the environmental condition inside the environmentally-controlled structure. The controller receives the indication of the environmental condition inside the environmental control structure from the sensor, receives the information about the goods from the identification reader, and controls the environment implementer to maintain a desired environment inside the environmentally-controlled structure based on the information about the goods and the indication of the environmental condition. | 6 |
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of grants awarded by the National Institutes of Health.
FIELD OF THE INVENTION
The invention relates to the use of inhibitors of calcineurin to prevent glutamate neurotoxicity.
BACKGROUND OF THE INVENTION
Nitric oxide (NO) has been demonstrated to mediate neuronal relaxation of intestines (Bult (1990) Nature , 345:346-347; Gillespie (1989) Br. J. Pharmacol., 98 : 1080 - 1082 ; and Ramagopal (1989) Eur. J. Pharmacol ., 174:297-299) and to mediate stimulation by glutamate of cGMP formation (Bredt (1989) Proc. Natl. Acad. Sci. USA 86:9030-9033). Glutamate, the major excitatory neurotransmitter in the brain, acts through several receptor subtypes, some of which stimulate the formation of cGMP (Ferrendelli (1974) J. Neurochen . 22:535-540). Glutamate, acting at N-methyl-D-aspartate (NMDA) subtype of receptors, is responsible for neurotoxic damage in vascular strokes. Glutamate neurotoxicity has also been implicated in neurodegenerative disorders such as Alzheimer's and Huntington's diseases (Choi (1990) J. Neurosci . 10:2493-2501; and Meldrum (1990) Trends in Pharmiacol. Sci . 11:379-387). Selective antagonists of NMDA glutamate receptors prevent neuronal cell death in animal models of hypoxic-ischemic brain injury (Choi (1990) J. Neurosci ., 10:2493-2501). In addition, inhibitors of nitric oxide synthase prevent neuronal cell death (Dawson, Proc. Natl. Acad. Sci., USA , 88:6368 (1991)).
Besides their roles in the immune system, the immunophilins, cyclophilin and FK-506 binding protein (FKBP), are highly concentrated in the brain in discrete neuronal structures where they are co-localized with the Ca + 2 activated phosphatase, calcineurin (Steiner, et al., Nature , 358:584-587 (1992). Liu ( Cell , 66:807-815 (1991)) demonstrated that very low concentrations of FK-506 and cyclosporin A, which bind to FKBP and cyclophilin, respectively, inhibit calcineurin, and Steiner showed that both drugs enhance the phosphorylation of a number of proteins in the brain. Glutamate neurotoxicity acting via N-methyl-D-aspartate (NMDA) receptors is implicated in neuronal damage associated with strokes and neurodegenerative diseases (Choi, Neuron , 1:623-634 (1988); Meldrum, et al., Trends Pharmacol. Sci ., 11:379-387 (1990); Choi, Science , 258:241-243 (1992)). In primary cerebral cortical cultures (Dawson, et al., Proc. Natl. Acad. Sci., USA , 88:6368-6371 (1991)), hippocampal slices (Izumi, et al., Neurosci. Lett ., 135:227-230 (1993)), and in animal models of focal ischemia Nowicki, et al., Euro. J. Pharma ., 204:339-340 (1991)), NMDA toxicity is mediated, at least in part, by nitric oxide (NO), as NO synthase (NOS) inhibitors block this toxicity.
Effective methods of preventing, treating or ameliorating diseases caused by glutamate neurotoxicity are needed in the art.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a method of treating diseases caused by glutamate neurotoxicity.
It is another object of the invention to provide a method of treating vascular stroke and neurodegenerative diseases.
It is another object of the invention to provide a method of screening compounds to identify neuroprotective drugs.
These and other objects of the invention are provided by one or more of the embodiments described below. In one embodiment of the invention, a method for treating vascular stroke and neurodegenerative disease patients to block glutamate-mediated neurotoxicity is provided. The method comprises: administering to a vascular stroke or neurodegenerative disease patient a drug which binds to an immunophilin, in an amount effective to inhibit glutamate-mediated neurotoxicity.
In another embodiment of the invention, a method is provided for treating vascular stroke and neurodegenerative disease patients to block glutamate-mediated neurotoxicity. The method comprises: administering to a vascular stroke or neurodegenerative disease patient a drug which binds to an immunophilin, in an amount effective to inhibit calcineurin.
In still another embodiment of the invention, a method is provided for screening compounds to identify neuroprotective drugs. The method comprises the steps of: applying an immunophilin-binding test compound to cultured mammalian neuronal cells; applying a neurotoxic agent selected from the group consisting of NMDA and glutamate to said cultured mammalian neuronal cells; assessing toxicity by determining viability of the cultured mammalian neuronal cells, a neuroprotective drug being identified when a test compound inhibits the toxic effects of said neurotoxic agent.
Thus the present invention provides the art with methods for treating neurological diseases associated with glutamate neurotoxicity, as well as methods of identifying other pharmacological agents which will block glutamate neurotoxicity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 demonstrates that phosphorylation of nitric oxide synthase (NOS) is regulated by calcineurin and FK-506-FKBP. FIGS. 1A-1C show the dephosphorylation of phosphorylated purified brain NOS. 32 P-labeled proteins were incubated with brain calcineurin for various times (FIG. 1B) and probed with anti-NOS antibody (FIG. 1 A). The phosphorylation of NOS was quantitated and is shown in a bar graph (FIG. 1 C). FIGS. 1D-E show that FK-506 enhances the phosphorylation of NOS. Purified brain NOS was labeled with 32 p in the presence of 0-tetradecanoylphorbol 13-acetate (TPA) and whole rat brain soluble extracts. The proteins were resolved by polyacrylamide gel electrophoresis and autoradiographed. (FIG. 1 D). The level of phosphorylation was determined quantitatively (FIG. 1 E).
FIG. 2 proposes a mechanism for the regulation of the phosphorylation state and catalytic activity of NOS.
DETAILED DESCRIPTION OF THE INVENTION
It is a discovery of the present invention that immunosuppressant-type drugs, such as FK-506 and cyclosporin A, which bind to immunophilins, block glutamate neurotoxicity that is mediated by N-methyl-D-aspartate (NMDA) receptors. Upon binding of FK-506 and cyclosporin A to their respective immunophilins (binding proteins), the activity of the calcium-activated phosphatase calcineurin is inhibited. Thus treatment with this class of drugs increases the phosphorylation of proteins which are substrates of calcineurin. It is a further discovery of this invention that phosphorylated nitric oxide synthase (NOS) is a substrate for calcineurin. A model which accounts for these findings is that immunosuppressant-type drugs block neurotoxicity by inhibiting calcineurin, thereby increasing the phosphorylation of NOS, thereby inhibiting production of nitric oxide.
During the normal course of a vascular stroke or neurodegenerative disease, glutamate released from adjacent nerve terminals activates the NMDA subclass of glutamate receptors to increase intracellular Ca 2+ (Zorumski, et al., Progr. Neurobiol ., 39:295-336 (1992); Mayer, et al., Ann. N.Y. Acad. Sci ., 648:194-204 (1992)). The Ca 2+ binds to calmodulin, activating NOS. Ca 2+ entry also activates calcineurin, which dephosphorylates and activates NOS. The NO generated by NOS diffuses to adjacent cells to activate guanylate cyclase and increase intracellular cGMP levels (Moncada, et al., Pharmacol. Rev ., 43:109-142 (1991). If sufficient quantities of NO are produced, adjacent cells die (via undefined mechanisms) (Dawson, et al., Ann. Neurol ., 32:297-311 (1992)), whereas the neurons which produce NO are uniquely resistant. NOS catalytic activity is inhibited by protein kinase C (PKC)-mediated phosphorylation (Bredt, et al., J. Biol. Chem ., 267:10976-10981 (1992)).
FK-506, complexed to FKBP, binds to calcineurin, inhibiting its phosphatase activity. This prevents the dephosphorylation of NOS, which decreases NOS catalytic activity. With lowered NO production, adjacent neurons remain viable. Other immunophilin-binding drugs act by a similar mechanism.
The immunophilin-binding drugs may be used to prevent, treat, arrest, or ameliorate the progression of any disease condition caused by glutamate neurotoxicity. Such conditions include vascular strokes and neurodegenerative diseases, such as Alzheimer's, Huntington's and Parkinson's diseases, as well as other disease states. For example, following the symptoms of a stroke, an immunophilin-binding drug can be administered to a patient to block damage to the brain. Patients with symptoms of Alzheimer's or Huntington's disease can be treated with immunophilin-binding drugs to halt the progression of the disease. The symptoms of these disease states are known by one skilled in this art.
Immunophilin-binding drugs useful for the present invention are compounds which upon binding to immunophilins inhibit the activity of the phosphatase calcineurin and inhibit the toxicity of glutamate via NMDA-receptors. The present invention contemplates the use of any physiologically acceptable immunophilin-binding drug which inhibits calcineurin activity. The effectiveness of a compound, and its relative potency as a calcineurin inhibitor, can be tested and routinely determined by measuring inhibition of calcineurin activity, for example, by monitoring the level of phosphorylation of NOS in cerebellar homogenates or cultured neuronal cells. An increase in NOS phosphorylation indicates inhibitory activity of the compound. The magnitude of the increase in NOS phosphorylation, attributable to the presence of the compound being tested, indicates the potency of the compound as a calcineurin inhibitor. Alternatively, compounds can be tested to determine whether they inhibit the amount of NO formed, cGMP formed, or cell death occurring after treatment with glutamate or NMDA. The extent of inhibition of cGMP increases correlates with the ability to protect against neurotoxicity.
Both FK-506 and cyclosporin A, two immunophilin-binding calcineurin inhibitors, have been found to prevent neurotoxicity in proportion to their relative potencies as calcineurin inhibitors. In addition to these compounds, other immunophilin-binding drugs have been developed. Such drugs include FK-520, FK-523, 15-0-DeMe-FK-520, (4R)-[(E)-L-butenyl]-4,N-dimethyl-L-threonine. (Liu, Biochemistry , 31:3896-3902 (1992)).
The dosage and length of treatment with immunophilin-binding drugs depends on the disease state being treated. The duration of treatment may be a day, a week, or longer, and may, in the case of a chronic progressive illness, such as Alzheimer's disease, last for decades. The immunophilin-binding drugs are administered in a therapeutically effective amount, a typical human dosage of FK-506 ranging from about 0.1 mg/kg of body weight of FK-506 to about 1.0 mg/kg of FK-506, in single or divided doses. The dosage will vary depending on the immunophilin-binding drug to be used and its relative potency. Dosage and length of treatment are readily determinable by the skilled practitioner based on the condition and stage of disease.
In therapeutic use, immunophilin-binding drugs can be administered by any route whereby drugs are conventionally administered. Such routes of administration include intraperitoneally, intravenously, intramuscularly, subcutaneously, intrathecally and intraventricularly, as well as orally.
Typical preparations for administration include sterile aqueous or nonaqueous solutions, suspensions and emulsions. Examples of nonaqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions and buffered media. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers, such as those based on Ringer's dextrose, and the like. Preservatives and other additives may also be present such as, for example, antimicrobials, anti-oxidants, chelating agents, inert gases, and the like. Oral preparations, such as capsules, tablets, and other forms, can include additives such as cellulose, silica gel and stearic acid.
To be effective therapeutically, an immunophilin-binding drug desirably should be able to penetrate the blood-brain barrier when peripherally administrated. However, some immunophilin-binding drugs, like cyclosporin A, do not readily penetrate into the brain. Immunophilin-binding drugs which are unable to penetrate the blood-brain barrier can be effectively administered by, for example, an intraventricular route of delivery.
EXAMPLES
The following examples are provided to exemplify various aspects of the invention and are not intended to limit the scope of the invention.
Example 1
This example demonstrates that NOS is a substrate for calcineurin and that FK-506 enhances phosphorylation of NOS.
Purified brain NOS from NOS-transfected 293 kidney cells (Bredt, et al., J. Biol. Chem ., 267:10976-10981 (1992)), was preincubated with whole rat brain soluble fraction and phosphorylated by the endogenous protein kinase C in the whole rat brain soluble extracts (200 mg/ml net weight homogenate) plus 50 μg/ml phosphatidyl serine, 20 μM gramma 32 P-ATP in 50 mM Hepes, 1 mm NaEGTA, 5 mm MgCl 2 , 2mM DTT in pH 7.4 buffer for 20 min. at 25° C.
32 P-labeled proteins, transferred electrophoretically to nitrocellulose, were incubated with 5 nM brain calcineurin (Sigma, St. Louis, MO), 500 nM calmodulin, 10 μM free calcium, 20 μM MnCl 2 in 150 mM NaCl, 50 mM Hepes pH 7.5, 1 mM DTT, 0.5 mg/ml BSA buffer for various times at 25° C. Reactions were stopped by washing the nitrocellulose strips in ice cold buffer plus 2 mM NaEDTA three times, and autoradiograms were prepared. These same nitrocellulose strips were probed with affinity purified NOS antibody and developed with alkaline phosphatase-donkey anti-rabbit IgG. 32 P-labeled NOS bands were excised at the various time points and compared with NOS immunoreactivity in these fractions. The level of phosphorylation of NOS was quantitated using the Eagle Eye Imaging System (Stratagene) and NIH Image (version 1.44) software (Sutherland, et al., Biotech ., 10:492-497 (1991), Correa-Rotter, et al., Biotech ., 12:154-158 (1992)).
FIGS. 1A-1C show a representative dephosphorylation which has been replicated three times with similar results.
The data demonstrate that NOS is a calcineurin substrate by showing that NOS, phosphorylated following stimulation of protein kinase C activity with the phorbol ester O-tetradecanoylphorbol 13-acetate (TPA), is dephosphorylated in the presence of calcineurin.
Purified brain NOS from NOS-transfected 293 kidney cells (Bredt, et al., J. Biol. Chem ., 267:10976-10981 (1992)), was then pre-incubated with whole rat brain soluble extracts (200 mg/ml wet weight homogenate) plus 50 μg/ml phosphatidylserine, 20 μM gamma 32 P-ATP in 50 mM Hepes, 1 mM NaEGTA, 5 mM MgCl 2 , 2 mM DTT in pH: 7.4 buffer in the absence or presence of 10 μM free Ca 2+ , 200 nM TPA and 100 nM FK-506 for 20 min. at 25° C. Proteins were resolved on 3.5-17% linear gradient polyacrylamide gel using Laemmli buffers, gels were dried and exposed to X-ray film and autoradiograms were prepared. The results are as shown in FIG. 1 D. (Lane A, control (no. Ca 2a+ , no TPA), lane B, Ca 2+ , TPA-stimulated phosphorylation, lane C, Ca 2+ , TPA-stimulated phosphorylation in presence of 100 nM FK506.) Molecular weight markers, in kilodaltons, are indicated. The level of phosphorylation of purified NOS was quantitated as described above. This experiment has been replicated three times with similar results. The results demonstrate that TPA-stimulated phosphorylation of NOS is substantially increased in the presence of 100 nM FK-506 (see FIGS. 1 D and 1 E).
Example 2
This example demonstrates that FK-506 and cyclosporin A treatments markedly diminish NMDA neurotoxicity.
We monitored neurotoxicity in primary cerebral cortical neuronal cultures in which a 5 min. exposure to NMDA results in death of about 80% of neurons when observed 24 hrs. later (Dawson, et al., Proc. Natl. Acad. Sci., USA , 88:6368-6371 (1991)). Treatment of the cultures with FK-506 for 5 min. prior to application of NMDA and during the 5 min. of NMDA application provides marked protection from neurotoxicity (Table 1). As little as 25 nM FK-506 provides significant protection, while 50% protection is evident between 25-100 nM. To ascertain whether FK-506 exerts its protective effects by interacting with its receptor FKBP, we examined the effect of rapamycin which binds to FKBP and blocks effects of FK-506 (Liu, et al., Cell , 66:807-815 (1991); Chang, et al., Trends Pharmacol. Sci ., 12:218-223 (1991); Thomas, Immunology Today , 10:6-9 (1989); Schreiber, Science , 253:283-287 (1991)). Rapamycin (1 μM) completely reverses the effects of FK-506.
The immunosuppressants, FK-506 and cyclosporin A, exert a number of different actions but share the ability to inhibit the Ca 2+ -dependent phosphatase activity of calcineurin (Liu, et al., Cell , 66:807-815 (1991); Fruman, et al., Proc. Natl. Acad. Sci. USA , 89:3686-3690 (1992); Swanson, et al., Proc. Natl. Acad. Sci., USA , 89:3741-3745 (1992); Liu, et al., Biochemistry , 31:3896-3901 (1992)). Cyclosporin A (1 μM) also protects against NMDA neurotoxicity, suggesting that the protection involves inhibition of calcineurin (Table 1). When applied by themselves, in the absence of NMDA, FK-506 (500 nM), cyclosporin (1 μM), and rapamycin (1 μM) have no effect on neuronal viability (data not shown). Moreover, FK-506 (500 nM) has no effect on NMDA elicited Ca 2+ currents in these cultures (data not shown).
Earlier we showed that NMDA neurotoxicity in these cultures is prevented by inhibition of NO formation, suggesting that NO plays a role in NMDA neurotoxicity (Dawson, et al., Proc. Nati. Acad. Sci., USA , 88:6368-6371 (1991); Dawson, et al., Ann. Neurol ., 32:297-311 (1992)). While NMDA neurotoxicity involves NO, neurotoxicity following treatment with the glutamate derivatives quisqualate and kainate is not influenced by inhibition of NOS and so presumably involves other mechanisms such as oxygen free radicals (Choi, Neuron , 1:623-634 (1988); Meldrum, et al., Trends Pharmacol. Sci ., 11:379-387 (1990); Puttfarcken, et al., Neuropharm ., 31:565-575 (1992)). In our cultures quisqualate (500 μM) and kainate (100 μM) elicit as much cell death as glutamate (500 μM) (Table 1). However, whereas glutamate toxicity is inhibited by 500 nM FK-506 with this inhibition reversed by 1 μM rapamycin, 500 nM FK-506 fails to protect against quisqualate or kainate toxicity.
TABLE 1
FK-506 Attenuates NMDA Neurotoxicity
Drug
% Cell Death (± S.E.M.)
500 μM NMDA
82.8 ± 4.3
+ 500 pM FK-506
78.3 ± 4.7
+ 1 nM FK-506
77.1 ± 4.0
+ 10 nM FK-506
68.5 ± 11.2
+ 25 nM FK-506
*67.2 ± 4.1
+ 50 nM FK-506
*61.9 ± 5.8
+ 100 nM FK-506
*40.0 ± 9.1
+ 500 nM FK-506
**29.7 ± 5.8
+ 1 μM FK-506
**29.2 ± 4.1
+ 500 nM FK-506 + 1 μM RAPA
82.4 ± 3.3
+ 1 μm CyA
*56.7 ± 4.8
500 μM Glutamate
76.0 ± 5.2
+ 500 nM FK-506
*40.6 ± 3.9
+ 500 nM FK-506 + 1 μM RAPA
61.7 ± 5.4
500 μM Quisqualate
85.9 ± 6.0
+ 500 nM FK-506
90.5 ± 4.4
100 μM Kainate
83.2 ± 6.3
+ 500 nM FK-506
88.1 ± 3.8
Statistical significance was determined by the Student's t-test
*p ≦ 0.05,
**p ≦ 0.0001.
Methods:
Primary neuronal cultures from cortex were prepared from fetal Sprague-Dawley rats gestation day 13-14. After dissection, the cells were dissociated by trituration, counted, and plated in 15 mm multi-well (Nunc) plates coated with polyornithine at a density of 3-4 × 10 5 cells per well. Proliferation of non-neuronal cells was inhibited by applying 10 μg of 5-fluor-2′-deoxyuridine 4 days after plating for a total of 3 days. Neurons were maintained in modified Eagle's
# medium (MEM), 5% horse serum, 2 mM glutamine in 8% CO 2 , humidified at 37° C. Media was changed twice a week. Mature neurons (greater than 21 days in culture) were used in all experiments. In these cultures neurons comprise approximately 70-90% of the total number of cells as assessed by neurons specific enolase and glial fibrillary acidic protein immunohistochemistry (unpublished observation).
Neurotoxicity was determined by exposing the neurons to the various test solutions as previously described (Dawson, et al., Proc. Natl. Acad. Sci., USA, 88:6368-6371 (1991)). Prior to exposure, the cells were washed 3 times with a Tris-buffered control solution (CSS) containing 120 mM NaCl, 5.4 mM KCl, 1.8 mM CaCl 2 , 25 mM Tris-HCl, 15 mM glucose at pH 7.4. FK-506 and cyclosporin A (CyA) were applied
Statistical significance was determined by the Student's t-test *p ≦0.05, ** p≦0.0001.
Methods: Primary neuronal cultures from cortex were prepared from fetal Sprague-Dawley rats gestation day 13-14. After dissection, the cells were dissociated by trituration, counted, and plated in 15 mm multi-well (Nunc) plates coated with polyornithine at a density of 3-4×10 5 cells per well. Proliferation of non-neuronal cells was inhibited by applying 10 μg of 5-fluor-2′-deoxyuridine 4 days after plating for a total of 3 days. Neurons were maintained in modified Eagle's medium (MEM), 5% horse serum, 2 mM glutamine in 8% CO 2 , humidified at 37° C. Media was changed twice a week. Mature neurons (greater than 21 days in culture) were used in all experiments. In these cultures neurons comprise approximately 70-90% of the total number of cells as assessed by neuron specific enolase and glial fibrillary acidic protein immunohistochemistry (unpublished observation).
Neurotoxicity was determined by exposing the neurons to the various test solutions as previously described (Dawson, et al., Proc. Natl. Acad. Sci., USA , 88:6368-6371 (1991)). Prior to exposure, the cells were washed 3 times with a Tris-buffered control solution (CSS) containing 120 mM NaCl, 5.4 mM KCl, 1.8 mM CaCl 2 , 25 mM Tris-HCl, 15 mM glucose at pH 7.4. FK-506 and cyclosporin A (CyA) were applied 5 min. prior to and during the application of the excitatory amino acids. Rapamycin (RAPA) was applied 5 min. prior to and during the application of FK-506 and the excitatory amino acids. Following immunosuppressant drug pretreatment, NMDA and quisqualate were applied to the cells for 5 min., then the cells were washed with CSS and replaced with MEM, 21 mM glucose for 24 hr. in the incubator. Exposures to kainate were performed in MEM, 21 mM glucose for 24 hr. in the incubator. NMDA, quisqualate, and kainate were also applied to the neurons without immunosuppressant drug pretreatment. The effect of N-Arg (L-nitroarginine) on NMDA neurotoxicity was assessed as described (Dawson, et al., Proc. Natl. Acad. Sci., USA , 88:6368-6371 (1991)). Twenty to 24 hr. after exposure to test solutions, the neurons were exposed to 0.4% trypan blue in CSS to stain the residue of non-viable cells and to assess toxicity. Viable and non-viable cells were counted with approximately 500-1,500 cells counted per well. At least two separate experiments utilizing four separate wells were performed for each data point shown. A minimum of 4,000-12,000 neurons were counted for each data point. In some experiments photomicrographs were made before and after treatment using a transparent grid at the bottom of each culture plate. Viable and non-viable neurons in identical fields were counted by an observer blinded to study design and treatment protocol.
Example 3
This example demonstrates that the enhanced phosphorylation of NOS by F-506 diminishes functional NO activity.
We monitored cGMP levels in neuronal cultures (Table 2). In brain slices (Bredt, et al., Proc. Natl. Acad. Sci., USA , 86:9030-9033 (1989); Moncada, et al., Pharmacol. Rev ., 43:109-142 (1991); Garthwaite, Trends Neurol. Sci ., 14:60-67 (1991) and neuronal cultures (Dawson, et al., Proc. Nati. Acad. Sci., USA , 88:6368-6371 (1991)) NMDA increases cGMP levels several fold and the increase is prevented by NOS inhibitors (Dawson, et al., Proc. Natl. Acad. Sci., USA , 88:6368-6371 (1991), Bredt, et al., Proc. Natl. Acad. Sci., USA , 86:9030-9033 (1989)). In these cultures FK-506 (100 nM) reduces the NMDA stimulation of cGMP levels by approximately 80%. Rapamycin (1 μM) also diminishes the NMDA stimulation of cGMP. Evidence that FK-506 is acting at the level of NOS rather than blocking the effects of generated NO on guanylyl cyclase comes from our experiments showing that the stimulation of cGMP levels by sodium nitroprusside (SNP), which generates NO, is not affected by FK-506.
TABLE 2
FK-506 Inhibits NO Stimulated cGMP Formation
Drug
% Basal cGMP Level (± S.E.M.)
500 μM NMDA
552.6 ± 95.6
+ 100 nM FK-506
*89.3 ± 25.4
+ 100 NM FK-506 ± 1 μM RAPA
178.3 ± 40.6
+ 1 μm CyA
*221.1 ± 31.9
300 μM SNP
625.2 ± 85.4
+ 100 nM FK-506
509.9 ± 63.4
Methods:
Primary neuronal cortical cultures were treated under identical conditions as those used for assessment of neurotoxicity except for the addition of 100 μM isobutylmethylxanthine (IBMX) to all wells to inhibit phosphodiesterases. Immediately after the 5 min. application of NMDA or SNP (sodium nitroprusside) with or without the various other drugs, the cells were quenched with 15% trichloroacetic acid. Following ether extraction, cGMP was assayed utilizing an Amersham 125 I-assay kit
# according to the manufacturer's instructions. Data represent the mean (± S.E.M.) of 6-12 wells (2-3 different plating of cultures) in duplicate.
Statistical significance was determined by the Student's t-test,
*p ≦ 0.005.
Methods: Primary neuronal cortical cultures were treated under identical conditions as those used for assessment of neurotoxicity except for the addition of 100 μM isobutylmethylxanthine (IBMX) to all wells to inhibit phosphodiesterases. Immediately after the 5 min. application of NMDA or SNP (sodium nitroprusside) with or without the various other drugs, the cells were quenched with 15% trichloroacetic acid. Following ether extraction, cGMP was assayed utilizing an Amersham 125 I-assay kit according to the manufacturer's instructions. Data represent the mean (±S.E.M.) of 6-12 wells (2-3 different plating of cultures) in duplicate. Statistical significance was determined by the Student's t-test, *p≦0.005.
In total, these data establish that immunophilin-binding drugs, by inhibiting calcineurin, cause the enhanced phosphorylation of NOS, thereby leading to lowered nitric oxide production. Thus immunophilin-binding, calcineurin-inhibiting drugs may be used therapeutically to treat neurotoxicity mediated through NMDA-type glutamate receptors. | Immunophilin-binding agents inhibit the phosphatase calcineurin, leading to the increased phosphorylation of certain brain proteins, including nitric oxide synthase. The increased levels of phosphorylation of nitric oxide synthase inhibits the enzymatic production of nitric oxide. Thus the neurotoxic effects of glutamate, which are ordinarily the result of vascular strokes and other neurodegenerative diseases, are minimized, because the neurotoxic effects are at least partially mediated by nitric oxide. Thus immunophilin-binding drugs can be used therapeutically in the treatment of vascular stroke and neurodegenerative disorders such as Alzheimer's disease and Huntington's disease. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. Ser. No. 08/982,220, filed Dec. 1, 1997 and which issued as U.S. Pat. No. 6,050,968.
INCORPORATION BY REFERENCE
Reference is made to the following patent applications which are hereby fully incorporated by reference:
U.S. patent Ser. No. 08/308,025, filed on Sep. 16, 1994 entitled “BALLOON CATHETER WITH IMPROVED PRESSURE SOURCE”, now U.S. Pat. No. 5,545,133.
U.S. patent Ser. No. 08/586,514 filed on Jan. 16, 1996 entitled “BALLOON CATHETER WITH IMPROVED PRESSURE SOURCE”, now U.S. Pat. No. 5,695,468
U.S. patent Ser. No. 08/619,375 filed on May 21, 1996 entitled “BALLOON CATHETER WITH IMPROVED PRESSURE SOURCE”, now U.S. Pat. No. 5,728,064 and
U.S. patent Ser. No. 08/812,390 filed on Mar. 5, 1997 entitled “BALLOON CATHETER WITH IMPROVED PRESSURE SOURCE, now U.S. Pat. No. 5,785,685.
All of the above-referenced patent applications are assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
The present invention deals with catheters. More specifically, the present invention deals with delivery of a small bolus of liquid with a catheter.
A wide variety of different mechanisms and techniques have been developed in order to treat coronary disease. However, such techniques and devices are typically drawn to the physical manipulation of biological tissues, such as heart tissue, or other vascular tissue within the vascular system.
For example, some treatment techniques are drawn to the physical removal or dilation of restrictions (stenoses and total occlusions) in the vasculature. Techniques for dealing with this type of disease have included percutaneous transluminal coronary angioplasty (PTCA) in which an angioplasty balloon catheter is inserted into the body via the femoral artery and positioned across a restriction in an artery. The balloon is inflated to widen the restriction and restore blood flow to portions of the heart muscle previously deprived of oxygenated blood. Implantation of stents using PTCA is also a common technique for opening an arterial restriction.
Another technique for dealing with vascular disease includes coronary artery bypass graft (CABG) procedures. Such procedures typically include the placement of a graft at a desired location in the vasculature to supplement blood flow to the area previously deprived of blood for (or provided with reduced blood flow) due to the vascular restriction. One common type of CABG procedure involves placement of a saphenous vein graft (SVG) between the ascending aorta proximal of the restriction, and a region in the restricted vessel distal of the restriction.
Another technique for dealing with vascular disease includes an atherectomy procedure. In an atherectomy procedure, an atherectomy device is placed in the vasculature proximate the restriction. The atherectomy device is deployed to physically cut away, abrade, or otherwise physically remove, the occlusive material from the restricted vessel. The portions of the restriction which are severed by the atherectomy device are subsequently removed by aspiration, or by another suitable means.
Another technique called transluminal myocardial revascularization is also receiving attention in the medical community as an acceptable therapy.
Various drug therapies have also been developed. Such therapies have been used in place of, and in conjunction with, the above mentioned therapies under certain circumstances. For example, during grafting procedures, it may be desirable to deliver drugs to the graft site which inhibit the formation of thrombus. In addition, some drug therapies have been developed which involve the delivery of drugs directly to the heart tissue. With recent advancements in the pharmaceutical industry, other drug therapies have also become desirable. Some such recent pharmaceutical developments include the development of gene therapy drugs, such as growth factors.
A transluminal technique for delivering the drugs, along with the various types of known positioning and visualization techniques commonly used with transluminal treatments, can be highly desirable. The drug therapies typically require site-specific administration of the drug. Transluminal techniques can be effectively used to deliver a liquid material to a selected site in the vasculature.
However, drug therapies, can be prohibitively expensive. For example, newly developed drugs are commonly extremely expensive and can only be administered in any pragmatic fashion in very low volumes. Typically, such drugs only need to be administered to the vascular site being treated. However, there is no technique available to date by which the site to be treated can be accessed transluminally with a catheter and which enables only a very small quantity of drug to be delivered from the distal tip of the catheter to the treatment site.
Rather, conventional transluminal drug delivery catheters require a proximal infusion device which is connected to a proximal end of the infusion catheter and which is used to pressurize a fluid or infusate which contains the drug to be delivered. The catheter is filled with the infusate and the drug is administered at the distal tip of the infusion catheter (upon pressurization of the infusate) after the catheter is inserted and properly positioned. While the internal volume of such infusion catheters is typically small, it is still much too large to make drug delivery with extremely expensive drugs practical.
SUMMARY OF THE INVENTION
The present invention is drawn to the delivery of a low volume bolus of drug or other treatment material to the myocardium, a vessel, or any other organ or area for which transluminal access is desirable. For example, anti-arrhythmia drugs may be injected into the myocardium using the present invention for electrophysiological therapy. Also, growth factors and other gene therapy substances can be injected into the myocardium for myocardial revascularization.
The catheter system includes a catheter having a proximal end, a distal end, and a lumen extending therein. An elongate member slidably disposed in the lumen has a distal end located proximate the distal end of the catheter. An administering tip is disposed at the distal end of the catheter and is configured to express a bolus of liquid in response to positive pressure in a distal portion of the lumen created by movement of the elongate member distally in the lumen.
The present invention also includes a method of administering a liquid to a treatment site. A catheter, having a proximal end, a distal end and a lumen extending therein, as well as an elongate member, slidably disposed in the lumen, are provided. The distal end of the catheter is transluminally positioned proximate the treatment site. The catheter is charged by placing a bolus of the liquid in a distal end of the lumen between a distal tip of the catheter and a distal end of the elongate member. The elongate member is then moved distally within the lumen to express the bolus from the distal end of the catheter.
Also, the present device should not be limited to implementation using only conventional catheters per se, but also contemplates any steerably, maneuverable syringe structure. Thus, the term catheter should be construed to include both conventional catheters and elongate, maneuverable syringe barrel structures suitable for maneuvering, manipulation, tracking and steering within a vessel.
The catheter system can be navigated through several lumens and cavities within the body. Intravascular access by the femoral, brachial and radial arteries is contemplated for accessing target sites within the heart or peripheral vasculature. Alternatively, the catheter may be navigated into the ventricles of the heart by way of the aorta for direct treatment of the heart muscle (myocardium). Yet another alternative for accessing the heart chamber is via the vena cava. Lastly, nonvascular ducts or lumens within the body can be accessed for drug delivery such as for cancer treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side sectional view of a catheter system in accordance with one preferred embodiment of the present invention.
FIG. 1A illustrates an embodiment of a catheter system of the present invention including a guidewire lumen having a guidewire extending therethrough.
FIG. 2 is an enlarged side sectional view of second embodiment of a distal tip of the catheter system in accordance with the present invention.
FIG. 3 is an enlarged view of the distal end of a catheter system in accordance with another preferred embodiment of the present invention.
FIG. 4 is an enlarged side sectional view of another embodiment of a distal tip of the catheter system in accordance with the present invention.
FIG. 5 is an enlarged side sectional view of another embodiment of a distal tip of the catheter system in accordance with the present invention.
FIG. 6 is an enlarged side sectional view of another embodiment of a distal tip of the catheter system in accordance with the present invention.
FIG. 7 is an enlarged side sectional view of another embodiment of a distal tip of the catheter system in accordance with the present invention.
FIG. 8 is a side sectional view of another embodiment of a catheter system in accordance with the present invention.
FIG. 9 is a side sectional view of the catheter system of FIG. 8, with a modified liquid reservoir configuration.
FIG. 10 is a side sectional view of a catheter system in accordance with one aspect of the present invention, deploying a two piston arrangement.
FIG. 11 is a side sectional view of a catheter system in accordance with one aspect of the present invention utilizing a bifurcated piston configuration.
FIG. 12 is a side sectional view of a catheter system in accordance with one aspect of the present invention utilizing a valve and engageable valve seat configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a side sectional view of a catheter system 10 in accordance with one preferred embodiment of the present invention. Catheter system 10 includes catheter 12 having a distal end 14 and a proximal end 16 and a lumen 18 running therethrough. In the embodiment shown in FIG. 1, distal end 14 is simply an open end providing distal opening 20 , and proximal end 16 is coupled to proximal manifold 22 in any known conventional manner.
Manifold 22 preferably has a lumen 24 extending therethrough which is coaxial with lumen 18 . Lumen 24 is also preferably in fluid communication with lumen 18 .
System 10 also preferably includes piston rod 26 . Piston rod 26 is preferably an elongate member which extends from a proximal end 28 (which preferably extends to a region proximal of manifold 22 ) to a distal end 30 which is preferably proximate distal end 14 of catheter 12 . Piston rod 26 preferably has an outer diameter which is just smaller than the inner diameter of lumen 18 . Also, piston rod 26 is preferably slidably disposed within lumen 18 such that piston rod 26 can slide in a direction generally parallel to the longitudinal axis of catheter 18 , in the direction indicated by arrow 32 .
Piston rod 26 is supported for reciprocal movement within lumen 18 by virtue of its outer dimensions relative to the inner dimensions of lumen 18 , and also be seal arrangement 34 . Seal arrangement 34 is preferably an o-ring type seal which fluidically seals the interior of lumen 18 from the exterior of system 10 through the proximal end of manifold 22 . Thus, seal arrangement 34 preferably includes an o-ring 36 which is disposed within a generally annular depression or recess 38 formed in lumen 24 of manifold 22 . O-ring 36 is preferably formed of a conventional sealing material, such as silicon rubber, and is secured in annular recess 38 utilizing a suitable adhesive.
The distal end 30 of rod 26 , when positioned as shown in FIG. 1, preferably cooperates with the inner periphery of the distal end 14 of catheter 12 to form a bolus chamber 37 for containing a bolus of treatment material. The treatment material contained in chamber 37 can be a drug, growth factors, gene therapy materials, radioactive fluid for restenosis or cancer treatment, clot dissolution agent, or any other desired fluid or liquid material. Also, the material can be injected by high pressure, at high velocity, to mechanically break up clots. As described later in the specification, material delivered by system 10 is administered to a desired site in the body by reciprocation of rod 26 in lumen 18 .
The proximal end 28 of piston rod 26 is preferably formed in any suitable manner which allows the user to easily grasp and reciprocate rod 26 within lumen 18 . For example, in the above-identified patent applications which are hereby fully incorporated by reference, a number of different proximal grasping and manipulating members are disclosed. In one arrangement, a threadable connection is provided between proximal end 28 of rod 26 and manifold 22 . In this way, the user can rotate rod 26 to cause either proximal or distal reciprocal movement within lumen 18 . In another preferred embodiment, a release mechanism is provided such that the threadable engagement between rod 26 and manifold 22 can be disengaged to simply push or pull rod 26 for quicker longitudinal movement of rod 26 . Then, for finer adjustment of rod 26 , the threaded engagement is re-engaged and rod 26 is rotated to accomplish longitudinal movement. Further, in the references which are incorporated herein, various grasping members are provided to facilitate grasping and manipulation of rod 26 by the user. Also, electromechanical (e.g., solenoid) actuation of rod 26 can also be used.
In any case, in a preferred embodiment, catheter 12 is preferably formed of a suitable material to track through desired vasculature and to access a treatment site in the body. Therefore, in operation, prior to being inserted in the vasculature, catheter 12 is preferably filled with a solution, such as saline, such that all areas between rod 26 and the inner wall of lumen 18 are filled with the liquid solution to eliminate any dead space in lumen 18 . A therapeutic drug or other fluid material is then loaded into the distal end 14 of catheter 18 . This may be done, for example, by moving rod 26 to a position in which its distal end 30 is approximately coterminous with the opening 20 in lumen 18 of catheter 12 . Then, distal end 14 of catheter 12 is placed in the liquid solution to be introduced into the vasculature, and rod 26 is withdrawn a desired distance proximally. Withdrawing rod 26 proximally creates a vacuum in chamber 37 of catheter 12 and thus draws some of the liquid solution to be introduced into chamber 37 of catheter 12 . In one preferred embodiment, visual indicia are provided at the proximal end 28 of rod 26 to indicate to the user the total volume of liquid solution which has been drawn into the distal end 14 of catheter 12 based on proximal withdrawal of rod 26 .
After catheter 12 has been charged with the treatment solution, distal end 14 of catheter 12 is advanced through the vasculature and positioned proximate a desired treatment site. This can be accomplished in any number of known manners. For example, the distal tip 14 of catheter 12 can be provided as a cutting tip which can be used to pierce the skin and enter the desired vessel. Further, a separate cutting device can be provided which is used in conjunction with (e.g., over the top of) catheter 12 to introduce catheter 12 into the desired vessel. Still further, conventional guidewire or guide catheter assemblies can be used in conjunction with catheter 12 to guide catheter 12 to a desired location in the vasculature. Use of a guidewire with catheter 12 is preferably accomplished by either providing a separate lumen in catheter 12 , separate from lumen 18 , over which catheter 12 can track the guidewire. FIG. 1A illustrates a catheter 12 A including a separate guidewire lumen 18 - 1 having a guidewire 18 - 2 inserted therethrough to track the catheter from a percutaneous insertion position to a treatment site. Alternatively, catheter 12 can be formed as a single-operator-exchange catheter which includes a distal guidewire tube for tracking over the guidewire. Such arrangements are more fully discussed in the above-referenced U.S. patent applications.
In any case, distal end 14 of catheter 12 is advanced under suitable visualization, or according to other positioning techniques, until it resides proximate the site to be treated. Once appropriately positioned, the user advances rod 26 distally such that the distal end 30 of rod 26 creates a positive pressure within chamber 37 of lumen 18 at the distal end 14 of catheter 12 . This positive pressure forces the liquid treatment material out the distal opening 20 in catheter 12 so that it is administered at the desired.
In a preferred embodiment, the volume of the chamber 37 , which is defined by the interior periphery of catheter 12 and the distal tip of rod 26 , is preferably less than or equal to approximately 1 ml. Thus, it can be seen that the present invention can be used to directly administer a very low volume bolus of drug or other therapeutic material directly to a desired treatment site within the body, using a transluminal technique.
The specific materials used in implementing catheter system 10 can be any suitable, and commercially available materials. For example, manifold 22 is preferably made of an injection molded polycarbonate. Recess 38 within which o-ring 36 resides preferably has approximately a 0.123 inch diameter recess formed in manifold 22 , and the inner diameter of lumen 24 in manifold 22 is preferably approximately 0.042 inches. Catheter 12 can be formed of several sections, or only a single section. Catheter 12 can also be made of any suitable materials, depending on the performance characteristics desired. For example, catheter 12 can be made of an extruded polymer tube, stainless steel hypotube, or a composite material such as stainless steel braid encased in polyimide. To impart different characteristics along its length, catheter 12 may incorporate changes in diameter or combine different constructions. For example, catheter 12 may have a composite proximal section combined with a polymer distal section. Other suitable configurations can be used as well.
Rod 26 is preferably made of a stainless steel wire surrounded by a Kynar™ tube. The stainless steel wire preferably has a diameter of approximately 0.019 inches and a length of about 50 inches. The tube surrounding the wire preferably has an outside diameter of approximately 0.038 inches and an inside diameter of 0.020 inches. When fully actuated in the distal direction, rod 26 preferably extends such that its distal end 30 is co-terminus with the distal end 14 in catheter 12 . Positive stops (not shown) can optionally be provided at the distal end 14 of catheter 12 to limit the distal movement of rod 26 .
Generally, connections between the various polymer components may be made utilizing suitable grade medical adhesives or thermal bonds which are well known to those skilled in the art. Connections between metallic components are preferably made, for example, by utilizing solder, by brazing, welding, or other suitable techniques.
FIG. 2 is an enlarged view of a distal end portion 14 of catheter 12 . Some items shown in FIG. 2 are similar to those shown in FIG. 1, and are correspondingly numbered. However, FIG. 2 illustrates that, rather than rod 26 simply having distal end 30 , a plunger 40 is coupled to distal end 30 of rod 26 . Plunger 24 has an outer diameter which is approximately the same as, or just smaller than, the inner diameter of lumen 18 . Thus, when rod 26 is actuated in the distal direction, plunger 40 and rod 26 act much like a conventional syringe in that the distal chamber 37 defined by the distal end 14 of catheter 12 and plunger 40 , is pressurized. This forces the bolus of treatment material out through the distal opening 20 in catheter 12 . However, since plunger 40 is provided, the outer periphery of the remainder of actuating rod 26 need not be approximately the same as, or just smaller than, the interior periphery of lumen 18 . Instead, it can be much smaller. This significantly reduces the frictional forces acting on rod 26 as it is reciprocated within lumen 18 . It should be noted that plunger 40 can be a separate member attached to the distal end 30 of rod 26 , or it can be formed integrally with rod 26 simply by broadening out the distal end 30 of rod 26 .
FIG. 3 is another enlarged view of the distal end of rod 26 . Some items are similar to those shown in FIG. 2, and are similarly numbered. However, rather than having simply plunger 40 , the embodiment shown in FIG. 3 includes plunger head 42 . Plunger head 42 includes a pair of discs 44 and 46 which are mounted about the outer periphery of the distal end 30 of rod 26 . The discs 44 and 46 are preferably separated by an o-ring 48 formed of silicone or other suitable material and sized to fluidically seal lumen 18 . Discs 44 and 46 are also preferably formed of silicon rubber material, or other suitable material, or can be formed integrally with rod 26 .
FIG. 4 is an enlarged side sectional view of the distal end 14 of catheter 12 in accordance with another aspect of the present invention. Some items are similar to those shown in FIG. 2 and are correspondingly numbered. However, rather than simply having a distal opening 20 in the distal end 14 of catheter 12 , FIG. 4 illustrates that a separable seal 50 is provided in distal end 14 . Separable seal 50 preferably includes a rubber or polymer material inserted into the distal end 14 of catheter 12 and connected thereto with a suitable adhesive.
Separable seal 50 preferably includes a seam 52 therein. Seam 52 is simply formed by the abutment of the surfaces of seal 50 against one another, but those portions are not adhesively or otherwise sealed to one another (other than through friction). This arrangement allows the introduction of a conventional, small diameter, needle which is attached to a syringe containing the treatment solution into the distal end 14 (and hence chamber 37 ) of catheter 12 , and through seam 52 . Thus, the treatment solution can be injected into chamber 37 of catheter 12 , as plunger 40 is withdrawn in the proximal direction to draw the treatment solution therein.
Once the distal end 14 of catheter 12 is placed at the treatment site in the vasculature, distal actuation of rod 26 causes plunger 40 to create a pressure behind seal 50 causing seal 50 to separate at seam 52 and thus release the treatment solution at the desired location. In another preferred embodiment, seal 50 is a rolling diaphragm type of seal, or another suitable type of seal configuration.
FIG. 5 is an enlarged side sectional view of distal end 14 of catheter 12 in accordance with another aspect of the present invention. Similar items are similarly numbered to those shown in previous figures. However, FIG. 5 illustrates that the distal tip of catheter 12 is provided with a needle having a plurality of apertures 54 therein. Apertures 54 allow the treatment solution 37 to be withdrawn into the distal end 14 of catheter 12 , and to be forced out through the distal end thereof.
FIG. 6 illustrates yet another embodiment in accordance with the present invention. FIG. 6 is similar to FIG. 5 except that, rather than having uniformly spaced apertures 54 at the distal tip of catheter 12 , the distal tip or nozzle region is provided with side ports 56 which allow the treatment solution in chamber 37 to be directionally administered in the direction in which side ports 56 are disposed.
FIG. 7 illustrates another preferred embodiment in accordance with the present invention. Similar items are similarly numbered to those shown in previous figures. However, the distal end of catheter 12 , rather than being provided as a solid member with apertures therein, is provided as a porous needle portion 58 . Porous needle portion 58 can be provided as a microporous membrane, as a selectively porous membrane, or as any other suitable porous or capillary type material, suitable for the introduction of treatment solution from chamber 37 to the treatment site.
FIG. 8 is a side sectional view of a catheter system 60 in accordance with another preferred embodiment of the present invention. Some items are similar to those shown in FIGS. 1-7, and are similarly numbered. However, catheter 12 is also provided with a treatment fluid reservoir 62 defined by wall 64 which is preferably arranged about an exterior portion of catheter 12 . Reservoir 62 extends from a distal end 66 which is arranged just proximal of administration tip (or nozzle) 68 , to a proximal end 70 which is provided with a suitable fitting for receiving the treatment solution.
In operation, the treatment solution is preferably injected, using a standard syringe, through proximal portion 70 of reservoir 62 . A flapper valve 72 is preferably provided at distal end 66 of reservoir 62 to fluidically separate lumen 18 in catheter 12 from reservoir 62 . In the preferred embodiment, flapper valve 72 is arranged such that it pivots generally in a direction indicated by arrow 74 and is hingedly attached by hinge 76 to the wall of catheter 12 . Flapper valve 72 has a distal end 78 which engages a positive stop 80 on the inside of lumen 18 of catheter 12 .
Therefore, when plunger 40 is withdrawn proximally, this creates a vacuum or low pressure area within chamber 37 , relative to reservoir 62 . This causes flapper valve 72 to lift upwardly to allow fluid to escape from reservoir 62 into chamber 37 . Then, when plunger 40 is advanced distally, this creates a high pressure region in lumen 18 relative to reservoir 62 so that flapper valve 72 closes and the distal end 78 of flapper valve 72 abuts positive stop 80 .
As plunger 40 continues to be advanced distally, the treatment solution in chamber 37 is passed through administering tip 68 to the desired site. In the preferred embodiment, administering tip 68 is provided with very small apertures, or pores, or valved openings, such that a greater pressure differential is required between the interior lumen 18 and the exterior of catheter 12 to cause liquid material to pass through administering tip 68 than is required to lift flapper valve 72 . Therefore, as plunger 40 is withdrawn proximally, flapper valve 72 opens to allow the treatment material in chamber 62 to enter lumen 18 , but no fluid, or very little fluid, is drawn into lumen 18 from outside catheter 12 . Then, as plunger 40 is advanced distally, flapper valve 72 closes and a great enough pressure is built within chamber 37 to cause the treatment material to pass through administering tip 68 to the desired position.
It will thus be appreciated that the embodiment disclosed in FIG. 8 allows the user to position distal tip 14 of catheter 12 at the desired location within the body before chamber 37 is charged with the bolus of treatment material to be injected at the treatment site.
FIG. 9 shows another embodiment of the distal end 14 of catheter 12 in catheter system 60 . Similar items are similarly numbered to those shown in FIG. 8 . However, rather than providing reservoir 62 extending all the way from distal end 66 thereof to proximal end 70 thereof, reservoir 62 is maintained only at a distal portion of catheter 12 . Reservoir 62 is also provided with a suitable introduction valve 82 which can preferably be used in conjunction with a conventional syringe, to introduce the bolus of treatment material into reservoir 62 . By not requiring reservoir 62 to extend all the way to the proximal end 70 , the internal volume of reservoir 62 can be kept very small. This facilitates utilizing only a needed volume of treatment material. No extra material is required to fill the internal volume of reservoir 62 , since that volume is so small.
FIG. 10 shows another preferred embodiment of the catheter system 84 in accordance with the present invention. Catheter system 84 is similar to catheter system 60 shown in FIG. 8, and similar items are similarly numbered. However, catheter system 84 includes a modified form of treatment reservoir 62 . Rather than terminating in its proximal area at proximal end 70 , the proximal end of reservoir 62 in catheter system 84 extends all the way through proximal manifold 22 in the same fashion as lumen 24 . Also, reservoir 62 is provided with a reciprocally mounted rod 86 and plunger 88 . Further, rod 86 is sealably mounted within manifold 22 by seal configuration 90 which is similar to seal configuration 34 discussed with respect to FIG. 1 . The proximal ends of rods 26 and 86 can optionally be either connected to one another, or separate from one another for separate actuation by the user.
In any case, in order to introduce the bolus of treatment material into reservoir 62 , rod 86 and plunger 88 are advanced to the distal-most actuation point in which they abut a second flapper valve arrangement 92 . Flapper valve 92 is biased to normally close an aperture 94 against an inner portion 96 of the distal end of reservoir 62 . Then, the distal tip 14 of catheter 12 and reservoir 62 are placed in the drug solution to be administered. Rod 86 and plunger 88 are then withdrawn distally a desired amount such that flapper valve 92 opens to allow the fluid to be administered to enter reservoir 62 through aperture 94 . When the distal tip 14 of catheter 12 is appropriately positioned in the vasculature, rod 86 and plunger 88 are then advanced distally to charge catheter 12 by introducing the material to be administered from reservoir 62 , through flapper valve arrangement 72 , and into chamber 37 in catheter 12 . Once charged, catheter 12 is ready to administer the treatment solution. Thus, the user advances rod 26 and plunger 40 such that the bolus of treatment solution is injected from chamber 37 through the administering tip of catheter 12 to the desired site.
FIG. 11 shows another catheter system 98 in accordance with another preferred embodiment of the present invention. Similar items are similarly numbered to those shown in previous figures. Catheter system 98 is similar to catheter system 84 and similar items are correspondingly numbered. However, rather than providing two rods 26 and 86 , as in FIG. 10, catheter system 98 includes bifurcated rod 100 . Bifurcated rod 100 includes first leg portion 102 which is connected to plunger 40 and which resides within lumen 18 of catheter 12 . Bifurcated rod 100 also includes second leg portion 104 which is connected to plunger 88 and lies in reservoir 62 . Catheter system 98 shown in FIG. 11 is also preferably provided with a valve arrangement similar to valve arrangement 82 shown in FIG. 9 by which the treatment material is inserted into reservoir 62 .
In the embodiment shown in FIG. 11, the treatment material is simultaneously introduced from reservoir 62 into chamber 37 distal of plunger 40 , and it the bolus of material is injected at the desired site, as the user advances bifurcated rod 100 distally. Plunger 82 causes high pressure in reservoir 62 to move the bolus of treatment material from reservoir 62 into chamber 37 distal of plunger 40 . At the same time, plunger 40 causes high pressure to be developed in chamber 37 such that the bolus of material is advanced through the administering tip to the desired site.
FIG. 12 is similar to FIGS. 10 and 11, and similar items are similarly numbered. However, reservoir 62 is provided with different valve arrangements. Rather than flapper valve 72 , a simple aperture 106 is provided between reservoir 62 and lumen 18 . A plunger 108 is sized to completely cover aperture 106 when it is advanced to its distal most position (shown in phantom in FIG. 12 ). Thus, the operator can advance plunger 108 within reservoir 62 to charge lumen 18 with a bolus of material. The operator can, either simultaneously or separately, advance plunger 40 to administer the material through the tip of the catheter, once chamber 37 has been charged with the bolus.
Thus, it can be seen that the present invention provides a number of advantages over prior art infusion techniques. The present invention can be utilized to transluminally access a site to be treated within the body. The present invention can also be utilized to administer a therapeutic solution, or any desired solution, at that site. Further, the present invention can be utilized to administer only a very small volume bolus of material, preferably less than 1 milliliter at the site. This allows the pragmatic administration of even very expensive drugs in an efficient and accurate manner.
It should also be noted, of course, that the distal tip of the catheter can be arranged to provide any sort of nozzle configuration. The distal tip can be valved, it can have apertures uniformly distributed thereabout, it can have apertures directionally distributed thereabout, and it can have apertures which provide desired injection or dispersion characteristics.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | A catheter system includes a catheter having a proximal end, a distal end, and a lumen extending therein. An elongate mender slidably disposed in the lumen has a distal end located proximate the distal end of the catheter. An administering tip is disposed at the distal end of the catheter and is configured to express a bolus of liquid in response to positive pressure in a distal portion of the lumen created by movement of the elongate member distally in the lumen. The present invention also includes a method of administering a liquid to a treatment site. The distal end of the catheter is transluminally positioned proximate the treatment site. The catheter is charged by placing a bolus of the liquid in a distal end of the lumen between a distal tip of the catheter and a distal end of the elongate member. The elongate member is then moved distally within the lumen to express the bolus from the distal end of the catheter. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates generally to power management, and more particularly, to systems and methods for power management of different functional modes of operation of an integrated circuit such as a multi-core System on Chip (SOC).
To manage power consumption, an SoC may be partitioned into various power domains such that each peripheral belongs to one of the power domains. An SoC will further have multiple modes where some of the peripherals will be active and some will be powered off. The mode where only a minimum required set of peripherals are active, is referred to as a Standby mode. The subset of the modules that are always alive are referred to as being in the alive domain and the subset of the modules that are power gated are referred to as being in the power gated domain. Typically, isolation cells are used to isolate the alive domain from the power gated domain. The different functional modes of operation typically reside in different power domains and have different power requirements. Switching between modes typically involves stopping, pausing or re-setting various modules or peripherals comprising the SOC during a transition. These methods may interrupt operation of peripherals during a transition. These discontinuities in operation are undesirable for the end user of the system. Thus, it would be advantageous to provide a means for switching between modes having different power requirements, in a non-intrusive and easily managed manner from the end user's point of view, whereby continuity of operation of peripherals can be maintained. It would also be advantageous to minimize the time taken to switch between modes.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a schematic block diagram of an integrated circuit in accordance with the invention;
FIG. 2 is a schematic block diagram of two power domains of the integrated circuit of FIG. 1 ; and
FIG. 3 is a flow chart of a method of power management in an integrated circuit in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention, and is not intended to represent the only forms in which the present invention may be practised. It is to be understood that the same or equivalent functions may be accomplished by different embodiments that are intended to be encompassed within the spirit and scope of the invention. In the drawings, like numerals are used to indicate like elements throughout. Furthermore, terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that module, circuit, device components, structures and method steps that comprises a list of elements or steps does not include only those elements but may include other elements or steps not expressly listed or inherent to such module, circuit, device components or steps. An element or step proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements or steps that comprises the element or step.
In one embodiment, the present invention provides a method of power management of an integrated circuit (IC), where the IC has a main domain and a low power domain and capable of operating in a full power mode of operation in which both the main domain and low power domain are active and a low power mode of operation in which the main domain is inactive and the low power domain is active. The method comprises: operating the IC in the full power mode under the control of a central controller; receiving a first instruction to switch from the full power mode to the low power mode of operation; switching control of the low power domain from the central controller to the a low power mode controller, gating the main domain so that it is inactive, receiving a second instruction to revert to the full power mode, and subsequently controlling the main domain with the central controller and continuing to control the low power domain with the low power mode controller.
In another embodiment, the present invention provides an integrated circuit including a main domain and a low power domain and capable of operating in a full power mode of operation in which both the main domain and low power domain are active and a low power mode of operation in which the main domain is inactive and the low power domain is active. The low power domain includes a low power domain mode controller for controlling operation of the low power domain when operating in the low power mode and being arranged to continue controlling the low power domain on receipt of an instruction to switch from the low power mode to the full power mode.
The invention can provide a method for switching between a full power mode of operation where two domains are running synchronously, a low power mode where just one domain is operating or alive, and another full power mode where two domains are running asynchronously. A low power mode may comprise a reduced computing mode in which a small microcontroller subsystem (SMS) is operational but the main domain is gated. Thus, in effect, the invention supports various modes where an SOC is operating as a singular (full power subsystem), one or more low power subsystems or an asynchronous (full power) subsystem whereby each subsystem supports multiple power domains while switching between full power (“run”) and low power modes.
The invention permits the integrated circuit to transition from a full power mode to a “wait” or a “stop” mode while all domains are still powered or to a “standby” mode. The invention also permits the integrated circuit to transition from a low power mode to a “stop” or a “wait” mode while just the low powered domain is powered or to a “standby” mode. The invention also permits transitioning from an asynchronous full power mode to a synchronous full power mode, optionally moving through a “standby” mode in the process. These mode transitions may be represented in a state machine.
Advantageously, the invention permits a small microcontroller subsystem (SMS) or low power domain to continuously operate while a main subsystem domain is cycling from power on to off. When switching between low power and full power modes of operation, a main domain core and an SMS domain core can handshake based on a software interrupt. The invention also provides for switching between clock sources and data paths and the isolation of power domains on the fly.
In one example, the invention provides an architecture which supports asynchronous domains with common shared peripherals. The asynchronous domains operate as single entity while in a full power run mode with the peripheral and system resources being shared. As the peripherals and network fabric in both full power and low power modes are shared, there is no duplication of logic. The invention permits dynamic switching to multiple asynchronous power domains. In one embodiment, a main domain is kept power-gated while other (low power) subsystem domains operate on hierarchical controllers. On reverting to full power mode, the subsystem domains are switched back to a central controller. On moving from a full power mode of operation to a low power mode (or reduced computing mode), an SMS subsystem can take over control of necessary peripherals without disturbing any ongoing transactions. Hence, switching from a main run mode to a low power run mode is seamless from the perspective of peripherals operating in the low power run mode.
Referring now to FIG. 1 , a System on Chip device 100 in accordance with an embodiment of the present invention is shown. In this example, the SOC 100 has a first (main) domain 101 , a second (low power) domain 102 and a third, alive domain 103 . The main domain includes a (main) core 104 , a flash memory 105 and two functional (“IP”) modules 106 , 107 . Typically such a main domain may include further modules but in FIG. 1 just three are shown for the sake of clarity. The main domain is alive in a full power mode of operation only. A main regulator 108 can supply the main domain 101 and the low power domain 102 with a regulated voltage supply under certain operating conditions.
The second domain 102 in this example is an SMS domain which is alive in both a full power mode of operation and in a reduced computing mode of operation. The second domain 102 includes a low power core 109 , a Random Access Memory (RAM) 110 and two functional IP modules 111 , 112 . Typically such a domain may include further modules but in FIG. 1 just three are shown for the sake of clarity.
The third domain 103 in this example is an “always on” or “standby” domain which can be alive even when both the first and second domains 101 , 102 are inactive. Typically, the third domain includes several timer modules, wake-up circuitry and corresponding state machines as required to control power and isolations. FIG. 1 shows one timer module 113 and wake-up circuitry 114 .
The main domain 101 also includes a central controller 115 which controls an operating mode of the SOC and a central clock generator 116 . The SMS domain 102 also includes low power mode controller 117 which controls the SMS domain in a reduced computing mode of operation and in a full power, asynchronous subsystem mode of operation. The SMS domain 102 also includes a low power clock generator 118 . The low power mode controller 117 is operably coupled to the central controller 115 . The low power clock generator 118 is operably coupled to the central clock generator 116 and to the third domain 103 . The central clock generator 116 and the low power clock generator 118 form a hierarchical clocking system. The central controller 115 and low power mode controller 117 form a hierarchical mode control system. The low power mode controller 117 includes a state machine 119 for controlling mode transitions. The SOC 100 includes isolation control circuitry 121 . The isolation circuitry allows crossings between the main domain 101 and the low power domain 102 when they are operating asynchronously. The SOC also includes a low power regulator 122 which supplies the low power domain 102 with a regulated voltage supply under certain operating conditions.
The SOC 100 can make power mode transitions and can switch between synchronous and asynchronous modes of operation. In a synchronous, full power mode of operation, where both the main domain 101 and the SMS domain 102 are alive, both domains are controlled by the central controller 115 , powered by the main regulator 108 and clocked by the central clock controller 116 . In an asynchronous, full power mode of operation, where both the main domain 101 and the SMS domain 102 are alive, the main domain 101 is controlled by the central controller 115 , powered by the main regulator 108 and clocked by the central clock controller 116 but the SMS domain is controlled by the low power controller 117 , powered by the low power regulator 118 and clocked by the low power clock generator 120 . In a reduced computing mode of operation, the SMS domain is alive and the main domain is power gated. The SMS domain 102 is controlled by the low power controller 117 , powered by the low power regulator 118 and clocked by the low power clock generator 120 .
In FIG. 2 , a first power domain 201 and a second power domain 202 of an SOC are both connected to isolation circuitry 203 . In this example, the first domain is a low power or SMS domain (such as the SMS domain 102 of FIG. 1 ). In a first mode of operation, which is a reduced computing mode, the first domain is an alive domain and the second domain is a power-gated domain. FIG. 2 shows three exemplary peripherals 204 , 205 206 in the SMS domain 201 . These three peripherals 204 , 205 , 206 are alive. FIG. 2 shows three exemplary peripherals 207 , 208 , 209 in the second, power-gated domain 202 . The first, SMS domain 201 also includes a reset controller module 207 and a low power clock controller 208 . The power-gated domain 202 includes an SRAM 210 , central clock controller 211 and flash memory 212 and a core 213 . The reset controller 207 is provided for the purpose of sequencing resets to the switchable domain components (such as the core 213 and peripherals 207 , 208 , 209 ). While in an asynchronous mode (with both first and second domains alive), a reset source of the second domain may be allowed to reset the entire SOC, The low power clock controller 208 together with the central clock controller controls the switching of clock sources; that is, switching between a full power (or central) clock source and a low power clock source, the latter supplying the first domain 201 . The central clock controller 211 in the second domain 202 manages the sequencing of clock enabling and disabling to the core 213 and the peripherals 207 , 208 , 209 of the second domain 202 during a mode transition and during Run modes. Isolation between the two domains 201 and 202 remains active when in asynchronous mode and both domains are alive. The isolation circuitry 203 can be arranged to ensure that any asynchronous crossings from the alive domain to the power-gated domain do not impact the functionality of the main domain 202 . Typically, the isolation circuitry 203 includes synchronizers (not shown) which are provided to take care of meta-stability issues. These synchronizers are bypassed in a full power, singular subsystem mode and activated in a full power, asynchronous mode.
A method of power management of an integrated circuit (such as the SOC described with reference to FIG. 1 ) by switching between full power and reduced power modes of operation will now be described with reference to the flow chart of FIG. 3 and to FIG. 1 . In a full power mode of operation, both the main domain 101 and low power (SMS) domain 102 are powered up and active (i.e., alive). In a low power, reduced computing mode of operation, the main domain is inactive (i.e., power-gated) and the low power, (SMS) domain is active. Switching between full power and low power modes of operation is initiated by writing into a register in either the central controller or the low power mode controller.
At 301 , all domains are powered up and at 302 , the SOC runs as a singular subsystem. That is, the main domain and low power domain are run under the control of the central controller 115 , receive power from the main regulator 109 and clock signals from the central clock generator 116 .
At 303 the SOC generates an instruction to switch from a full power mode of operation to a low power (or reduced computing) mode of operation. This instruction is written into a register in the central controller by a core of the SOC. In an alternative embodiment, this instruction is written into the low power mode controller.
At 304 the low power mode of operation is entered which is typically one of reduced computing capability whereby only the SMS 102 is active (or alive). This transition involves switching control of the low power (SMS) domain from the central controller to the low power controller mode 117 and gating the main domain so that it becomes inactive. More specifically, the main core 104 and peripherals (eg. Flash 105 and modules 106 , 107 ) of the main domain 101 are stopped. Generation of clocking signals is switched over to the low power clock generator 118 and IO states corresponding to the main domain are latched. An isolation layer around the stopped main domain is enabled by the isolation control circuitry 121 . Power of the stopped domain is removed. The low power domain now receives power from the low power regulator 122 and clock signals from the low power clock generator 118 .
At 305 , an instruction, generated by a core of the SOC, to revert to a full power mode of operation is received at the low power mode controller. This instruction can be written into a register of the low power mode controller. This may be an interrupt requesting service which requires the main domain to be activated. On receipt of this instruction, signal crossings are allowed (by the isolation control circuitry 121 ) for initialization of the currently inactive main domain. The central clock generator 116 is enabled. Arbitration and synchronization for shared resources are enabled. The power-up sequence of the main domain is initiated. Latched IO are cleared after initialization. While the main domain is being re-enabled, all low power domain (SMS) modules continue to operate seamlessly under the control of the low power mode controller 117 and receive clock signal from the low power clock generator 118 .
At 306 , the SOC is now running in a full power mode as two asynchronous sub-systems. The main domain is being powered by the main regulator 108 , controlled by the central controller 115 and receiving clocking signals from the central clock generator 116 . The low power domain is being powered by the low-power regulator 122 , controlled by the low power mode controller 117 and receiving clocking signals from the low power generator 118 . Optionally, after step 306 , the main domain can then go back again to a power-gated mode (step 303 ) and can recursively go through power cycles while any application running in the low-power domain continues to operate seamlessly. This can be controlled through the state machine 119 . As a main domain can cycle while an SMS domain is active, this helps to maintain the continuity of operation.
At 307 , an instruction to return to a synchronous (singular subsystem) full power mode is generated by a core of the SOC and received by either the low-power mode controller 117 or central controller 115 . Following this instruction, a key-based handshake is used in order to merge the two asynchronous power subsystems into one by placing keys in the central controller 115 and in the low-power mode controller 117 . For example, a key is written into the low power mode controller 117 (or into the central controller 115 ) and this raises an interrupt which is sent to the main core 104 of the main domain (or to the core of the low power domain). In response, the main core (or low power core) writes the key into the central controller 115 (or low power controller). A key match is done and the state machine 119 merges the two asynchronous systems into one.
At 308 a handshake completes any ongoing transactions in the low-power domain and the low-power domain switches to being controlled by the central controller 115 and being clocked by the central clock generator 116 and receiving power from the main regulator. Any isolations between the low power domain and the main domain are dissolved.
At 309 the SOC now runs in a full power mode as a singular subsystem with all cores enabled.
The SOC can transition to a standby mode of operation 310 whereby just the third domain 103 is active. This can be done after step 304 when the SOC has switched to the low power mode of operation, for example. In this case, entering a standby mode of operation can be done by gating the low power domain so that it is inactive. Then, on receipt of the instruction to revert to a full power mode of operation, the low power domain is controlled with the low power controller so that it becomes active and the method continues from step 305 . Alternatively, the SOC can transition to a standby mode after step 302 or 309 , that is, while running in a full power mode as a singular subsystem. Alternatively, the SOC can transition to a standby mode after step 306 , that is, when running in full power mode as two asynchronous subsystems. Alternatively, the SOC can move through a standby mode whilst transitioning from an asynchronous full power mode of operation to a synchronous, full power mode of operation, that is, after receiving the instruction at step 307 .
It will be noted that advantageously, the transition time involved in switching from a low power mode to a full power mode is reduced when employing the asynchronous power subsystem arrangement of the present invention because the transition does not require the SOC to go through a quiescent stage but can occur once the main domain has been properly primed.
The connections as discussed herein may be any type of connection suitable to transfer signals from or to the respective nodes, units or devices, for example via intermediate devices. Accordingly, unless implied or stated otherwise, the connections may for example be direct connections or indirect connections. The connections may be illustrated or described in reference to being a single connection, a plurality of connections, unidirectional connections, or bidirectional connections. However, different embodiments may vary the implementation of the connections. For example, separate unidirectional connections may be used rather than bidirectional connections and vice versa. Also, plurality of connections may be replaced with a single connection that transfers multiple signals serially or in a time multiplexed manner. Likewise, single connections carrying multiple signals may be separated out into various different connections carrying subsets of these signals. Therefore, many options exist for transferring signals.
Those skilled in the art will recognize that the boundaries between logic blocks are merely illustrative and that alternative embodiments may merge logic blocks or circuit elements or impose an alternate decomposition of functionality upon various logic blocks or circuit elements. Thus, it is to be understood that the architectures depicted herein are merely exemplary, and that in fact many other architectures can be implemented which achieve the same functionality.
Any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermediate components. Likewise, any two components so associated can also be viewed as being “operably connected” or “operably coupled” to each other to achieve the desired functionality.
Furthermore, those skilled in the art will recognize that boundaries between the above described operations merely illustrative. The multiple operations may be combined into a single operation, a single operation may be distributed in additional operations and operations may be executed at least partially overlapping in time. Moreover, alternative embodiments may include multiple instances of a particular operation, and the order of operations may be altered in various other embodiments.
Also for example, in one embodiment, the illustrated examples may be implemented as circuitry located on a single integrated circuit or within a same device. Further, the entire functionality of the modules shown in FIG. 1 may be implemented in an integrated circuit. Such an integrated circuit may be a package containing one or more dies. Alternatively, the examples may be implemented as any number of separate integrated circuits or separate devices interconnected with each other in a suitable manner. An integrated circuit device may comprise one or more dies in a single package with electronic components provided on the dies that form the modules and which are connectable to other components outside the package through suitable connections such as pins of the package and bond wires between the pins and the dies.
The description of the preferred embodiments of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or to limit the invention to the forms disclosed. It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but covers modifications within the spirit and scope of the present invention as defined by the appended claims. | A power management system permits a small microcontroller subsystem or low power domain to continuously operate while a main subsystem domain is cycling from power on to off. The power management system supports asynchronous domains with common shared peripherals. The asynchronous domains operate as a single entity while in a full power mode with the peripheral and system resources being shared. The system can be used in automotive systems where most of the system is power-gated leaving just a power regulator controller, some counters and an input/output segment alive for wakeup purposes. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This present application is related to and claims priority from U.S. Provisional Application No. 60/318,971, Schoen et al., filed Sep. 13, 2001.
TECHNICAL FIELD
The present invention relates to a method for producing a grain oriented electrical steel strip with good magnetic properties from a continuously cast thin strip. The cast strip is cooled in a manner whereby a grain growth inhibitor needed to develop the grain orientation by the process of secondary grain growth is precipitated as a finely and uniformly dispersed phase. The cast strips produced by the present invention exhibit very good physical characteristics.
BACKGROUND OF THE INVENTION
Grain oriented electrical steels are characterized by the type of grain growth inhibitors used, the processing steps used and the level of magnetic properties developed. Typically, grain oriented electrical steels are separated into two classifications, conventional (or regular) grain oriented and high permeability grain oriented, based on the level of the magnetic permeability obtained in the finished steel sheet. The magnetic permeability of steel is typically measured at a magnetic field density of 796 A/m and provides a measurement of the quality of the (110)[001] grain orientation, as measured using Millers indices, in the finished grain oriented electrical steel.
Conventional grain oriented electrical steels typically have magnetic permeability measured at 796 A/m of greater than 1700 and below 1880. Regular grain oriented electrical steels typically contain manganese and sulfur (and/or selenium) which combine to form the principal grain growth inhibitor(s) and are processed using one or two cold reduction steps with an annealing step typically used between cold reduction steps. Aluminum is generally less than 0.005% and other elements, such as antimony, copper, boron and nitrogen, may be used to supplement the inhibitor system to provide grain growth inhibition. Conventional grain oriented electrical steels are well known in the art. U.S. Pat. Nos. 5,288,735 and 5,702,539 (both incorporated herein by reference) describe exemplary processes for the production of conventional grain oriented electrical steel whereby one or two steps of cold reduction, respectively, are used.
High permeability grain oriented electrical steels typically have magnetic permeability measured at 796 A/m of greater than 1880 and below 1980. High permeability grain oriented electrical steels typically contain aluminum and nitrogen which combine to form the principal grain growth inhibitor with one or two cold reduction steps with an annealing step typically used prior to the final cold reduction step. In many exemplary processes for the production of high permeability grain oriented electrical steels in the art, other additions are employed to supplement the grain growth inhibition of the aluminum nitride phase. Such exemplary additions include manganese, sulfur and/or selenium, tin, antimony, copper and boron. High permeability grain oriented electrical steels are well known in the art. U.S. Pat. Nos. 3,853,641 and 3,287,183 (both incorporated herein by reference) describe exemplary methods for the production of high permeability grain oriented electrical steel.
Grain oriented electrical steels are typically produced using ingots or continuously cast slabs as the starting material. Using present production methods, grain oriented electrical steels are processed wherein the starting cast slabs or ingots are heated to an elevated temperature, typically in the range of from about 1200° C. to about 1400° C., and hot rolled to a typical thickness of from about 1.5 mm to about 4.0 mm, which is suitable for further processing. The slab reheating in current methods for the production of grain oriented electrical steels serves to dissolve the grain growth inhibitors which are subsequently precipitated to form a fine dispersed grain growth inhibitor phase. The inhibitor precipitation can be accomplished during or after the step of hot rolling, annealing of the hot rolled strip, and/or annealing of the cold rolled strip. The additional step of breakdown rolling of the slab or ingot prior to heating of the slab or ingot in preparation for hot rolling may be employed to provide a hot rolled strip which has microstructural characteristics better suited to the development of a high quality grain oriented electrical steel after further processing is completed. U.S. Pat. Nos. 3,764,406 and 4,718,951 (both incorporated herein by reference) describe exemplary prior art methods for the breakdown rolling, slab reheating and hot strip rolling used for the production of grain oriented electrical steels.
Typical methods used to process grain oriented electrical steels may include hot band annealing, pickling of the hot rolled or hot rolled and annealed strip, one or more cold rolling steps, a normalizing annealing step between cold rolling steps and a decarburization annealing step between cold rolling steps or after cold rolling to final thickness. The decarburized strip is subsequently coated with an annealing separator coating and subjected to a high temperature final annealing step wherein the (110)[001] grain orientation is developed.
A strip casting process would be advantageous for the production of a grain oriented electrical steel since a number of the conventional processing steps used to produce a strip suitable for further processing can be eliminated. The processing steps which can be eliminated include, but are not limited to, slab or ingot casting, slab or ingot reheating, slab or ingot breakdown rolling, hot roughing and hot strip rolling. Strip casting is known in the art and is described, for example, in the following U.S. Pat. Nos. (all of which are incorporated herein by reference): 6,257,315; 6,237,673; 6,164,366; 6,152,210; 6,129,136; 6,032,722; 5,983,981; 5,924,476; 5,871,039; 5,816,311; 5,810,070; 5,720,335; 5,477,911; and 5,049,204. When employing a strip casting process, at least one casting roll and, preferably, a pair of counter rotating casting rolls is used to produce a strip that is less than about 10 mm in thickness, preferably less than about 5 mm in thickness and, more preferably, about 3 mm in thickness. The application of strip casting to the production of grain oriented electrical steels differs from processes established for the production of stainless steels and carbon steels due to the technically complex roles of the grain growth inhibitor system (such as MnS, MnSe, AIN and the like), grain structure and crystallographic texture which are essential to produce the desired (110)[001] texture by secondary grain growth.
SUMMARY OF THE INVENTION
The present invention relates to a process for producing grain oriented electrical steel from a cast strip wherein rapid secondary cooling of the cast strip is employed to control the precipitation of the grain growth inhibiting phases. The cooling process can be accomplished by the direct application of cooling sprays, directed cooling air/water mist, or impingement cooling of the cast strip onto solid media such as a metal belt or sheet. While the cast strip is typically produced using a twin roll strip caster, alternative methods using a single casting roll or a cooled casting belt may also be used to produce a cast strip having a thickness of about 10 mm or less.
Specifically, the present invention provides a method for producing grain oriented electrical steel strip comprising the steps of:
(a) forming a continuously cast electrical steel strip having a thickness of no greater than about 10 mm;
(b) cooling said strip to a temperature of from about 1150° C. to about 1250° C. such that it becomes solidified; and
(c) subsequently performing a rapid secondary cooling on said steel strip wherein the strip is cooled at a rate of from about 65° C./second to about 150° C./second to a temperature of no greater than about 950° C.
In one embodiment, the steel strip produced by the foregoing process is coiled at a temperature below about 850° C., preferably below about 800° C.
In another embodiment, the present invention provides a method for producing a grain oriented electrical steel strip comprising the steps of:
(a) forming a continuously cast electrical steel strip having a thickness of no greater than about 10 mm;
(b) cooling said strip to a temperature below about 1400° C. such that it becomes at least partially solidified;
(c) performing an initial secondary cooling on said solidified strip to a temperature of from about 1150° C. to about 1250° C.; and
(d) subsequently performing a rapid secondary cooling on said steel strip wherein the strip is cooled at a rate of from about 65° C./second to about 150° C./second to a temperature of no greater than about 950° C.
In one embodiment of this invention, the steel strip produced by the foregoing process is coiled at a temperature below about 850° C., preferably below about 800° C.
This process provides a grain oriented electrical steel having the appropriate grain orientation, and also provides steel with good physical properties, such as reduced cracking.
For purposes of clarity, the rate of cooling during solidification will be considered to be the rate at which the molten metal is cooled through the casting roll or rolls wherein the substantially solidified cast strip is cooled to a temperature at or above about 1350° C. The secondary cooling of the cast strip will be considered divided into two stages: (i) initial secondary cooling is conducted after solidification to a temperature range of about 1150 to 1250° C., and, (ii) rapid secondary cooling is employed after the strip is discharged from the initial cooling and serves to control the precipitation of the grain growth inhibiting phase(s) present in the steel.
Prior to initiation of rapid secondary cooling, it is an optional feature of the present invention to slow the rate of initial secondary cooling of the cast strip to allow the strip temperature to equalize before initiating rapid secondary cooling. For example, the cast and solidified strip may be discharged into and/or pass through an insulated chamber (see FIG. 1) to both slow the initial secondary cooling rate and/or to equalize the strip temperature after solidification. Although not critical to the practice of the present invention, a nonoxidizing atmosphere may be optionally used in the chamber to minimize the surface scaling, thereby helping to maintain a low surface emissivity which can further slow the rate of initial secondary cooling preceding the rapid secondary cooling of the present invention. These optional configurations are helpful as they permit rapid secondary cooling of the solidified strip to be conducted at a substantially greater distance from the strip casting machine, thereby, providing some isolation of the liquid steel handling and strip casting equipment from the rapid secondary cooling equipment. In this manner, any negative interaction between the media used for the rapid secondary cooling process of the present invention and the liquid steel handling and/or strip casting process and/or equipment can be minimized. For example, if a water spray or a water/air mist is used as the cooling media, the liquid steel and/or strip casting equipment must be protected from any steam formed as a result of rapid secondary cooling. Moreover, conducting both the initial and rapid secondary cooling in a nonoxidizing atmosphere will minimize metal yield losses due to oxidation of the strip during cooling.
During solidification, the liquid metal is cooled at a rate of at least about 100° C./second to provide a cast and solidified strip having a temperature in excess of about 1300° C. The cast strip is subsequently cooled to a temperature of about 1150° C. to about 1250° C. at a rate of at least about 10° C./second, whereupon the strip is subjected to rapid secondary cooling to reduce the strip temperature from about 1250° C. to about 850° C. In the broad practice of this invention, rapid secondary cooling is conducted at a rate of at least about 65° C./second while a preferred cooling rate is at least about 75° C./second, and a more preferred rate is at least about 100° C./second. The cast and cooled strip may be coiled at a temperature below about 800° C. for further processing.
In the practice of the invention, several methods for the rapid secondary cooling have been employed such as direct impingement cooling to provide a cooling rate at or in excess of about 150° C./second or water spray cooling to provide a cooling rate at or in excess of about 75° C./second. It has been further found in the development of the present invention that producing a cast and rapidly cooled electrical steel strip with good mechanical and physical characteristics may limit the rate of rapid secondary cooling. Rapid secondary cooling at rates in excess of about 100° C./second requires that the strip be cooled in a manner which prevents significant temperature differentials to develop during cooling since the strain created by differential cooling has been found to result in cracking of the cast strip, making the cast strip unusable for further processing.
The conditions for the rapid secondary cooling steel strip may be controlled using a system comprising a spray nozzle design wherein the rapid cooling is provided by establishing a desired spray water density. The spray density may be controlled by the water flow rate, the number of spray nozzles, the nozzle configuration and type, spray angle and length of cooling zone. It has been found that a water spray density of from about 125 liters per minute per square meter of surface area (l/[min-m 2 ]) to about 450 l/[min-m 2 ] provides the desired cooling rate. Since it is difficult to monitor the strip temperature during water spray cooling due to the variations in and turbulence of the water film applied onto the strip, water spray density measurements are typically used.
The term “strip” is used in this description to describe the electrical steel material. There are no limitations on the width of the cast material except as limited by the width of the casting surface of the roll(s). The cast and cooled strip is typically further processed using hot and/or cold rolling of the strip, annealing of the strip prior to cold rolling to final thickness in one or more stages, annealing between cold rolled stages if more than more than one cold reduction stage is used, decarburization annealing of the finally cold rolled strip to lower the carbon content to less than about 0.003%, applying an annealing separator coating such as magnesia, and a final annealing step wherein the (110)[001] grain orientation is developed by the process of secondary grain growth and the final magnetic properties are established.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simple layout for a twin drum caster to illustrate use of the process of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The development of the (110)[001] grain orientation is important in achieving the desired magnetic properties in a conventional or high permeability grain oriented electrical steel strip. To achieve such grain orientation, several conditions should be satisfied. These include: (i) the presence of nuclei grains having an orientation at or near (110)[001]; (ii) the presence of a primary recrystallized structure with a distribution of crystalline orientations which foster the growth of (110)[001] nuclei; and (iii) a means of retarding the primary grain growth of the non-(110)[001] oriented grains and allowing the (110)[001] oriented grains to preferentially grow and consume the non-(110)[001] oriented grains. The inclusion of a fine, uniform dispersion of inhibitor particles, such as MnS and/or AlN, is a common means of achieving such grain growth inhibition.
The cooling rates provided by present conventional methods of slab or ingot casting provide very slow cooling during and after solidification, resulting in the precipitation of the inhibitor phase(s) as a coarse particulate. In the application of strip casting to the production of grain oriented electrical steels, the formation of the coarse inhibitor particulate phase commonly found in ingots and continuous slab casting can be avoided by controlled cooling of the cast strip. Accordingly, the inhibitor phase(s) can be precipitated into fine and dispersed form in the cast and cooled strip, thereby eliminating the need for a high temperature slab reheating treatment to dissolve the grain growth inhibiting phase(s).
For the present invention, the liquid steel may be solidified into a strip form using either a single or two opposing counter rotating casting rolls or drums (or twin roll), cast onto a moving cooling belt or strip, or a combination thereof. In a typical method of the present invention, the cast steel strip is produced using a twin roll strip casting machine. In such a process, the liquid steel, typically at a temperature above 1500° C., is cooled at a rate of at least about 100° C./second to provide a cast and solidified strip, said cast strip exiting the twin roll casting machine at a temperature of about 1350° C. After exiting the casting roll(s), the strip is further cooled to a temperature of from about 1250° C. to about 1150° C., at which temperature the cast strip is subjected to rapid secondary cooling at a rate of greater than about 65° C./second; and preferably greater than about 70° C./second; more preferably greater than about 75° C./second; and, most preferably at a rate of greater than about 100° C./second, to lower the strip temperature to below about 950° C.; preferably below about 850° C.; preferably below about 800° C.; and, more preferably, below about 750° C.; and, most preferably, below about 700° C. The time required for rapid secondary cooling is a function of the production speed of strip caster, the rapid secondary cooling rate and the desired length of the rapid secondary cooling zone. In the practice of the present invention, it is preferred that rapid secondary cooling be applied with a high degree of uniformity both across the width of the strip and on the top and bottom surfaces of the strip, particularly at the end of the cooling zone (see FIG. 1 ). In this manner, a strip with good physical integrity and free of cracks can be produced.
The spray density of the cooling water is the preferred method for defining the cooling rate. The spray density is given by the following expression:
Spray Density= Q /(π/4) d 2
Where:
Q=water flow rate (using a single nozzle)
d=diameter of spray area
In the practice of the present invention, the water spray density typically used is between about 125 and about 450 l/[min-m 2 ; preferably between about 300 and about 400 l/[min-m 2 ]; and, more preferably between about 330 and about 375 l/[min-m 2 ]. The temperature of the water used for cooling is preferably between about 10° C. and about 75° C., preferably about 25° C. The spray on a given area of strip typically lasts between about 3 and about 12 seconds, preferably between about 4 and about 9 seconds (i.e., the length of time the strip is in the spray zone).
FIG. 1 is a simple layout for a twin drum caster which utilizes the process of the present invention. In the embodiment shown in this figure, molten steel (1) moves through the twin roll caster (2), forming steel strip (3). The strip (3) discharges from the caster at about 1300° C.-1400° C. The strip (3) moves through an insulated initial cooling chamber (4) wherein the temperature of the strip is reduced to about 1200° C. This chamber (4) slows the cooling rate of the strip to allow the water cooling system to be located at a greater distance from the caster. The strip then moves to a water spray cooling system (5) which includes rollers (6) for moving the strip through and water sprays (7) on both sides of the strip. It is here that the rapid secondary cooling takes place. The water sprays (7) cool the strip from about 1200° C. to about 800° C. In this particular embodiment, the spray is divided into three discrete zones, each of which has a different water spray density (as indicated in the figure). After cooling, the strip is coiled on a coiler (8), at a temperature below about 800° C. Typically, the coiling temperature is about 725° C.
EXAMPLE 1
A conventional grain oriented electrical steel having the composition shown in Table I is melted and cast into a sheet having a thickness of about 2.9 mm and a width of about 80 mm. The cast sheets are held at a temperature of about 1315° C. for a time of about 60 seconds in a nonoxidizing atmosphere and cooled at a rate of about 25° C./second in ambient air to a temperature of about 1200° C. The sheets are subsequently subjected to rapid secondary cooling by water spraying both surfaces for a time of about 7 seconds at which point the surface temperature of the sheet is at or below about 950° F.
TABLE I
Composition of Grain Oriented Electrical Steel
C
Mn
S
Si
Cr
Ni
Cu
Al
N
0.034
0.056
0.024
3.10
0.25
0.08
0.09
<0.0030
<0.0060
Table II summarizes the conditions used for and results from the applications of rapid secondary cooling:
TABLE II
Effect of Cooling Spray Water Density on Physical Quality of
Strip Cast Grain Oriented Electrical Sheet Steel
Maximum Water
Cooling Water
Spray Density,
Test
Cooling Water
Spray Duration,
Pressure,
liters/(min-m 2 )
Run
Temperature, ° C.
seconds
kPascals
per side
Cracking
1
25° C.
7 seconds
1241
1108
yes
2
25° C.
7 seconds
552
739
yes
3
25° C.
7 seconds
345
358
no
4
25° C.
7 seconds
345
358
no
5
25° C.
7 seconds
414
451
no
6
25° C.
7 seconds
483
572
yes
7
25° C.
7 seconds
483
571
yes
The effect of using cooling water spray densities exceeding about 570 l/[min-m 2 ] and up to 1100 l/[min-m 2 ] per side on each sheet surface resulted in cracking of the steel sheet during rapid secondary cooling.
EXAMPLE 2
Additional samples of the conventional grain oriented electrical steel of Example 1 were subjected to the rapid secondary cooling of the cast strip as shown in Table III below.
TABLE III
Effect of Cooling Spray Water Density on Physical Quality of Strip Cast Grain Oriented Electrical Steel Sheet
Maximum
Water Spray
Spray
Test
Water
Water Pressure,
Density,
Duration,
End-Cooling
Run
Temperature, ° C.
kPascals
liters/(min-m 2 )
seconds
Temperature, ° C.
Cracking
Quality of MnS Precipitation
1
25° C.
1379
398
>20 seconds
100° C.
slight
2
25° C.
1207
359
3.4 seconds
100° C.
no
Fair - Little precipitation
3
25° C.
862
332
4.0 seconds
—
no
Fair - Little precipitation
4
25° C.
862
332
8.5 seconds
no
Good - Fine and uniformly dispersed MnS
precipitation
5
25° C.
689
329
4.4 seconds
—
no
Good - Fine and uniformly dispersed MnS
precipitation
6
25° C.
517
305
8.3 seconds
600° C.
no
Fair - slight coarsening of MnS precipitates,
preferential precipitation on grain boundaries
7
25° C.
345
266
12.8 seconds
600° C.
no
Fair - slight coarsening of MnS precipitates,
preferential precipitation on grain boundaries
8
25° C.
345
199
17.0 seconds
600° C.
no
Fair - slight coarsening of MnS precipitates,
preferential precipitation on grain boundaries
The spray density is varied from about 200 l/[min-m 2 ] to about 400 l/[min-m 2 ] per side while the ending temperature of the rapid secondary cooling method of the present invention is varied from about 100° C. and about 600° C. After cooling to room temperature, the sheets are inspected for physical characteristics and sectioned to examine the morphology of the grain growth inhibitor. As shown in Table III, rapid secondary cooling at a cooling water density in excess of about 300 l/[min-m 2 ] per side is sufficient to provide control of inhibitor precipitation while cooling water densities below about 300 l/[min-m 2 ] per side result in slight coarsening precipitation of the inhibitor phase.
EXAMPLE 3
Conventional grain oriented electrical steels having the compositions shown in Table IV are melted and cast into sheets of a thickness of about 2.5 mm using a twin roll strip caster. The cast and solidified sheet is discharged into air at a temperature of about 1415° C. and cooled in an insulated enclosure at a rate of about 15° C./second to a surface temperature of about 1230° C. at which point the cast strip is subjected to rapid secondary cooling using the water spray method of the present invention. Rapid secondary cooling is accomplished by applying spray water to both surfaces of the sheet.
TABLE IV
Composition of Grain Oriented Electrical Steel
Example
C
Mn
S
Si
Cr
Ni
Cu
Al
N
A
0.029
0.064
0.023
3.28
0.25
0.080
0.080
0.0060
0.0058
B
0.033
0.051
0.026
2.94
0.25
0.080
0.082
0.0005
0.0065
Steel A of Table IV is provided with rapid secondary cooling whereby a water spray density 1000 l/[min-m 2 ] on each surface of the sheet is applied for a time of about 5 seconds to lower the strip surface temperature from about 1205° C. to about 680° C. Steel B is provided with rapid secondary cooling using a water spray density of about 175 l/[min-m 2 ] for about 0.9 second followed by a 400 l/[min-m 2 ] application for about 4.5 seconds on each surface of the steel sheet to lower the strip surface temperature from about 1230° C. to about 840° C. The cast and cooled strip is air cooled to 650° C., coiled and cooled thereafter to room temperature.
Extensive cracking occurred with Steel A, resulting in a material which could not be further processed, while Steel B has excellent physical characteristics and is readily processable. Examination of the MnS precipitates showed that the cooling conditions used for Steels A and B both provide a fine and uniformly dispersed inhibitor, as was desired.
EXAMPLE 4
Sheet samples from Steel B of the prior example are processed using the following conditions. First, the cast strip is heated to about 150° C. and cold rolled to a range of a thickness of about 1.25 mm, about 1.65 mm and about 2.05 mm after which the sheets are annealed in a mildly oxidizing atmosphere for about 10-25 seconds at or above a temperature of about 1030° C. and a maximum temperature of about 1050° C. The samples are further cold rolled to a thickness of about 0.56 mm after which the sheets are annealed in a nonoxidizing atmosphere for about 10-25 seconds at or above a temperature of about 950° C. and a maximum temperature of about 980° C. The samples are cold rolled to a final thickness of about 0.26 mm after which the sheets are decarburization annealed to less than about 0.0025% carbon in a humidified hydrogen-nitrogen atmosphere using an annealing time of about 45-60 seconds at or above a temperature of about 850° C. and a maximum temperature of 870° C. The samples are then coated with an annealing separator coating comprised basically of magnesium oxide and further subjected to a high temperature anneal to effect secondary grain growth and to purify the steel of sulfur, selenium, nitrogen and like elements. The high temperature anneal is conducted such that the samples are heated in an atmosphere comprised of hydrogen using an annealing time of 15 hours to a temperature at or above 1150° C. After the high temperature anneal step is completed, the samples are scrubbed to remove any remaining magnesium oxide, sheared into dimensions appropriate for testing and stress relief annealed in an nonoxidizing atmosphere comprised of 95% nitrogen and 5% hydrogen, using an annealing time of two hours at or above 830° C., after which their magnetic properties are determined.
TABLE V
Magnetic Properties of Grain Oriented Steel
Thickness After
Sample
Magnetic
Specimen
First Cold Rolling
Final
Permeability at
Core Loss at 1.5 T
Core Loss at 1.7 T
ID
(mm)
Thickness
796 A/m
and 60 Hz (w/kg)
and 60 Hz (w/kg)
B-1
2.03
0.262
1849
1.10
1.59
0.261
1847
1.05
1.57
0.261
1858
1.04
1.48
0.262
1841
1.12
1.65
B-2
1.65
0.267
1849
1.10
1.60
0.266
1859
1.01
1.47
0.262
1872
1.04
1.47
0.263
1867
1.02
1.46
B-3
1.27
0.264
1864
1.04
1.48
0.265
1862
1.11
1.60
0.263
1864
1.08
1.55
0.264
1848
1.13
1.66
The magnetic permeability measured at 796 A/m and core losses measured at 1.5T 60 Hz and 1.7T 60 Hz in Table show that Steel B (present invention) provides magnetic properties comparable to a conventional grain oriented electrical steel made using present conventional production methods. | A method for continuously casting grain oriented electrical steel is disclosed. This method utilizes a controlled rapid cooling step, such as one using a water spray, to control the grain orientation in the finished product. The product formed not only has the appropriate grain orientation but also has good physical properties, for example, minimized cracking. In this process, after a continuously cast electrical steel strip is formed, the strip undergoes an initial secondary cooling to from about 1150 to about 1250° C., and finally undergoes a rapid secondary cooling (for example, by water spray) at a rate of from about 65° C./second to about 150° C./second to a temperature of no greater than about 950° C. | 1 |
TECHNICAL FIELD
The present invention relates to a method and apparatus for detecting faults in a fuel injector arrangement, and particularly to a method and apparatus for detecting short circuit faults in piezoelectric fuel injectors.
BACKGROUND TO THE INVENTION
In a direct injection internal combustion engine, a fuel injector is provided to deliver a charge of fuel to a combustion chamber prior to ignition. Typically, the fuel injector is mounted in a cylinder head with respect to the combustion chamber such that its tip protrudes slightly into the chamber in order to deliver a charge of fuel into the chamber.
One type of fuel injector that is particularly suited for use in a direct injection engine is a so-called piezoelectric injector. A piezoelectric injector 12 and its associated control system 14 are shown schematically in FIG. 1 .
The piezoelectric injector 12 includes a piezoelectric actuator 16 that is operable to control the position of an injector valve needle 17 relative to a valve needle seat 18 . The piezoelectric actuator 16 includes a stack 19 of piezoelectric elements, having the electrical characteristics of a capacitor. The stack 19 may be charged or discharged by application of a differential voltage to positive and negative terminals of the actuator 16 , which causes the stack of piezoelectric elements to expand or contract. The expansion and contraction of the piezoelectric elements is used to vary the axial position, or ‘lift’, of the valve needle 17 relative to the valve needle seat 18 .
The piezoelectric injector 12 is controlled by an injector control unit 22 (ICU) that forms an integral part of an engine control unit 24 (ECU). The ICU 22 typically comprises a microprocessor 26 and memory 28 . The ECU 24 also comprises an injector drive circuit 30 , to which the piezoelectric injector 12 is connected by way of first and second power supply leads 31 , 32 . In a so-called ‘discharge to inject’ injector, in order to initiate an injection event, the injector drive circuit 30 causes the differential voltage applied to the injector 12 to transition from a high voltage (typically 200 V), at which no fuel delivery occurs, to a relatively low voltage (typically −55 V), which causes the valve needle 17 to lift away from the valve needle seat 18 .
Like any circuit, faults may occur in a drive circuit. In safety critical systems, such as diesel engine fuel injection systems, a fault in the drive circuit may lead to a failure of the injection system that could consequentially result in a catastrophic failure of the engine. Diagnostic systems for detecting short circuit faults in piezoelectric actuators of piezoelectric injectors are disclosed in applicant's co-pending patent applications EP1843027, EP1860306, EP1927743, and EP07252534.8, EP07254036.2 the contents of each document being incorporated herein by reference.
Of particular relevance to this application is co-pending application EP 07252534.8, which describes a diagnostic method for detecting three main types of short circuit fault, these are:
i) a short circuit between the terminals of a piezoelectric actuator; otherwise referred to as a ‘stack terminal’ short circuit;
ii) a short circuit from the positive terminal of a piezoelectric actuator to a ground potential; the positive terminal is also referred to as the ‘high’ terminal, and this type of short circuit is generally referred to as a ‘high side to ground’ short circuit; and
iii) a short circuit from the negative terminal of a piezoelectric actuator to a ground potential; the negative terminal is also referred to as the ‘low’ terminal, and this type of short circuit is generally referred to as a ‘low side to ground’ short circuit.
Referring also to FIG. 2 , this shows the injector drive circuit 30 described in EP 07252534.8. The injector drive circuit 30 comprises an injector bank circuit 33 , in which a pair of piezoelectric injectors 12 a , 12 b are connected. It should be appreciated that although the respective injectors 12 a , 12 b are shown as integral to the injector bank circuit 33 in FIG. 2 , in practice the injector bank circuit 33 would be remote from the injectors 12 a , 12 b and connected thereto by way of power supply leads.
The drive circuit 30 includes three voltage rails: a high voltage rail VH (typically 255 V), a mid voltage rail VM (typically 55 V), and a ground voltage rail VGND (i.e. 0 V). The drive circuit 30 is generally configured as a half H-bridge with the mid voltage rail VM serving as a bi-directional middle current path 34 . The injector bank circuit 33 is located in the middle current path 34 of the drive circuit 30 and comprises a pair of parallel branches 33 a , 33 b , in which the piezoelectric actuators 16 a , 16 b (hereinafter referred to simply as ‘actuators’) of the injectors 12 a , 12 b are respectively connected. The injector bank circuit 33 further comprises a pair of injector select switches SQ 1 , SQ 2 connected in series with the respective injectors 12 a , 12 b in the respective branches 33 a , 33 b of the injector bank circuit 33 . Each injector select switch SQ 1 , SQ 2 has a respective diode D 1 , D 2 connected across it. The injector bank circuit 33 is located between, and coupled in series with, an inductor L 1 and a current sensing and control means 35 .
A voltage source VS is connected between the mid voltage rail VM and the ground rail VGND of the drive circuit 30 . The voltage source VS may be provided by the vehicle battery (not shown) in conjunction with a step-up transformer (not shown), or other suitable power supply, for increasing the voltage from the battery to the required voltage of the mid voltage rail VM.
A first energy storage capacitor C 1 is connected between the high and mid voltage rails VH, VM, and a second energy storage capacitor C 2 is connected between the mid and ground voltage rails VM, VGND. The first capacitor C 1 , when fully charged, has a potential difference of about 200 Volts across it, whilst the potential difference across the second capacitor C 2 is maintained at about 55 Volts. A charge switch Q 1 is located between the high and mid voltage rails VH, VM, and a discharge switch Q 2 is located between the mid voltage and ground rails VM, VGND.
In essence, the drive circuit 30 comprises a charge circuit and a discharge circuit. The charge circuit comprises the high and mid voltage rails VH, VM, the first capacitor C 1 and the charge switch Q 1 , whereas the discharge circuit comprises the mid and ground rails VM, VGND, the second capacitor C 2 and the discharge switch Q 2 . The charge switch Q 1 is operable to connect the injectors 12 a , 12 b to the first capacitor C 1 causing a current to flow in the charge circuit, in the direction of the arrow ‘I-CHARGE’, to charge the actuators 16 a , 16 b to a known voltage. The diodes D 1 , D 2 connected across the injector select switches SQ 1 , SQ 2 allow the injectors 12 a , 12 b to charge in parallel when the charge switch Q 1 is closed. To initiate an injection event from a selected injector 12 a or 12 b , a current is caused to flow in the discharge circuit, in the direction of the arrow ‘I-DISCHARGE’. This is achieved by closing both the discharge switch Q 2 and an injector select switch SQ 1 , SQ 2 to connect the selected injector 12 a or 12 b to the second capacitor C 2 .
The drive circuit 30 further includes a resistive bias network 36 connected between the high voltage rail VH and ground rail VGND, and intersecting the middle circuit branch 34 at a bias point PB. The restive bias network 36 is used to determine the voltage VB at the bias point PB in order to detect short circuit faults on the injectors 12 a , 12 b.
The resistive bias network 36 includes first, second and third resistors R 1 , R 2 , R 3 connected together in series. The first resistor R 1 is connected between the high voltage rail VH and the bias point PB, and the second and third resistors R 2 and R 3 are connected in series between the bias point PB and the ground rail VGND. The first, second and third resistors R 1 , R 2 , R 3 each have a known resistance of a high order of magnitude, typically of the order of hundreds of kiloohms. For convenience, R 1 , R 2 and R 3 are used herein to refer to both the resistors and to the resistances of the resistors R 1 , R 2 , R 3 .
To determine the voltage VB at the bias point PB, a voltage VS is sampled between the second and third resistors R 2 , R 3 in the resistive bias network 36 using an analogue to digital (A2D) module of the microprocessor 26 ( FIG. 1 ). The resistors R 2 and R 3 form a potential divider, and so the voltage VB at the bias point PB is calculated according to equation 1 below.
V
B
=
V
S
(
R
2
+
R
3
)
R
3
1
To detect high and low side to ground short circuit faults on the injectors 12 a , 12 b , a so-called ‘unselected voltage reading’ technique can be employed. The unselected voltage reading technique involves determining the voltage VB at the bias point PB with neither of the injectors 12 a , 12 b selected, i.e. with both injector select switches SQ 1 , SQ 2 open. When both injector select switches SQ 1 , SQ 2 are open, a voltage V Bpred at the bias point PB can be predicted from the high rail voltage VH, and the value of the resistors R 1 , R 2 , R 3 in the resistive bias network 36 , according to equation 2 below.
V
Bpred
=
V
H
(
R
2
+
R
3
)
R
1
+
R
2
+
R
3
2
In the event that either of the injectors 12 a or 12 b has a high side to ground short circuit, then this short circuit behaves as a resistor connected in parallel with the resistors R 2 and R 3 in the resistive bias network 36 . If the voltage VB is measured at the bias point PB when there is a high side to ground short circuit, then the measured voltage will be lower than the predicted voltage V Bpred according to equation 2 above. However, if one of the injectors 12 a , 12 b has a low side to ground short circuit, then the measured voltage at the bias point PB will be higher than the predicted voltage V Bpred according to equation 2, and will depend upon the inherent resistance of the low side to ground short circuit. Hence, by measuring the voltage at the bias point PB and comparing it to the predicted voltage V Bpred according to equation 2 above, high and low side to ground short circuit faults on the injector bank 33 can be detected.
Stack terminal short circuits can also be detected using the resistive bias network 36 . If an injector 12 a , 12 b has a stack terminal short circuit, then it will not hold its charge following a charge event on the bank 33 . Instead, the injector 12 a , 12 b will discharge through the stack terminal short circuit at a rate governed by the inherent resistance of the stack terminal short circuit. Stack terminal short circuits of suitably high resistance may not be detrimental to the normal operation of the system, and so a maximum acceptable rate of discharge may be predetermined, corresponding to a minimum acceptable resistance of a stack terminal short circuit.
To detect a stack terminal short circuit, a so-called ‘selected voltage reading’ technique can be employed. The selected voltage reading technique involves determining the voltage VB at the bias point PB with an injector 12 a or 12 b selected, i.e. with an injector select switch SQ 1 or SQ 2 closed. When an injector select switch SQ 1 or SQ 2 is closed, the voltage VB measured at the bias point PB is related to the voltage on the selected injector 12 a or 12 b . The voltage on the selected injector 12 a or 12 b can be obtained by subtracting the voltage on the mid voltage rail VM (55 V in this example) from the voltage VB at the bias point PB.
In the selected voltage reading technique, the voltage measurement is performed after a predetermined period following a charge event on the bank 33 . The voltage on an injector 12 a , 12 b at the end of a charge event is known. If the voltage VB at the bias point PB is less than a predetermined voltage level, then this is indicative of a stack terminal short circuit, having a resistance below a predetermined minimum acceptable value, on one or both of the injectors 12 a , 12 b . It should be appreciated that the expression ‘voltage on an injector’ is used for convenience and refers to the voltage on the piezoelectric stack of the injector actuator 16 a , 16 b.
A disadvantage of using the selected voltage reading as described above to determine stack terminal short circuits on the injectors 12 a , 12 b , is that this technique can entail a charge share between the injectors 12 a and 12 b in the event of a stack terminal fault. Charge sharing occurs when a non-faulty injector 12 a , 12 b is selected causing it to discharge into a faulty injector 12 a , 12 b.
For example, referring to FIG. 2 , if the second injector 12 b has a stack terminal short circuit, then selecting the first injector 12 a by closing the first injector select switch SQ 1 will result in a closed loop in the injector bank circuit 33 . The closed loop includes the diode D 2 connected across the second injector select switch SQ 2 , and the closed first injector select switch SQ 1 . An uncontrolled current will flow from the non-faulty first injector 12 a , around the closed loop to charge the discharged faulty second injector 12 b , in turn resulting in the non-faulty first injector 12 a discharging. Charge sharing can also occur if one of the injectors 12 a , 12 b has a stack terminal short circuit, when an injector 12 a or 12 b is selected for discharge by closing the associated injector select switch SQ 1 or SQ 2 . Whilst the selected voltage reading technique is able to determine stack terminal short circuit faults on the injector bank 33 , charging sharing prevents this technique from being able to determine which of the individual injectors 12 a , 12 b is at fault.
An alternative diagnostic technique for detecting stack terminal faults is a so-called ‘charge pulse’ technique, as described in EP 06256140.2 and EP 07252534.8. The charge pulse technique comprises performing a first ‘charge pulse’ on the injectors 12 a and 12 b by closing the charge switch Q 1 for a short period of time; opening the charge switch Q 1 and allowing a predetermined period of time to elapse before closing the charge switch Q 1 again for another short period of time to perform a second charge pulse on the injectors 12 a , 12 b . If either of the injectors 12 a , 12 b has a stack terminal short circuit, then it will discharge to an extent during the predetermined period prior to the second charge pulse being performed. Hence, when the second charge pulse is performed, a current will flow in the charge circuit to recharge the discharged faulty injector 12 a or 12 b.
If neither of the injectors 12 a , 12 b has a stack terminal short circuit, then both injectors 12 a , 12 b should substantially hold their charge during the predetermined period prior to the second charge pulse being performed, in which case substantially no current will flow in the charge circuit when the second charge pulse is performed. The current sensing and control means 35 is arranged to monitor current flow during the second charge pulse. The presence of a current during the second charge pulse above a predetermined threshold current level is indicative of a stack terminal short circuit on one or both of the injectors 12 a , 12 b on the bank 33 . The predetermined threshold current level is based on a minimum acceptable resistance of stack terminal short circuit and the duration of the predetermined period prior to the second charge pulse being performed.
Whilst the charge pulse technique described above does not suffer from the charge share problems of the selected voltage reading technique (because both injector select switches SQ 1 , SQ 2 remain open), in common with the other diagnostic techniques described above, the charge pulse technique is not able to determine which of the individual injectors 12 a , 12 b is at fault.
As mentioned above, in each of the diagnostic techniques described above, faults can be traced as far as the injector bank 33 , but faulty injectors 12 a , 12 b cannot be identified. In such circumstances, the recovery action on detection of a fault is to shut down the entire injector bank 33 . In the case of a four-cylinder engine, this would result in the engine running on only two cylinders, when the fault may only be associated with one of the injectors 12 a , 12 b on the bank 33 . This can cause associated problems at engine service, because further tests must be performed to identify the injector 12 a , 12 b at fault.
SUMMARY OF INVENTION
It is against this background that the invention provides, in a first aspect, a method of detecting faults in an injector arrangement comprising a plurality of piezoelectric injectors, the piezoelectric injectors being located in parallel branches of an injector bank circuit of an injector drive circuit and each branch of the injector bank circuit comprising a respective high side isolation switch operable to enable an associated piezoelectric injector in the injector bank circuit when closed, and disable the associated piezoelectric injector in the injector bank circuit when open, wherein the method comprises the steps of: operating the high side isolation switches so as to enable one of the piezoelectric injectors and disable the other piezoelectric injector(s); and performing diagnostics to detect the presence or absence of faults on the enabled piezoelectric injector.
The injector drive circuit is operable to selectively connect the injector bank circuit to a first voltage source to charge the piezoelectric injectors and to a second voltage source to discharge the piezoelectric injectors, the first voltage source being of higher voltage than the second voltage source. Each high side isolation switch is connected between a piezoelectric injector and the first voltage source in the respective branches of the injector bank circuit.
The use of high side isolation switches provides improvements in the diagnostics of short circuits on an injector bank. This is because the injectors can be tested for faults individually, one by one, so that a single faulty injector can be identified. This provides advantages when the engine is serviced, because the faulty injector can immediately be replaced without further tests being required to identify which injector on the bank is at fault. As such, the method may provide recording the location or address of a faulty injector in a memory device. The memory device can be read at engine service so that a service engineer can readily locate and replace the faulty injector.
Once a faulty injector has been identified by the diagnostics, the associated high side isolation switch may be opened to disable the faulty injector from the injector bank so that the engine can continue to run on all the remaining non-faulty injectors on the bank. Accordingly the method may provide the additional step of operating the associated high side isolation switch so as to disable the enabled injector in the event that a fault is determined on the enabled injector. Disabling the faulty injector results in the faulty injector being electrically isolated from the injector bank so that the faulty injector does not interfere with the normal operation of the remaining non-faulty injectors on the bank. A significant advantage of the high side isolation switches is that they enable high side to ground faults to be electrically isolated, which is not otherwise possible using switches located on the low sides of the injectors, which are commonly found in prior art injector drive circuits.
The diagnostics may include testing the enabled injector for high and low side to ground short circuit faults. This may be achieved by determining a bias voltage at a bias point in the injector drive circuit, and determining the presence of a high or low side to ground short circuit on the enabled piezoelectric injector if the bias voltage is not within a predetermined tolerance of a predicted bias voltage. A high side to ground short circuit may be determined if the bias voltage is lower than the predicted bias voltage by more than a first predetermined tolerance value. A low side to ground short circuit may be determined if the bias voltage is more than the predicted bias voltage by more than a second predetermined tolerance value. The unselected voltage reading technique, as described above by way of background to the invention, may be performed on the enabled injector to determine high and low side to ground short circuits.
Alternatively or additionally, the diagnostics may include testing the enabled injector for stack terminal short circuit faults. To test the enabled injector for a stack terminal fault, the method may comprise measuring a voltage indicative of the voltage on the enabled injector, comparing the measured voltage to a predetermined threshold voltage level, and determining the presence of a stack terminal short circuit if the measured voltage is less than the predetermined threshold voltage level. The selected voltage reading technique, as described above by way of background to the invention, may be performed on the enabled injector to determine stack terminal short circuits. As an alternative to using the selected voltage reading technique, the charge pulse technique, also described above by way of background to the invention, may be performed on the enabled injector.
In one embodiment of the invention, the high side isolation switches are predominantly open, such that the operating step comprises closing a high side isolation switch so as to enable the associated piezoelectric injector. With the high side isolation switches being predominantly open, the piezoelectric injectors are always electrically isolated from each other. This eliminates the possibility of charge sharing occurring between faulty and non-faulty injectors. Furthermore, this technique allows a faulty injector to be identified immediately and disabled without any post-processing steps being required to identify the injector at fault once a fault on the injector bank is detected. Relatively high speed high side isolation switches are required in this embodiment.
However, in another embodiment of the invention, the high side isolation switches are predominantly closed, such that the operating step comprises opening at least one high side isolation switch in order to leave a single high side isolation switch closed, and hence the associated piezoelectric injector enabled. With the high side isolation switches being predominantly closed, there remains a risk of charge sharing occurring between faulty and non-faulty injectors because the injectors are not always electrically isolated from each other. However, this technique allows relatively slow speed high side isolation switches to be used, which may provide a cost benefit.
In the case where the high side isolation switches are predominantly closed, the method may comprise performing a set of initial diagnostics on the injectors with all of the injectors enabled, i.e. with all of the high side isolation switches closed. The initial diagnostics enable the presence or absence of a fault on the injector bank to be determined, but do not locate the injector at fault. In the event that a fault is detected on the injector bank, one of high side isolation switches remains closed whilst the other high side isolation switches are opened so that only a single injector remains enabled on the bank. The enabled injector is then tested for faults as described above.
If the enabled injector is found to be at fault, then the associated high side isolation switch is opened to disable the faulty injector from the injector bank circuit. However, if the enabled injector is not found to be at fault, then in the case where there are only two injectors on the injector bank, the fault determined by the initial diagnostics can be attributed to the other injector. Alternatively, if the injector bank comprises more than two injectors, the remaining injectors are tested individually one at a time by closing and opening the high side isolation switches in the appropriate combinations. In either case, once the injector at fault has been determined, the high side isolation switch associated with the faulty injector is opened to disable the faulty injector, whilst the high side isolation switches associated with the injectors found to be non-faulty are closed to enable the non-faulty injectors so that the engine can run on all of the non-faulty injectors. In the unlikely event that more than one injector is found to be faulty, each faulty injector is disabled.
The initial diagnostics may comprise testing the injector arrangement for stack terminal faults using the charge pulse technique described above by way of background to the invention. Initially the charge pulse technique may be performed on all of the injectors, i.e. with each high side isolation switch closed so that each injector is enabled. In the event that a stack terminal short circuit is detected, then the method may comprise performing the charge pulse technique on individually enabled injectors to locate the injector at fault. However, once a stack terminal fault has been detected generally on the injector bank, and the injectors electrically isolated from one another, the selected voltage reading technique may be used, as described above by way of background to the invention, to determine which of the injectors is at fault. The selected voltage reading technique is of higher resolution than the charge pulse technique and the risk of charge sharing is eliminated when the injectors are electrically isolated from one another.
Additionally or alternatively, the initial diagnostics may include testing the injector arrangement for high side and low side to ground short circuits using the unselected voltage reading technique, also described above by way of background to the invention. In the event that a high or low side to ground short circuit is detected, then the method may comprise performing the unselected voltage reading technique on individually enabled injectors to locate the injector at fault.
According to a second aspect of the present invention, there is provided an apparatus for detecting faults in an injector arrangement comprising a plurality of piezoelectric injectors, the piezoelectric injectors being located in parallel branches of an injector bank circuit of an injector drive circuit and each branch of the injector bank circuit comprising a high side isolation switch operable to enable an associated piezoelectric injector in the injector bank circuit when closed, and disable the associated piezoelectric injector in the injector bank circuit when open, the apparatus further comprising diagnostic means for determining faults on the enabled piezoelectric injectors.
The injector drive circuit may be operable to selectively connect the injector bank circuit to a first voltage source to charge the piezoelectric injectors and to a second voltage source to discharge the piezoelectric injectors, wherein the first voltage source is of higher voltage than the second voltage source. The injectors are preferably discharge to inject injectors.
The injector bank circuit preferably includes a plurality of injector select switches individually associated with the respective injectors and connected on the low sides of the injectors. The injector select switches may be operated to select the individual piezoelectric injectors to perform an injection event. In this configuration, the piezoelectric injectors are each connected between a pair of switches: an injector select switch on the low side, and a high side isolation switch on the high side.
It will be appreciated that optional features of the method aspect of the invention are equally applicable to the apparatus aspect and vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference has already been made to FIGS. 1 and 2 by way of technical background to the present invention.
FIG. 1 is a schematic representation of a known piezoelectric injector and its associated control system comprising injector drive circuit, and
FIG. 2 is a circuit diagram of the injector drive circuit in FIG. 1 .
In order that it may be more readily understood, the present invention will now be described with reference to the following figures, in which:
FIG. 3 is a circuit diagram of an injector drive circuit for a pair of piezoelectric injectors, the injector drive circuit including a pair of high side isolation switches that are both open;
FIG. 4 is a circuit diagram of the injector drive circuit of FIG. 3 , in which both of the high side isolation switches are closed;
FIG. 5 is a flow chart of a first diagnostic routine for detecting faults on the piezoelectric injectors connected in the injector drive circuit of FIGS. 3 and 4 , with the default state of the high side isolation switches being closed as shown in FIG. 4 ; and
FIG. 6 is a flow chart of a second diagnostic routine for detecting faults on the piezoelectric injectors connected in the injector drive circuit of FIGS. 3 and 4 , with the default state of the high side isolation switches being open as shown in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 3 , this shows an injector drive circuit 30 a similar to the drive circuit 30 in FIG. 2 , but comprising a modified injector bank circuit 33 . The modified injector bank circuit 33 is similar to the injector bank circuit 33 in FIG. 2 , but also includes a pair of high side isolation switches QHS 1 , QHS 2 connected in respective branches 33 a , 33 b of the injector bank circuit 33 , on the high sides of the respective injectors 12 a , 12 b . Hence, each injector 12 a , 12 b is connected between an injector select switch SQ 1 , SQ 2 on the low side, and a high side isolation switch QHS 1 , QHS 2 on the high side.
There now follows a description of two different diagnostic routines for detecting short circuits on the injectors 12 a , 12 b , in which the high side isolation switches QHS 1 , QHS 2 are utilized to determine which injector 12 a , 12 b is at fault and to disable the faulty injector 12 a , 12 b . As explained in further detail below, in the first diagnostic routine the default state of the high side isolation switches QHS 1 , QHS 2 is closed as shown in FIG. 4 , whilst in the second diagnostic routine the default state of the high side isolation switches QHS 1 , QHS 2 is open as shown in FIG. 3 .
Referring to FIG. 4 , this shows the drive circuit 30 a of FIG. 3 with both of the high side isolation switches QHS 1 , QHS 2 closed. As described in further detail below, if a short circuit fault on the injector bank 33 is detected with the high side isolation switches QHS 1 , QHS 2 closed, then the high side isolation switches QHS 1 , QHS 2 are opened in turn and further tests conducted to determine which of the injectors 12 a , 12 b is at fault.
FIG. 5 is a flow diagram showing the steps of the first diagnostic routine, with the default state of the high side isolation switches QHS 1 , QHS 2 being closed as shown in FIG. 4 . Referring to FIG. 5 and also to FIG. 4 :
[Step A 1 ] With both high side isolation switches QHS 1 , QHS 2 closed, and both injectors 12 a , 12 b deselected, i.e. with both of the injector select switches SQ 1 , SQ 2 open, a voltage VB 1 at the bias point PB is determined by sampling the voltage VS between the second and third resistors R 2 , R 3 in the resistive bias network 36 and calculating VB 1 according to equation 1 above.
[Step A 2 ] The voltage VB 1 at the bias point PB is compared to a set of predetermined voltage limits. As described earlier, if either or both of the injectors 12 a , 12 b has a high side to ground short circuit, then the voltage VB 1 at the bias point PB will be lower than the predicted voltage V Bpred according to equation 2. Conversely, if either or both of the injectors 12 a , 12 b has a low side to ground short circuit, then the voltage VB 1 at the bias point PB will be higher than the predicted voltage V Bpred according to equation 2. This allows suitable voltage limits to be set, respectively, above and below the predicted voltage V Bpred .
[Step A 3 ] If the voltage VB 1 at the bias point PB is within the predetermined voltage limits, there are no high- or low-side to ground faults on the injector bank 33 . Further tests are then performed as described later to determine if either or both of the injectors 12 a , 12 b has a stack terminal short circuit fault.
[Step A 4 ] If the voltage VB, is not within the predetermined voltage limits, this is indicative of a high or low side to ground short circuit on the bank 33 . When a high or low side to ground short circuit is detected on the injector bank 33 , subsequent injections on both of the injectors 12 a , 12 b on the bank 33 are suspended and further tests are performed [Steps A 5 -A 9 ] to determine which of the injectors 12 a , 12 b is at fault.
[Step A 5 ] The second high side isolation switch QHS 2 is opened to disconnect or electrically isolate, the second injector 12 b from the injector bank 33 .
[Step A 6 ] A voltage VB 2 at the bias point PB is determined with the second injector 12 b disconnected from the injector bank 33 . At this point, the first high side isolation switch QHS 1 is closed, the second high side isolation switch QHS 2 is open, and both injector select switches SQ 1 , SQ 2 are open.
[Step A 7 ] The voltage VB 2 at the bias point PB determined at step A 6 above is compared to the voltage limits described in Step A 2 .
[Step A 8 ] If the voltage VB 2 at the bias point PB is outside the limits, then this indicates that the first injector 12 a has a short circuit fault, and hence the fault detected at Step A 4 is attributable, at least in part, to the first injector 12 a . In this case, the first injector 12 a is electrically isolated/disconnected from the injector bank 33 by opening the first high side isolation switch QHS 1 to disable further charging and discharging of the first injector 12 a and further injections from the first injector 12 a . If the first injector 12 a is found to be at fault, the second injector 12 b is assumed to be non-faulty, and so the second high side isolation switch QHS 2 is re-closed, to connect the second injector 12 b back to the injector bank circuit 33 , and injections on the second injector 12 b are re-enabled. In the unlikely event that both injectors 12 a and 12 b are at fault, then the fault on the second injector 12 b is detected by further diagnostics performed on the injector bank 33 with just the second injector 12 b enabled i.e. with QHS 2 closed and QHS 1 open.
[Step A 9 ] If the voltage VB 2 at the bias point PB is within the limits, then this indicates that the first injector 12 b is non-faulty, and hence the short circuit fault detected at Step A 4 above is on the second injector 12 b . In this case, the second high side isolation switch QHS 2 remains open and injections on the faulty second injector 12 b are disabled, whilst injections on the non-faulty first injector 12 a are re-enabled.
As mentioned at Step A 3 above, if the voltage VB 1 at the bias point PB is within the predetermined voltage limits, then further tests are preformed to determine if either of the injectors 12 a , 12 b has a stack terminal short circuit fault. With the default state of the high side isolation switches QHS 1 , QHS 2 being closed, the selected voltage reading technique, described above by way of background to the invention with reference to FIG. 2 , is not utilized initially, because charge share between the injectors 12 a , 12 b can occur in the event of a stack terminal short circuit on one of the injectors 12 a , 12 b . Instead, the charge pulse technique, also described above by way of background to the invention with reference to FIG. 2 , is used initially with both high side isolation switches QHS 1 , QHS 2 closed. If a current is detected by the current sensing and control means, depicted in FIGS. 3 and 4 as a current sense resistor 35 , when the second charge pulse is performed, and if this current exceeds a predetermined threshold level, this is indicative of a stack terminal short circuit on either or both of the injectors 12 a , 12 b on the injector bank 33 .
To determine which of the injectors 12 a or 12 b is at fault, the selected voltage reading technique is used, as described above by way of background to the invention. To test the first injector 12 a for a stack terminal short circuit using the selected voltage reading technique, the second high side isolation switch QHS 2 is opened to disable the second injector 12 b , leaving just the first injector 12 a enabled. The first injector 12 a is selected by closing the first injector select switch SQ 1 and the voltage VB at the bias point PB is determined. If the voltage VB at the bias point PB is less than a predetermined voltage level, then this is indicative of a stack terminal short circuit on the selected first injector 12 a . However, if the voltage VB is equal to or greater than the predetermined voltage level, then it can be inferred that the second injector 12 b has a stack terminal fault.
Referring now to the second diagnostic routine. As mentioned above, in the second diagnostic routine the default state of the high side isolation switches QHS 1 , QHS 2 is open, as shown in FIG. 3 . The high side isolation switches QHS 1 , QHS 2 are only closed when an injection or diagnostic event is to be performed on the bank 33 . The high side isolation switches QHS 1 , QHS 2 are closed in turn to enable a single injector 12 a or 12 b , and to allow diagnostics to be performed on the single enabled injector 12 a or 12 b.
FIG. 6 is a flow diagram showing the steps of the second diagnostic routine to determine if a fault exists on the first injector 12 a . A similar test could be performed to determine if a fault exists on the second injector 12 b . Initially both high side isolation switches QHS 1 , QHS 2 are open as shown in FIG. 3 . Referring now to FIG. 6 and also to FIG. 3 :
[Step B 1 ] The first high side isolation switch QHS 1 is closed to enable the first injector 12 a on the injector bank 33 . The second high side isolation switch QHS 2 remains open such that the second injector 12 b is disabled from the bank 33 . Both injector select switches SQ 1 , SQ 2 are open.
[Step B 2 ] The voltage VB at the bias point PB is determined.
[Step B 3 ] The voltage VB at the bias point PB is compared to a set of predetermined voltage limits, in the same way as described above for Step A 2 of the first diagnostic routine, in order to test the first injector 12 a for high or low side to ground short circuit faults.
[Step B 4 ] If the voltage VB at the bias point PB is not within the predetermined voltage limits, this is indicative of a high or low side to ground short circuit on the first injector 12 a . If a high or low side to ground short circuit is detected on the first injector 12 a , then the first high side isolation switch QHS 1 is opened to disable the first injector 12 a from the bank 33 .
[Step B 5 ] If the voltage VB at the bias point PB is within the predetermined voltage limits, then there are no high or low side to ground short circuits on the first injector 12 a . The first injector 12 a is then selected by closing the first injector select switch SQ 1 , and tested for stack terminal short circuits using the selected voltage reading technique [Steps B 6 to B 9 ], which is also described above by way of background to the invention with reference to FIG. 3 .
[Step B 6 ] With both the first high side isolation switch QHS 1 and the first injector select switch OS 1 closed, the voltage VB at the bias point PB is determined.
[Step B 7 ] The voltage VB at the bias point PB is compared to a predetermined threshold level.
[Step B 8 ] If the voltage VB at the bias point PB is less than the predetermined threshold level, this is indicative of a stack terminal short circuit on the first injector 12 a . If a stack terminal short circuit is determined on the first injector 12 a , then the first high side isolation switch QHS 1 is opened to disable the faulty first injector 12 a from the bank 33 . No further injections are performed on the faulty first injector 12 a.
[Step B 9 ] If the voltage VB at the bias point PB is greater than the predetermined threshold level, then there is not a stack terminal short circuit fault on the first injector 12 a . In this case, normal running is continued on the first injector 12 a . The second injector 12 b is tested by opening the first high side isolation switch QHS 1 , closing the second high side isolation switch QHS 2 , and performing steps B 1 to B 9 on the second injector 12 b.
With the high side isolation switches QHS 1 , QHS 2 being predominantly open as in the second diagnostic routine ( FIGS. 3 and 6 ), the injectors 12 a , 12 b are always electrically isolated from one another. This allows a faulty injector 12 a , 12 b to be identified immediately and switched off with no risk of charge share occurring between the injectors 12 a , 12 b . This also allows the voltage on an injector 12 a , 12 b to be measured with no risk of charge share with the other injector 12 a , 12 b , thereby providing added flexibility to the diagnostics. The second diagnostic routine ( FIG. 6 ) requires relatively high speed high side isolation switches QHS 1 , QHS 2 .
With the high side isolation switches QHS 1 , QHS 2 being predominantly closed as in the first diagnostic routine ( FIGS. 4 and 5 ), there remains a risk of charge sharing occurring and additional diagnostic steps must be performed to determine the injector 12 a , 12 b at fault once the presence of a fault is determined on the bank 33 . These additional diagnostic steps, which are otherwise referred to as ‘post-processing’, require both injectors 12 a , 12 b to be shut down until the faulty injector 12 a , 12 b is identified. However, this technique allows slower speed high side isolation switches QHS 1 , QHS 2 to be used, which may provide cost benefits.
In both the first and second diagnostic routines, described above with reference to FIGS. 5 and 6 respectively, the use of high side isolation switches QHS 1 , QHS 2 enables a faulty injector 12 a , 12 b to be diagnosed and disabled from the injector bank 33 . Disabling the faulty injector 12 a , 12 b electrically isolates the faulty injector 12 a , 12 b from the other injectors 12 a , 12 b on the bank 33 . Once disabled, any short circuit faults associated with the faulty injector 12 a , 12 b will then not affect the normal operation of the remaining non-faulty injectors 12 a , 12 b on the bank 33 .
In addition to the advantages described above, the inclusion of isolation switches QHS 1 , QHS 2 on the high sides of the injectors 12 a , 12 b enables high side to ground faults on the injectors 12 a , 12 b to be electrically isolated. This has not been possible until now, because switches have traditionally been located on the low side of the injectors 12 a , 12 b , which means that even when these switches are opened, a high side to ground short circuit is not electrically isolated and may disrupt the normal operation of non-faulty injectors 12 a , 12 b on the bank 33 .
The terms ‘open’ and ‘close’ used to described the operation of the various switches are used herein for convenience. These terms are not intended to limit the invention, and as such, the term ‘close’ is intended to mean operating a switch to allow current to pass, whereas the term ‘open’ is intended to mean operating a switch to substantially prevent current from passing.
It will be appreciated that the methods described above are automated under the control of the microprocessor 26 of the ECU 24 ( FIG. 1 ). It will also be appreciated that whilst two injectors 12 a , 12 b are shown in the injector bank circuits 33 in FIGS. 3 and 4 , in other embodiments of the invention, the injector bank 33 may include more than two injectors connected in parallel. Furthermore, whilst only one injector bank 33 is described herein, the ECU 24 may be arranged to control more than one injector bank 33 , in which case, each injector bank 33 will have its own drive circuit similar to the drive circuit 30 a in FIGS. 3 and 4 . | A method and apparatus for detecting faults in an injector arrangement is described. The injector arrangement comprises a plurality of piezoelectric injectors that are located in parallel branches of an injector bank circuit of an injector drive circuit. Each branch of the injector bank circuit comprises a high side isolation switch. The high side isolation switches are each operable to enable an associated piezoelectric injector in the injector bank circuit when closed, and disable the associated piezoelectric injector in the injector bank circuit when open. The fault detection method comprises the steps of operating the high side isolation switches so as to enable one of the piezoelectric injectors and disable the other piezoelectric injector(s), and performing diagnostics to detect the presence or absence of faults on the enabled piezoelectric injector. | 5 |
The present invention relates to a hydraulic drive system for a press, comprising a hydrostatic machine operating to maintain a substantially constant pressure in a fluid system and a hydraulic transformer.
BACKGROUND OF THE INVENTION
A system of this type is disclosed in German patent 32 02 015 owned by applicants. The system refers to a so-called secondary controlled drive system comprising a hydraulic transformer which is hydraulically connected to the fluid system in which a substantially constant pressure is being impressed. The transformer is defined by a pair of mechanically coupled hydrostatic machines each having an adjustable flow rate capacity. While the first hydrostatic machine is hydraulically connected to the fluid system, the second hydrostatic machine is hydraulically connected to a working cylinder. Accordingly, a secondary controlled drive system may be utilized for operating a working cylinder, resulting in a substantial saving of energy since the first hydrostatic machine connected to the fluid system of constant pressure only draws the amount of hydraulic energy from the fluid system which is required to satisfy the energy demand of the load, whereas in reverse the hydraulic energy being produced when the first hydraulic machine is operating as a pump, is returned to the fluid system to load an accumulator.
Generally, it is an aim of the present invention to operate a press cylinder of a hydraulic press in using a secondary controlled drive system of the type referred to. Principally it is known to subject both cylinder chambers of a press cylinder to a predetermined biasing pressure which is delivered by a separate biasing pump. For a press cylinder of the synchronizing type, i.e. a piston having equal annular piston area, identical biasing pressures readily result in both cylinder chambers. However, considering a differential cylinder, identical biasing pressures in the piston sided cylinder chamber as well as in the piston-rod-sided cylinder chamber may be produced by additional by providing at least a supplemental cylinder, i.e. the annular piston area of all cylinders should be substantially identical to the piston area of the press cylinder. This principle is known in fluid systems of different types.
SUMMARY AND OBJECT OF THE INVENTION
Accordingly, it is an object of the present invention to provide a drive system of the type referred to such that the biasing pressure may be produced in a simple and effective manner and that the losses in operating a press may be substantially reduced and, furthermore controlling press is simplified.
According to the invention, the press cylinder is hydraulically connected to the fluid system of the primary hydraulic machine, i.e. the fluid system in which an impressed pressure of substantially constant value is maintained, thus delivering the biasing pressure required for the press cylinder. According to the invention, the biasing of the press cylinder thus is provided free of any losses in tapping the constant pressure system which in combination supplies fluid to the first hydraulic machine of the hydraulic transformer. It is thus an advantage of the present invention to eliminate a separate biasing pump. Neither, the biasing pressure is produced by lowering a higher hydraulic pressure, for example by reducing a maximum operating pressure to the biasing pressure, nor by providing a special means as required in prior art systems. Furthermore, the supplemental cylinders required for a pressure balance of the press are also hydraulically connected to the fluid system of substantially constant pressure, i.e. the cylinder chambers of said supplemental cylinders are subjected to the biasing pressure. The supplemental cylinders are provided for acting in parallel to the press cylinder and the total sum of all annular areas of the cylinder pistons is equal or somewhat higher than the piston area in the piston sided chamber of the press cylinder.
The fluid system of substantially constant pressure is connected to the press cylinder through a check valve so that any fluid drained to a reservoir due to a possible leakage in the press and/or in a flushing operation can be replaced anytime. In addition, the fluid line between the fluid system and the press cylinder may comprise a pressure control valve which is used to reduce the impressed pressure in the fluid system to the biasing pressure required in cases only when the biasing pressure shall be smaller than the pressure required for the motor operation of the first hydrostatic machine of the transformer. As a rule, the biasing pressure and thus the operational pressure for the first machine of the transformer is about two third of the maximum press pressure. Thus the second hydrostatic machine of the hydraulic transformer acting as a pump for moving the press piston is designed such that the maximum flow volume is delivered at about two third of the maximum pressure. Accordingly, should the pump reach the maximum pressure when performing the press stroke, the pump must pivot back to two third of the maximum delivery capacity. From this, however, there are no limitations to the pressing cycle.
A particular advantage of the drive system results from the fact that the complete pressing cycle such as advancing in a rapid traverse, pressing, decompressing, returning in rapid traverse and flushing the hot fluid may be controlled by a single hydrostatic machine to be used as the actuating unit. For controlling the fluid flow, less valves are required, particularly using 2/2 directional control valves (two ports/two positions). No proportional valves are required in the system, except the pilot valves of the variable displacement pump. Changing over from rapid traverse to the pressing operation takes place through the check valve function of the 2/2 directional control valves associated to the press cylinder without requiring any active change-over means as this will be explained later.
Furthermore, the press cylinder and the supplemental cylinders are designed with respect to volume such that the complete pressing cycle may be performed in a closed circuit, i.e. there is no need to exterminate any energy inherent to the system. Accordingly (claim 5), the piston areas of the cylinders in relation to the piston area of the press cylinder are designed such that the rapid traverse as well as the pressing stroke are performed in a closed loop of the fluid via the second machine of the hydraulic transformer, not considering volumetric losses of the pumps. These losses are automatically compensated by the valve 23, thus eliminating the need of supplying fluid from the fluid system or returning fluid from the reservoir. According to the invention, the system is designed such that throttling and fluid losses are avoided which are inherent to the prior art. The energy recovered in the decompressing and flushing operation is returned to the fluid system of substantially constant pressure, i.e. a hydraulic accumulator. According to the invention, the press may thus perform a high number of strokes. The volume of fluid needed for rapid traverse and for pressing is small. Still further the losses are small.
Despite the fact that the drive system for the press needs a total of three hydrostatic machines resulting in a worse efficiency because of a multiple energy conversion, it can be shown that the losses are nevertheless substantially reduced up to 65% when compared to conventional drive systems. For the required power merely a medium power rate must be installed. The required power rate may be thus reduced down to 15% of the required power rate of conventional systems. Thus, an optimum efficiency results for the pressing cycle.
The hydraulic drive system according to the invention may be either applied to a differential cylinder or to a synchronizing cylinder. In the latter case, however, a pair of hydraulic transformers must be provided, i.e. a first transformer for performing the rapid traverse of the press cylinder and a second hydraulic transformer for performing the pressing stroke. Otherwise the means for subjecting the press to the biasing pressure and so on are identical to the means utilized for the drive system comprising a differential cylinder.
BRIEF DESCRIPTION OF THE DRAWING
Preferred embodiments of the drive system of the invention are illustrated in the drawings in which:
FIG. 1 is a schematic diagram of a hydraulic drive system according to the invention for a press cylinder of the differential type;
FIG. 2 is a diagram of the valve positions and of the adjustment of the hydraulic transformer for a pressing operation including decompressing of the drive system of FIG. 1;
FIG. 3 a schematic diagram of a hydraulic drive system according to the invention for a press cylinder of the synchronizing type;
FIG. 4 a diagram of the valve position and of the adjustment of the hydraulic transformer for a pressing operation including decompressing in the drive system of FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
According to FIG. 1 a hydrostatic machine 1 of variable capacity which is driven from a motor 2 delivers fluid to a pressure line 3 including a hydraulic accumulator 4. The adjustment of the hydraulic machine 1 is controlled such that an impressed pressure of a substantially constant value is maintained in the pressure line 3. The valve 5 is a safety pressure valve.
A hydraulic transformer comprises a first hydrostatic machine 6 and a second hydrostatic machine 7 mechanically coupled to said first machine. Both machines are variable capacity units with two directions of flow. The designations DS and HS relate to the adjusting system for controlling the flow capacity of each machine. Either machine can operate as a pump or, respectively, as a motor. When the first machine 6 operates as a motor, the safety valves 8 and 8' are operated to be in open position and the machine 6 is driven by the pressure fluid from the fluid system 3 of constant pressure. The fluid leaving the machine 6 flows to a low pressure system 9 which may comprise an accumulator ND. The pressure in the low pressure system is determined by a valve 11 which is adjusted such that a relatively small pressure, but somewhat above the pressure in a reservoir 12 is maintained in the low pressure system. The machine 6 operating as a motor drives the second hydrostatic machine 7 which ports are hydraulically connected through lines 14 and 15 to a press cylinder 16. The line 14 is connected to the piston sided cylinder chamber 17 and the line 15 is connected to the piston rod sided cylinder chamber 18. The piston 19 of the press cylinder 16 thus includes a piston face adjacent the chamber 17 and an annular face adjacent the annular chamber 18. The piston is mechanically connected to a press 20.
The piston 19 of the press cylinder 16 is thus displaced by the fluid delivered by the second machine 7 depending on the sense of rotation. The sense of rotation is controlled by the adjusting system HS of the machine 7 which can be pivoted across zero. The pivot angle determines the flow rate delivered and thus the speed of the piston 19. The operation of the hydraulic transformer 6, 7 for driving a working cylinder is also explained in German 32 02 015 above referred to.
In order to obtain a displacement of the press piston in a closed loop free of losses in performing a rapid traverse and a pressing stroke, a pair of single acting supplemental cylinders 28 and 29 is provided, the pistons thereof also being connected to the press 20. The annular piston areas of the supplemental cylinders 28 and 29 together with the annular piston area of the piston 19 are substantially identical to the piston area of the press cylinder, i.e. the area of the piston 19 adjacent the cylinder chamber 17.
Accordingly, in lowering the press, the fluid displaced from the piston rod sided cylinder chambers of the cylinders 16, 28 and 29 will fill the piston-sided cylinder chamber 17 which increases in volume, i.e. there is no need for additionally supplying any fluid from the system 3. Preferably, the annular piston areas are a bit larger to compensate for any leakage of the driving machine 7, thus avoiding a reduced biasing force while the press operates in a rapid traverse.
The piston-rod-sided cylinder chambers 30, 31 of the supplemental cylinders 28 and 29 are connected to each other through a line 32 which is hydraulically connected through safety valves 33 and 33' required by safety regulations to the low pressure port of the machine 7 including the line 15 which in turn is connected through a valve 35 to the piston rod sided cylinder chamber 18 of the press cylinder 16. The piston sided cylinder chambers of the supplemental cylinders 28 and 29 are connected to the reservoir (not shown).
All the pistons of the cylinders 19, 28 and 29 of the press are biased on either side thereof, i.e. the cylinder chamber 17, 18,30 and 31 each are subjected to a biasing pressure. According to the invention, this is accomplished by a tapping line 22 comprising a check valve 23 opening towards the hydraulic line 14. Both the cylinder chambers 17 and 18 are connected to each other through a valve 25. This valve is also referred to as a short circuit valve 25. In the short circuit position shown in the drawings, the valve 25 connects both cylinder chambers 17 and 18 to each other, i.e. the constant pressure in the pressure line 3 functions to be the biasing pressure for the press cylinder 16 in both cylinder chambers 17 and 18. Furthermore, the cylinder chambers 30 and 31 of the supplemental cylinders 28 and 29 are connected to the cylinder chamber 18 of the press cylinder 16 via the line 32, both the safety valves 33, 33' required by safety regulations, the hydraulic line 15 and the directional control valve 35. The valve 38 located in the low pressure system is in a closed position. According to the invention the biasing pressure is thus made available in a simple way in all cylinder chambers 17, 18, 30 and 31 required for pressure compensation free of losses by tapping the pressure line 3 through the check valve 23.
The operation is as follows: For travelling a rapid traverse in advancing the press 20 the short circuit valve 25 is in the position shown according to which both cylinder chambers 17 and 18 of the press cylinder 16 are connected to each other so that both chambers are subjected to the biasing pressure from the constant pressure line 3. The directional control valve 35 is positioned as shown and the safety valves 33 and 33' are operated to be opened. As soon as the second hydraulic machine 7 being driven by the machine 6 to operate as a pump is adjusted towards a higher flow rate, the pump 7 delivers fluid from the piston rod sided cylinder chambers 30 and 31 through the lines 32 and 14 to the piston sided cylinder chamber 17, i.e. the piston 19 of the press cylinder 16 is rapidly lowered. At the same time, fluid passes through the short circuit valve 25 from the annular chamber 18 of the press cylinder 16 to the piston chamber 17. While the cylinder chambers are subjected to the biasing pressure, the piston 19 is exclusively displaced by the fluid flowing out of the piston-rod-sided cylinder chambers 30 and 31 of the supplemental cylinders 28 and 29. However, the hydraulic machine 7 operating as a motor may drive the hydraulic machine 6 for returning fluid from the low pressure system 9 to the accumulator 4, thus recovering energy, when the weight of the press is heavy enough so that the press does not require any pressurized fluid to perform the rapid traverse, but rather is lowered by the fluid displaced from the cylinder chambers 30 and 31 of the supplemental cylinders 28 and 29.
In performing the pressing stroke the hydraulic machine 7 is pivotally adjusted to change from the flow rate required for the rapid traverse to the pressing speed, i.e. the press slows down. At the time of contacting a work piece (not shown) a counterforce results decreasing the holding pressure in the line 15 or 32, and thus in the cylinder chambers associated therewith. Now, the short circuit valve 25 is in a closed position resulting in a pressure difference prevailing in the cylinder chambers 17 and 18. The short circuit valve 25 may be designed such that it automatically closes when the counterforce occurs. Now the pump 7 is pivoted to a higher flow rate delivering the fluid displaced from all piston-rod-sided cylinder chambers 18, 30 and 31 to the piston-sided-cylinder chamber 17. In this operation, the valve 38 associated to the low pressure system is regularly in a closed position so that the pressure increase required for the pressing stroke is obtained by using the relatively high pressure in the piston-rod-sided cylinder chambers rather than delivering fluid from the low pressure system 9. However, when the high pressure should decrease resulting in the danger that the pump 7 suffers from cavitation, the check valve 38 opens and fluid may be sucked from the low pressure system.
When reaching the maximum pressure, the pump 7 is pivoted to a lower capacity. Accordingly, the drive unit 6 must be not rated accordingly. The available maximum pressure can be thus arbitrarily selected to be higher than the biasing pressure.
Performing the pressing stroke results in a compression of the fluid in the cylinder chamber 17. The hydraulic machine 7 functions to decompress the fluid by being driven from the high-pressure fluid delivered from the cylinder chamber 17, thus driving the hydraulic machine 6 acting as a pump. The energy made available in the decompressing step will be thus recovered and fluid is pumped through the safety valves 8, 8' to the hydraulic accumulator 4 of the high pressure system 3. In performing this step, the valves 33 and 33' are in the position shown, i.e. check valve function and the short circuit valve 25 is in open position.
As the operating cycles above referred to do not regularly need an additional fluid supply from the fluid system 3, the fluid circulating in the drive system while performing the rapid traverse and pressing stroke will be substantially heated. Accordingly, the fluid circulation is provided with a flushing operation.
For flushing during stillstand of the press a directional control valve 36 located in the hydraulic line 14 is opened to connect the outlet port of the pump 7 to the reservoir 12. The fluid volume drained to the reservoir is replaced from the constant pressure system 3 via the check valve 23 opening towards line 14 such that the total volume of heated fluid filling the press cylinder 16, the line 15 and the machine 7 is drained to the reservoir and is replaced by fresh fluid. While performing the flushing step, the hydraulic machine 7 is driven by the fluid displaced from the press cylinder 16 and the remaining system, the fluid being delivered through the line 15 to the machine 7, thus utilizing the pressure difference between the biasing pressure and the reservoir pressure even in flushing to recover energy and to supply fluid through the hydraulic machine 6 acting as a pump to the constant pressure system 3. While flushing, the supplemental cylinders 28 and 29 are blocked by the safety valves 33 and 33', i.e. the press is being maintained in a predetermined position. The operation above referred to relates to flushing the fluid while the press is stopped or in a stillstand position.
However, the flushing step may be also performed while the press is operating. During decompressing the fluid flowing out from the hydraulic machine 7 operating as a motor for driving the hydraulic machine 6 will be not returned to the piston rod sided cylinder chambers 18, 30 and 31, but is rather supplied to the low pressure system 9 through the valve 38. Replacing the fluid again takes place from the constant pressure system 3 through the check valve 23 now opening. The time required for balancing the pressure in the cylinder chambers possibly then requires a longer period of time since the fluid flowing out of the cylinder chamber 17 is not used for increasing the pressure in the chambers 18, 30 and 31. In any case, the press must be not at stillstand when a flushing operation is desired.
FIG. 2 shows the valve position as well as the adjustment of the hydraulic machines of the transformer during the stillstand ST of the press, for the biasing operation V, a rapid traverse in lowering Eab, slowing down (braking) B, pressing P, decompressing D, returning R of the press and flushing SP at stillstand. Concerning the hydraulic machines 6 and 7 of the transformer, FIG. 2 indicates their operation as a pump or as a motor, thus consuming energy from the constant pressure system or recovering energy to the constant pressure system.
FIG. 3 shows a drive system for a press cylinder 16' of the synchronizing type including a piston 19' having a piston rod at either side and cylinder chambers 17' and 18'. All the other components corresponding to the drive system of FIG. 1 have the same reference numerals. To accomplish the closed loop operation according to the invention and in performing the pressing operation for the embodiment of FIG. 3 as well, it is required to disconnect the supplemental cylinders 28 and 29 from the press cylinder 16'. For performing a rapid traverse of the press, a second hydraulic transformer is therefore required, again comprising a first hydrostatic machine 6' and a second hydrostatic machine 7' which both are mechanically coupled and each having a variable capacity. Again, the first machine 6' is connected to the hydraulic line 22, i.e. the pressure system of impressed pressure, while the second hydraulic machine 7' is connected to the piston-rod-sided cylinder chambers 30 and 31 of the supplemental cylinders 28 and 29. The remaining ports of both machines 6' and 7' are connected to the reservoir or, respectively, to the low pressure system 9.
It is possible to accomplish a closed loop for the fluid while performing a rapid traverse and the pressing stroke of the press cylinder 16'. The volumes of both cylinder chambers 17' and 18' are identical. Decompressing and flushing the fluid available in the closed loop is performed in the manner already described with respect to FIG. 1. The same applies to supplying the biasing pressure through the hydraulic line 22 including the check valve 23.
A rapid traverse in lowering the press 20 as well as lifting the press is performed by means of the second hydraulic transformer 6' and 7', wherein the cylinder chambers 17' and 18' are merely connected to each other through the short circuit valve 25 while these steps are performed.
The valve positions as well as the adjustment of the hydraulic machines of both hydraulic transformers are indicated in FIG. 4 again. For the operation of the second hydraulic transformer 6', 7' it is assumed that the weight of the press is heavy enough to be lowered after actuating the valves 33 and 33' to an open position, thus the fluid displaced from the cylinder chambers 30 and 31 driving the second hydraulic machine 7' to act as a motor driving the hydraulic machine 6' for returning the energy to the pressure system. Accordingly, for lifting the press merely the hydraulic machine 7' must be driven to operate as a pump for delivering fluid to the cylinder chambers 30 and 31. | The invention relates to a drive system for a hydraulic press. The drive system is of the type of secondary controlled system maintaining an impressed pressure of substantially constant magnitude in a pressure system. A hydraulic transformer comprises a pair of mechanically coupled hydrostatic machines each having a variably capacity. The first machine is connected to the pressure system and the second machine to the press cylinder. The invention provides a drive system in which biasing the press cylinder, rapid tranverse and pressing stroke, decompressing the fluid and flushing of hot fluid is accomplished in a closed loop free of throttling losses. The hydraulic transformer further allows to recover energy to the pressure system. | 5 |
This is a division of application Ser. No. 034,171, filed Apr. 26, 1979, now U.S. Pat. No. 4,316,715.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to concrete screeds, and more particularly, open frame vibratory screeds.
2. Description of the Prior Art
A wide variety of vibrating concrete screeds are disclosed in the prior art. An open frame, vibrating screed is manufactured by the H. Compton Company of Conroe, Texas, and includes a plurality of penumatic vibrators mounted at intervals on front and rear screed blades. This screed is fabricated in variable length sections, is translatable over a freshly poured concrete surface by a pair of winches and can be adjusted to provide a variable contour for the surface of the concrete being screeded. Another related concrete screed is manufactured by AWS Manufacturing, Inc. of Naperville, Ill. The AWS concrete screed also includes a wall mounting bracket attachment which is bolted to an end bracket of the screed and includes a single length of angle iron which engages the top and side surfaces of a 2×4 wall mounted guide rail. U.S. Pat. No. 4,030,873 (Morrison) discloses a multi-element concrete screed having variable length elements and a rotating shaft which extends along the length of the screed for imparting uniform vibrations to the front and rear screed blades. All of the above described concrete screeds are vertically supported above opposing, parallel oriented side forms.
U.S. Pat. No. 3,110,234 (Oster) discloses a concrete screed having vertically adjustable blades which are translatable along parallel oriented rails. U.S. Pat. No. 3,435,740 (McGall) discloses a concrete screed including a hand operated winch for laterally translating the screed and a turnbuckle system for adjusting the concrete surface contour formed by the various sections of the screed.
U.S. Pat. No. 2,542,979 (Barnes) discloses a concrete screed having an inverted T-shaped screed blade and electric motor for imparting a vibratory motion to the screed blade.
U.S. Pat. No. 3,883,259 (Berg) discloses another concrete screed having parallel oriented blades and means for imparting vibratory motion to the blades.
The following U.S. Patents disclosed other concrete screed configurations: U.S. Pat. No. 2,372,163 (Whiteman); U.S. Pat. No. 1,386,348 (Maxon); U.S. Pat. No. 2,866,394 (Smith); U.S. Pat. No. 3,008,388 (Nave); U.S. Pat. No. 4,073,593 (Storm); U.S. Pat. No. 3,095,789 (Melvin); U.S. Pat. No. 3,523,494 (Kraemer); U.S. Pat. No. 2,219,247 (Jackson); U.S. Pat. No. 3,113,494 (Barnes); U.S. Pat. No. 2,693,136 (Barnes) and U.S. Pat. No. 4,105,355 (King).
SUMMARY OF THE INVENTION
The present invention contemplates a vibrating concrete screed system including a fixed blade extension bracket, an adjustable blade extension bracket, a detachable guide bracket, a detachable pan float finisher and a center mounted winch attachment. Each of these attachments can be readily coupled to a screed which converts freshly poured concrete freshly poured concrete lying in an area between opposing side forms into a smooth, finished concrete surface. The screed of this system comprises a frame having first and second ends, front and rear screed blades coupled in a spaced apart relationship to the lower portion of the front and rear of the frame to shape the upper surface of the concrete, and first and second end brackets which are coupled to the first and second ends of the frame.
The fixed blade extension bracket can be coupled to either or both ends of the screed and includes a front blade extension which is coupled in alignment with the front screed blade to extend the overall length of the front blade by a predetermined desired amount. The fixed blade extension bracket also includes a rear blade extension which is coupled in alignment with the rear screed blade to extend the overall length of the rear blade by a predetermined desired amount.
The adjustable blade extension bracket can be coupled to either one or both of the end brackets and includes horizontally adjustable front and rear blade sections, and means for coupling the front and rear blade sections to the first and second side members of an end bracket to permit the adjustable end bracket to be coupled at selected vertical positions to the end bracket while maintaining the front and rear blade sections in parallel alignment with the front and rear screed blades.
The detachable guide bracket functions to guide one end of the screed along a wall mounted, horizontally oriented guide member. The guide bracket includes a first vertically oriented side member, a second vertical oriented side member, means for detachably coupling the first and second side members to an end bracket of the screed, and guide means laterally extending from the first and second side members for contacting the guide member to maintain the screed at a predetermined desired vertical position as the guide means is laterally translated along the length of the guide member.
The detachable bottom pan is positioned between the first and second end brackets of the screen and includes a front edge which is coupled to the front screed blade and a rear edge which is coupled to the rear screed blade.
Certain embodiments of the screed of the present invention include first and second winches which are coupled to the first and second end brackets and include lines extending from the first and second winches which are coupled to a stationary object for exerting a traction force on the first and second end brackets of the screed when the lines are reeled in by the first and second winches. A detachable, center mounted winch may also be provided. The center mounted winch attachment includes a line extending from the winch to a stationary object for permitting the center mounted winch to exert a traction force on the central section of the screed to permit uniform translation of the entire length of the screed.
DESCRIPTION OF THE DRAWINGS
The invention is pointed out with particularity in the appended claims. However, other objects and advantages together with the operation of the invention may be better understood by reference to the following detailed description taken in connection with the following illustrations wherein:
FIG. 1 is a perspective view of a two section screed in accordance with the present invention.
FIG. 2 is a partial elevational view of the left hand portion of the screed illustrated in FIG. 1.
FIG. 3 is an enlarged perspective view of the means for adjusting the contour of the front and rear screed blades.
FIG. 4 is an enlarged view of the hardware utilized to join the blade sections of adjacent screed sections.
FIG. 5 illustrates the structure and positioning of the center mounted winch attachment.
FIG. 6 is a perspective view illustrating a blade extension bracket in accordance with the present invention, and indicating the manner in which the blade extension bracket is coupled to the screed.
FIG. 7 illustrates the adjustable blade extension bracket of the present invention and the manner of coupling this bracket to an end bracket of the screed.
FIG. 8 is a perspective view of a detachable guide bracket in accordance with the present invention.
FIG. 9 illustrates the manner of attaching the detachable guide bracket to an end bracket of the screed and the relative positioning of the guide bracket with respect to a wall mounted guide rail.
FIG. 10 illustrates a blade extension bracket having a shorter length blade extension than the blade extension bracket illustrated in FIG. 6.
FIG. 11 is a partial sectional view of the adjustable blade extension bracket shown in FIG. 7.
FIG. 12 is an elevational view of the screed illustrated in FIG. 1, taken along section line 12--12.
FIG. 13 is a view from above of the screed illustrated in FIG. 12, taken along section line 13--13.
FIG. 14 is an enlarged view of a section of the screed shown in FIG. 13, particularly illustrating the structure and relative orientation of the truss members of the screed.
FIG. 15 is a sectional view of the screed illustrated in FIG. 12, taken along section line 15--15, particularly illustrating the manner in which the detachable bottom pan is coupled to the front and rear screed blades.
FIG. 16 illustrates the detachable pan float finisher of the present invention.
FIG. 17 is a view from above of the adjustable extension bracket shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In order to better illustrate the advantages of the present invention and its contributions to the art, a preferred hardware embodiment of the inventive system will now be described in some detail.
Referring now to FIGS. 1 and 2, the vibrating concrete screed which forms the primary element of the screed system will be described. In many figures numerous support structures have been delected in the interst of more clearly illustrating other elements of the invention. The specific configuration of the open frame support structure will be fully described in connection with FIGS. 12, 13 and 14.
A horizontally oriented air transport pipe 10 extends between first and second end brackets 12 and 14. Two L shaped blades coupled back to back form a Tee-shaped front screed blade 16. An L-shaped rear screed blade 18 is also coupled to the first and second end brackets 12 and 14.
In the preferred embodiment the screed is fabricated in 5 foot and 71/2 foot lengths, any combination of which can be joined together to form a screed having a length reasonably close to the desired length.
FIG. 4 illustrates the manner in which a splice plate and a plurality of securing means such as nuts and bolts may be used to couple together abutting ends of each screed blade section.
FIG. 3 illustrates the structure utilized to coupled adjacent sections of air transfer pipe 10 to form a single structural element. Air transfer pipe 10 forms an air tight conduit which supplied a source of air under pressure along the entire length of the screed. The air transfer pipe junction illustrated in FIG. 3 comprises a threaded coupling unit 20 having left hand threads on one end and right hand threads on the other end which is rotatably adjusted to provide the desired angle of incidence between adjacent screed section. This adjustment provides the desired contour on the upper surface of the concrete being screeded. A jam nut 22 locks coupling unit 20 in the desired position.
Referring now to FIGS. 1 and 2, a high volume air compressor unit is coulped by a crow's foot coupling unit 24 to inline lubricator 26. An air control valve 28 and an air pressure gauge 30 are coupled between coupling unit 24 and filter 26. Lubricator 26 and its associated hardware is detachably coupled to air transfer pipe 10 by a pair of spring clips of the type indicated by reference number 32. A flexible air hose 34 is coupled at one end to lubricator 26 and at the other end to air transfer pipe 10 by crow's foot coupling unit 36.
A plurality of penumatic vibrators are coupled at intervals along the length of front screed blade 16 and rear screed blade 18. The pneumatic vibrators are coupled to the vertical face of rear screed blade 18 and to the rear horizontally oriented face of front screed blade 16. An air hose, such as air hose 40, couples each vibrator unit to the source of air under pressure within air transfer pipe 10. The vibrators are generally staggered front to back and are coupled at 30 inch intervals. A vibrator is coupled to the front and rear screed blade 30 inches from both end brackets 12 and 14 to maximize vibration fo the scrred in the vicinity of the side forms. Each air vibrator unit 38 includes a vertically displaceable piston and a pair of air discharge ports in the side of the cylinder wall. The piston within each cylinder vibrates at between 6000 to 8000 cycles per minute when air at approximately 40 PSI is supplied. Air vibrator units of the type used in connection with the present invention are well known to those skilled in the art and are commercially available.
The complete screed unit is translated along the upper surface of opposing side forms 42 and 44 by actuation of winches 46 and 48. These winches can be power driven or manually operated devices. A cable 50 from each winch passes around a pulley 52 which is coupled by bolt through the vertical face of front screed blade 16 to the front vertically oriented member of end bracket 12. The free end of cable 50 is coupled to a stationary object generally aligned with side form 42.
To prevent bowing of the central portion of a screed having a length around 60 feet or more, a center mounted winch assembly of the type depicted in FIG. 5 is generally utilized. A center mounting bracket 54 of a configuration virtually identical to end brackets 12 and 14 is coupled at the junction between two adjacent screed units in the center of the assembled screed. An additional winch 56 is coupled to the upper portion of bracket 54. The cable extending from winch 56 passes through a pulley in a manner similar to that described in connection with the pulleys for outboard winches 46 and 48. Workmen operate winches 46, 48 and 56 at an equal rate to uniformly translate the screed in the desired direction to prevent bowing of the central portion of the screed.
Since it is frequently desirable to more precisely tailor the length of a concrete screed to match the distance between side members 42 and 44 than is permitted by the previously described 5 foot and 71/2 foot screed sections, blade extension brackets of various fixed lengths have been provided as is illustrated in FIG. 6 and 10. To incorporate a blade extension bracket 58 into the screed, one or both of the end brackets 12 and 14 are removed from the screed. Extension bracket 58 is then coupled by securing means such as nuts and bolts to the front and rear screed blades. Each extension bracket includes a front blade extension 60 and a rear blade extension 62. As can be seen from FIG. 6 and 10, the length of the front and rear blade extensions can be fabricated in any desired length. In the system of the preferred embodiment, three blade extension brackets having lengths of 6, 12 and 18 inches are provided. Blade extension bracket 48 also includes a horizontally oriented strut 64 which extends between the end portions of blade extensions 60 and 62 to maintain a predetermined fixed spacing therebetween. Angled support struts 66 and 68 are coupled respectively to the outer end of front blade extension 60 and rear blade extension 62 and to the vertically oriented members of blade extension bracket 48. If desired, vibrators may be coupled to the blade extension bracket.
Referring now to FIGS. 11 and 17, a vertically and horizontally adjustable blade extension bracket 70 will be described. A bracket of this type is particularly desirable when it is necessary to form a step or sidewalk adjacent to the roadbed or warehouse flooring which is being formed by the remainder of the screed. The adjustable blade extension bracket 70 is coupled to the parallel oriented, vertically extending side members 72 and 74 of end bracket 12. Bracket 70 can be divided generally into a telescopically adjustable first section 76 which permits adjustment of the lateral extension of section 76 with respect to end bracket 12. A second vertically adjustable section 78 permits the entire unit to be adjustably secured to side members 72 and 74 of end bracket 12. Section 78 includes a pair of horizontally oriented channel members 80 and 82 which are dimensioned to permit the two telescopically adjustable legs of section 76 to be readily laterally translatable within the interior of sections 80 and 82. Securing means in the form of an adjustable bolt, such as bolt 84, are provided in the sides of channels 80 and 82 to clamp section 76 in the desired lateral position. The horizontal distance between the interior portions of channels 80 and 82 is just sufficient to permit them to be fitted within the interior walls of side members 72 and 74 of end bracket 12.
A horizontally oriented support strut 86 is of a length equal to the horizontally oriented support strut 88 of end bracket 12. The distance between the interior surfaces of channels 80 and 82 is equal to the overall width of strut 88. Pairs of parallel aligned steel plates, such as plate 90 are coupled by securing means, such as a plurality of nuts and bolts, at one end to each vertically extending strut 92 of bracket 70. A second plurality of securing means, such as another set of nuts and bolts, passes behind side member 72 and serves to hold the two parallel aligned steel plates 90 together around side member 72. A third set of bolts, such as bolt 94, are threadably coupled to the exterior of steel plate 90 and when tightened serve to clamp bracket 70 in a predetermined desired vertical position along side members 72 and 74. In the above described manner structure is provided which permits vertical and lateral adjustment of the adjustable blade extension bracket 70.
Referring now to FIGS. 8 and 9, a detachable guide bracket forming a portion of the system of the present invention will now be described. Guide bracket 96 includes vertically oriented members 98 and 100 and a horizontal member 102 from which a group of three lips, such as lip 104, extend to from a three-sided rectangular aperture fro accomodiating the upper horizontally oriented strut of end bracket 12.
A pair or parallel oriented rectangular steel plates, such as plate 106, are secured to the lower portion of each side member 98 and 100. As guide bracket 96 is rotatably fitted to end bracket 12, each pair of plates coupled to the lower portion of side members 98 and 100 slip around the lower portion of the side members of end bracket 12. Securing means, such as a pair of nut/bolt units 108, is provided to draw the parallel plates together to securely clamp guide bracket 96 to end bracket 12.
Additional bracket structure of the type illustrated extends outward from the side of guide bracket 96 and includes a pair of curved, horizontally oriented guide faces 110 and a pair of curved, vertical oriented guide faces 112. Guide faces 110 and 112 are configured to slide along the exposed horizontal and vertical faces of a 2×4 guide member 114 which is secured to a wall 116. The weight of one end of the screed is thus supported by guide rail 14 as the screed is translatable along the length of the concrete which is being shaped.
Referring now to FIGS. 12, 13, 15 and 16, a detachable aluminum pan float finisher is disclosed. Pan 118 includes a plurality of apertures in alignment with the horizontal sections of the front and rear screed blades. Securing means are passed through the plurality of apertures in order to couple pan 118 to the lower surface of front and rear screed blades 16 and 18. The pan float finisher includes upward curved front and rear end sections to assist in smoothing freshly poured concrete.
Referrng now to FIGS. 12, 13 and 15, pan float finisher 118 is shown coupled to the screed. These figures together with FIG. 14 also clearly illustrate the totality of the network of struts which form the open frame for the screed of the present invention. Similar strut elements in each figure are referred to by the same letter/number designator, e.g. strut Al in FIG. 12 corresponds to strut Al in FIG. 14. Each strut is coupled at both ends by welded junctions to the remainder of the screed and to the various adjacent other struts.
It will be apparent to those skilled in the art that the disclosed vibrating concrete screed system may be modified in numerous ways and may assume many embodiments other than the preferred forms specifically set out and described above, Accordingly, it is intended by the appended claims to cover all such modifications of the invention which fall within the true spirit and scope of the invention. | A triangular truss screed includes a frame having first and second ends and a top support member which forms the apex of the triangular truss. Front and rear screed blades extend between the first and second ends of the screed frame and are coupled in a spaced apart relationship to the lower portion of the front and rear of the frame. The front and rear screed blades each include a flat lower surface and form the front and rear edges of the triangular truss frame. A pan float finisher is coupled to the flat lower surface of the front and rear blades and includes a length substantially equal to the length of the screed frame and a width greater than the spacing between the front and rear blades. A vibration generating mechanism is coupled to the screed to vibrate the pan float finisher. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to color imaging systems, and more particularly to a sensor for color calibrating an imaging system, the sensor having both an emissive optical radiation transducer for measuring video display images and a reflective optical radiation transducer for measuring reflective light sources such as color printed media.
2. Description of the Background
Color imaging systems are capable of displaying and printing many varying shades of colors. Recently, color imaging systems have become increasingly sophisticated and better resolution color displays have become more readily available. As the availability and use of color imaging systems become more common, problems associated with the color accuracy of displays become more commercially important. For instance, colors on a color display are prone to drifting with temperature and age. Different color displays further exhibit different color display characteristics, which often can be quite noticeable and in some cases, user adjustable.
The different display characteristics of color displays are hard to predict and control--even the same type and model of color display can exhibit different color display characteristics. A way to ensure consistent color characteristics is to calibrate or characterize the color displays to a particular set of operating parameters.
Another problem that is also associated with color imaging systems arises in the printing of color media. Often, the colors that are displayed on a color display are not the shades of colors that are printed by the color printer. Color printing systems have a number of variables which affect color fidelity. For instance, printed color media varies depending on the type of paper material used. The paper material may be shiny, yellow office bond, thick, matted, or some other material combination. Humidity also changes the color display characteristics of a printer. Another factor which causes color variations in printers is the half-toning scheme used to achieve the different shades of colors.
From the standpoint of the user, the actual or perceived quality of a color imaging system depends on the degree to which the displayed color image appears to match the printed color media. Users of color imaging systems desire the printed color media to be an accurate reproduction of the image from the color display. The what you see is what you get (WYSIWYG) capability of a color imaging system is complicated by the color image conversion from red, green, and blue (RGB) color data to cyan, magenta, and yellow (CMY) or (CMYK where K stands for the black printer) color data. In order to display color images, the color displays utilize the three RGB color data format. Color printers, on the other hand, utilize the CMY or CMYK color data format for printing the color media. Techniques have been developed for converting the RGB color data format to the CMY color data format. U.S. Pat. No. 4,941,038, entitled "Method For Color Image Processing" describes a method for processing the RGB color data with the CMY color data.
Past color measurement systems have been comprised of color sensing elements which include optics, electrical measurement and signal conversion components, digital circuits, and software for either translating the measurements or providing communication capabilities for the color sensing device. Current color measurement devices acquire measured data in some standard form that requires reworking the measured data to another form before the color imaging system can use the measured data for actual calibration. Furthermore, these color measurement devices are often expensive, complex, and not readily accessible to the average user. Therefore, it is desirable to design a color measurement device for calibrating a color imaging system that can be used by the average user of the color imaging system which improves and overcomes the disadvantages of the prior art. The improved color measurement design should be inexpensive and affordable to an average user of the color imaging system.
SUMMARY OF THE INVENTION
In accordance with the present invention, a color calibration system comprises a color detector which receives color samples of images to provide sampling data. A processor coupled to the color detector receives the sampling data to generate a modified device profile. An output device coupled to the processor generates color output images and is responsive to the modified device profile to perform output adjustments to the output images. The sampling data includes a red sampling data, a green sampling data, and a blue sampling data. The red, green, and blue sampling data are directly processed by the processor to generate the modified device profile.
According to another aspect of the invention, the color detector is an emissive color detector which receives emissive color samples from a display device. The emissive color detector includes a first transducer having a red filter which provides red sampling data, a second transducer having a green filter which provides green sampling data, and a third transducer having a blue filter which provides blue sampling data. The processor receives the red sampling data, the green sampling data, and the blue sampling data and provides the modified device profile to the output device. The output device includes an output device profile that is updated in response to the modified device profile. The output device is a color printer that can be calibrated to render the colors of the color samples.
According to another aspect of the invention, the color detector receives reflective color samples from an article. The color detector includes a first transducer having a red filter which provides red sampling data, a second transducer having a green filter which provides green sampling data, and a third transducer having a blue filter which provides blue sampling data. The red data channel includes a red filter and a focusing lens, the green data channel includes a green filter and a focusing lens, and the blue data channel includes a blue filter and a focusing lens. The color detector includes a light source to illuminate a color sample of the article for use by the first transducer, the second transducer, and the third transducer. The color detector includes a sight access which provides visual orientation of the color detector to the article. The processor receives the red sampling data, the green sampling data, and the blue sampling data and provides the modified device profile to the output device. The output device includes an output device profile that is updated in response to the modified device profile. The output device is a display monitor. The color calibrator provides sampling data that modifies the device profile of the display monitor so that the colors of the article are rendered to the display monitor.
The present invention can also be characterized as a color sampling device comprising a first sensor which detects emissive color images to provide a first color sampling data, and a second sensor which detects reflective color images to provide a second color sampling data wherein the first color sampling data and the second color sampling data are in similar data formats. The first color sampling data and the second color sampling data are in a red, green, and blue data format. The first sensor includes a first emissive transducer having a red filter which provides a first red sampling data, a second emissive transducer having a green filter which provides a first green sampling data, and a third emissive transducer having a blue filter which provides a first blue sampling data. The second sensor includes a first reflective transducer having a red lens which provides a second red sampling data, a second reflective transducer having a green lens which provides a second green sampling data, and a third reflective transducer having a blue lens which provides a second blue sampling data.
According to another aspect of the invention, the second sensor includes an illuminating device which illuminates a sampling area to provide reflective color images to the first reflective transducer, the second reflective transducer, and the third reflective transducer. The second sensor includes a visual access to the sampling area so that the color sampling device can be placed over the sampled area.
Other aspects and advantages of the present invention can be seen upon review of the figures, the Detailed Description and the Claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an embodiment of the present invention for calibrating a color imaging system;
FIG. 2 depicts an embodiment of a color sensor of the present invention;
FIG. 3 depicts an alternative embodiment of a color sensor of the present invention;
FIG. 4 is a schematic diagram showing the sensor, processor, and output devices in a preferred configuration of the present invention;
FIG. 5 is a flow chart showing a method for calibrating an output device using the sensor of FIG. 2; and
FIG. 6 is a flow chart showing a method for closed loop operation of a processor and output device using the sensor of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 an embodiment of a system comprising an integrated sensor 20 of the present invention is shown for calibrating and adjusting a color imaging system. The term "integrated" as used in this description applies to an optical sensor containing both emissive and reflective components in a single housing or package. Sensor 20 is coupled to processor 11 and samples article 18 to provide color image data 12 to processor 11. Processor 11 receives the color image data 12 and manipulates the color image data 12 into a device independent color space 14. Processor 11 is preferably a general purpose computer, programmed to operate on sensor 20. Processor 11 of the preferred embodiment is implemented using a PowerPC computer manufactured by Apple Computer of Cupertino, Calif. Any suitable computing device can also be equivalently used. Processor 11 transforms the device independent color space 14 to a device profile 15 for color display device 19. Similarly, processor 11 transforms the device independent color space 14 to a device profile 16 for color printer device 17. Color display device 19 and color printer device 17 are both output devices. Color display device 19 is a display monitor which provides an emissive display. The emissive display of conventional color display device 19 is achieved by an additive process. An additive process sums the available output colors to achieve a desired color. The output of the emissive display begins with the color black. As output colors are added to the output of device 19, the desired colors are achieved. Summing the available output colors achieves the color white at the output of the emissive display. Color printer device 17 is a conventional output printer which provides a color print. A color print is achieved by a subtractive process, in which dyes variously absorb portions of a white light spectrum to achieve a desired color. The output of the color printer typically begins with the white color of the paper. Available output colors are removed from the output of the color printer to achieve the desired color on the color print.
The color display of color display device 19 comprises a three-color image of red, green, and blue (RGB). The color image red provides a red output. The color image green provides a green output, and the color image blue provides a blue output. The device profile 15 is in an RGB data format and drives the color display of color display device 19. The color print of color printer device 17 comprises a three-color image of cyan, magenta, and yellow (CMY) or (CMYK, where K is black). The color image cyan is a red absorber. The color image magenta is a green absorber, and the color image yellow is a blue absorber. Thus, using the three-color image of CMY, the color red in an RGB data format is achieved by combining magenta and yellow. The color green is achieved by combining cyan and yellow, and the color blue is achieved by combining cyan and magenta. The device profile 16 in a CMY data format drives the output of color printer device 17. Other variations to color image data formats can be similarly converted. For example, RGB data format can be converted to a four-color image which includes CMY and black.
Sensor 20 of the present invention is a device that obtains color image data 12 from a display output of color display device 19, a printed output of color printer device 17, or a sample article 18. Sample article 18 is an item that reflects or emits light, including an emissive display, printed matter, a painted object, a paint sample chart, a fabric, or other similar item. Processor 11 receives the color image data 12 and processes the color image data 12 to a device independent color space 14. When a display output from color display device 19 is produced, processor 11 transforms the device independent color space 14 to a device profile 15 for color display device 19. Device profile 15 drives the display output of color display device 19. When a printer output of color printer device 17 is produced, processor 11 transforms the device independent color space 14 to a device profile 16 for color printer device 17. Device profile 16 drives the print output of color printer device 17. The device profiles 15 and 16 provide device dependent color data for driving the outputs of color display device 19 and color printer device 17.
In an example to calibrate color display device 19 to the color of a sample article 18, sensor 20 measures the colorimetric data of sample article 18 and generates color image data 12. Processor 11 receives the sampled color image data 12 from sensor 20 and transforms the sampled color image data 12 to a device independent color space 14. Processor 11 transforms the device independent color space 14 to a device profile 15. Device profile 15 contains device dependent color space data that is used to provide RGB values for driving the display output of the color display device 19. The device profile 15 calibrates the display output of color display device 19 to the color of the sample article 18. Thus, a desired color is rendered onto the color display device 19 by measuring the colorimetric data of a sample article 18.
In another example, sensor 20 is used to colorimetrically calibrate the print output of color printer device 17 with the display output of color display device 19 so that the print output of color printer device 17 accurately reproduces the colors displayed on color display device 19. Once desired colors are achieved on the color display device 19, sensor 20 obtains color image data 12 from the emissive output of color display device 19 to colorimetrically calibrate the print output of color printer device 17. The sampled color image data 12 from sensor 20 is transferred to processor 11 which transforms the sampled color image data 12 of the color display device 19 to a device independent color space 14. Processor 11 transforms the device independent color space 14 to the device profile 16 for color printer device 17. The transformed device profile 16 calibrates the print output of color printer device 17 so that the display output of color display device 19 is rendered on the print output of the color printer device 17. Although, in the preferred embodiment the processor 11 is a stand-alone general purpose computer, alternatively, color printer device 17 can include the processor 11 to transform the device independent color space 14 to the device dependent color space of device profile 16.
In another example, the color printer output of device 17 can be colorimetrically calibrated to article 18 using sensor 20. Sensor 20 generates color image data 12 from a sample article 18. Processor 11 receives the sampled color image data 12 and transforms the color image data 12 to a device independent color space 14. The device independent color space 14 is transformed to the device profile 16 for color printer device 17. The transformed device profile 16 calibrates the print output of color printer device 17 so that the colors of sample article 18 are reproduced on the print output of color printer device 17.
As will be discussed below with reference to FIG. 2, sensor 20 is capable of measuring both reflective and emissive color components. Use of sensor 20 in combination with processor 11 enables an integrated closed-loop operation between the color display device 15 and the color printing device 17.
Referring now to FIG. 2, a preferred embodiment of sensor 20 is depicted, in which two sets of transducers 24, 26 are used to generate color image data 12 (FIG. 1) from the sample article 18. Each set of transducers 24, 26 contains three transducers 24(a, b, c) and 26(a, b, c) that provide RGB data format inputs to processor 11. The RGB data contains red color, green color, and blue color image data components. The first set of transducers are emissive transducers 24a, 24b, and 24c which sense data samples of article 18 that are emissive in character. Emissive data is generated by color display devices 19, and other sources that emit light. Emissive transducers 24a, 24b, and 24c are mounted to a transparent base plate 22, with RGB filters 25a, 25b, and 25c placed in front of the emissive transducers. Red filter 25a is placed in front of emissive transducer 24a. Green filter 25b is placed in front of emissive transducer 24b, and blue filter 25c is placed in front of emissive transducer 24c. The red filter 25a transmits red light The green filter 25b transmits green light, and the blue filter 25c transmits blue light from the emissive sample of article 18. The emissive transducers 24a, 24b, and 24c provide a red transducer data output, green transducer data output, and blue transducer data output, respectively. Emissive samples of article 18 are generated by placing base plate 22 against the emissive sample of article 18. Emissive transducers 24a, 24b, and 24c sense the light given off by the emissive sample of article 18 and provide color image data 12 in response to the amount of red, green, and blue light received. The combined emissive transducer data of the emissive transducers 24a, 24b, and 24c comprise the sampled color image data 12 that is transferred to processor 11. Processor 11 transforms the color image data 12 to the device independent color space 14 as discussed below, with respect to FIG. 4.
The second set of transducers are reflective transducers 26a, 26b, and 26c, which sense samples of article 18 that are reflective in character. Reflective samples include color printed matter, and other articles that reflect color when illuminated. Reflective transducers 26a, 26b, and 26c receive reflected color light from an active reflective area 29 to obtain the color image data 12 from the reflective sample article 18. Illuminating source 30 is positioned to reflect light from the reflective sample article 18 to partial mirror 21. Partial mirror 21 directs the reflected light from the reflective sample article 18 to lenses 28a, 28b, and 28c. The lenses 28a, 28b, and 28c each concentrate the reflected light to its respective transducer 26a, 26b, and 26c. The reflected light from the reflective sample of article 18 is filtered by a red filter 27a, green filter 27b, and blue filter 27c which correspond to reflective transducers 26a, 26b, and 26c, respectively. The red filter 27a transmits red light. The green filter 27b transmits green light, and the blue filter 27c transmits blue light from the reflected sample. The reflective transducers 26a, 26b, and 26c provide a red transducer data output, a green transducer data output, and a blue transducer data output, respectively. The combined reflective transducer data of the reflective transducers 26a, 26b, and 26c comprise the sampled color image data 12 that is transferred to processor 11. Partial mirror 21 further provides a sight access for a user 13 to visually position the active area 29 of sensor 20 over the reflective sample article 18.
The embodiment of sensor 20 depicted in FIG. 2 combines the emissive transducers 24a, 24b, and 24c and reflective transducers 26a, 26b, and 26c in a single package. In practice, emissive transducers 24a, 24b, and 24c and reflective transducers 26a, 26b, and 26c can be placed in separate sensor packages. Sensor 20 can be constructed to be comprised of only the emissive transducers 24a, 24b, and 24c. Similarly, sensor 20 can be constructed to be comprised of only the reflective transducers 26a, 26b, and 26c.
Referring now to FIG. 3, an alternate embodiment comprising the reflective transducers 36a, 36b, and 36c is depicted. Illuminating source 40 is projected through lens 32 and protective plate 34. Lens 32 concentrates illumination from illuminating source 40 to pass through protective plate 34 to active reflective area 39. Reflective sample article 18 is positioned to reflect color light from the illuminating source 40. The protective plate 34 enables the user of sensor 20 to position the illumination from illuminating source 40 over the sample area 39. The underside of protective plate 34 is a partial mirror 31 which directs the reflected light from the reflective sample article 18 to red filter 37a, green filter 37b, and blue filter 37c. The red filter 37a transmits red light. The green filter 37b transmits green light, and the blue filter 37c transmits blue light from the reflected sample. Lenses 38a, 38b, and 38c concentrate the reflected light from red filter 37a, green filter 37b, and blue filter 37c to reflective transducers 36a, 36b, and 36c, respectively. Each of the reflective transducers 36a, 36b, and 36c provides a respective red transducer data output, a green transducer data output, or a blue transducer data output. The combined reflective transducer data of the reflective transducers 34a, 34b, and 34c comprise the sampled color image data 12 that is transferred to processor 11.
Referring now to FIG. 4, a block diagram is shown of processor 11 connected to sensor 20 and to display 19, printer 17, and other output device 59. Processor 11 is preferably a general purpose computer having a data bus 43 through which various peripheral devices can be accessed. Program memory 45 is memory storage for containing a listing of sequential program steps for instructing the general operation of CPU 41. Sensor 20 contains an emissive transducer 49 as well as a reflective transducer 51 in an integrated package. Sensor driver 47 contains programmed instructions which are executed by CPU 41 for the operation of sensor 20. This sensor driver 47 may contain such instructions as identifying for the sensor 20 the format, offset voltages, or relative intensities, in which sensor 20 is to transmit data to CPU 41. Sensor driver 47 may also instruct CPU 41 to read and transmit calibration values to CPU 41 for receiving and interpreting the color measurement data received from sensor 20.
Once sampled, image data is transmitted from sensor 20 for storage in a memory location referred to as color space 14. Image data stored in color space 14 is conventionally characterized by three parametric values. In the preferred embodiment the color parameters of hue, chroma, and intensity, are used. Hue defines the color such as red, blue or green contained in the article 18 being sampled. Chroma refers to the amount of white or black contained in the color sample, and intensity refers to the lightness or darkness of the sampled value. Other parametric values such as relative values of basic color components, or some other scheme as known in the art for storing color data may also be used. Once image data 12 is stored in color space 14, the color transform engine 53 instructs the CPU 41 to convert the color space image data into device profile 16 (FIG. 1) which is dependent on a specific output device such as the display 19, printer 17, or other output device 59. This device profile data 16 is stored in device profile memory 57, preferably as a look-up table which maps a specific color parameter to a set of conversion values which are defined for the particular output device being driven. Whenever CPU 41 transmits color image data to printer 17, for instance, the CPU sends that data to device profile memory 57 which relates to printer 17. That transmitted image data is then converted or translated using the now calibrated device profile memory 57 to produce a printer 17 image which relates to color information from the sampled data received at sensor 20. Sensor calibration memory 55 is used by CPU 41 in initially and periodically calibrating sensor 20. During sensor 20 calibration, a known color sample is used as article 18 for measurement by sensor 20. That sample article 18 is then used to make data adjustments to sensor 20. In this way, sensor 20 can itself be calibrated against a known standard and this standard information (sensor profile) can be stored in sensor calibration memory 55 to be used by sensor driver 47 in the operation of sensor 20 with processor 11.
Referring now to FIG. 5, a flow chart is shown of a method for calibrating an output device such as display 19, printer 17 or other output device 59, of the present invention. The method begins with initialize sensor step 70. Various control codes are sent to sensor 20 to establish a communication link between sensor 20 and the processor 11. Registers and control circuits of sensor 20 are reset during the initialize sensor step 70. A second optional initialization occurs in step 72 with the calibration of the sensor 20. Calibration of the sensor 20 is effectuated by sampling an article 18 containing a color standard, such as white, that has known colorimetric data. This calibration data sampled from the color standard is stored as sensor characteristic data in sensor calibration memory 55 and used by the color transform engine 53 when color space data as collected from the sensor is converted to device profile data and stored in device profile memory 57. Calibration step 72 is generally performed only periodically or with the first operation of the sensor 20. Beginning in step 74, sensor 20 reads an article 18 for calibration of an output device (19, 17, or 59). For the purposes of this example, the method steps of FIG. 5 will be described with respect to calibration of a display 19, although the method equivalently applies to any color output device. In step 76, image data read from sensor 20 is stored in color space 14. Since display 19 is an emissive device, the emissive transducer 49 will be used in sensor 20 to generate the image data 12 which is stored in color space 14. In step 78, color space 14 is transformed using instructions from color transform engine 53 to generate a device profile for storage in device profile memory 57. This generation of a device profile may result in a newly generated device profile or may involve only the adjustment of an existing device profile as determined by the color transform engine 53 in step 80. New display image data that is subsequently designated for output on display 19 will then be processed using the data in the device profile memory 57. The calibration of display 19 ends in step 82 and processing returns to program memory 45.
Referring now to FIG. 6, a flow chart is shown of a method for closed loop operation of the processor 11 in conjunction with the sensor 20 and output devices (19, 17, 59). A valuable feature of the present invention is the ability to operate a color imaging system in a closed loop mode. As an example of closed loop mode, a desired color is sampled as an article 18 for output on printer 17. An exact color representation of article 18 can be generated by successively sampling the output from printer 17 using sensor 20 and adjusting the device profile stored in memory 57 until printer 17 produces an exact color replication of article 18.
The method of FIG. 6 begins in step 85 when the sensor 20 reads article 18. In step 87, image data 12 from article 18 is then transferred and stored to color space 14. The color transformation engine 53 converts the color space 14 into a device profile which is stored in device profile memory 57 in step 89. This device profile may be either a newly generated device profile or the adjustment of an existing device profile in step 91. Following the adjustment 91 of the device profile, printer 17 generates an output in step 93. This printer 17 output is then sampled using the reflective transducer 51 of sensor 20 in step 95, and a test is made by CPU 41 in step 97 to determine whether the image data resulting from the sampling of printer 17 output falls within a tolerance of the original image data 12 sampled from the original article 18. If the printer 17 output is not within a predetermined tolerance, the CPU 41 makes an adjustment to device profile memory 57, again in step 91, to further correlate the device profile memory 57 to produce a desired output result. A new output is generated in step 93 and this loop continues until an acceptable tolerance is reached and the process ends in step 99. It should be known that although this method of FIG. 6 is described with respect to a printer 17, this closed loop operation may also be effectively performed in conjunction with display 19 or other output device 59.
While the present invention has been particularly described with reference to FIGS. 1-6, and with emphasis to calibration of color outputs, it should be understood that the figures are for illustrative purposes and should not be taken as limitations on the invention. In addition, it is clear that the method and apparatus of the present invention have utility in many applications where specialized color matching between color presentation systems is desired. It is contemplated that many changes and modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the invention as disclosed. | A color calibration system comprises a processor for receiving and transmitting data. A first sensor coupled to the processor detects emissive color images for providing first color sampling data to the processor. A second sensor coupled to the processor detects reflective color images for providing second color sampling data to the processor. A color output device coupled to the processor is calibrated in response to data generated by at least one of the first and second sensors. | 7 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to the field of buoyancy modules, and in particular to the field of buoyancy modules that include syntactic foam.
[0002] Syntactic foam is known for use in deep-sea floats and buoys for offshore oil exploration and production. Syntactic foams are composite materials in which hollow structures, such as microspheres are dispersed in a resin matrix. A design objective involving buoyancy modules that include syntactic foam is typically to increase strength while reducing density and weight. For example, for use on an oil rig, an objective for a buoyancy module configured as a float is often to provide enough buoyancy to support the marine riser pipe while occupying as little space as possible.
[0003] There is a need for a buoyancy module that is lighter weight, less dense and smaller, and that may be used for offshore drilling.
SUMMARY OF THE INVENTION
[0004] Briefly, according to an aspect of the present invention a flotation device with a three-dimensional cellular structure comprises a plurality of lengthwise adjacent and radially adjacent hollow cylindrical tubes, wherein interstices between the plurality of cylindrical tubes are filled with a composite matrix of macrospheres and syntactic foam.
[0005] Lengthwise ends of the hollow cylindrical tubes may be sealed so the interior of the tubes is void of macrospheres and syntactic foam. The tubes may be formed of fiber reinforced plastic composite, such as for example filament wound carbon or glass fibers with a binder such as epoxy resin.
[0006] The flotation device may also include a protective outer layer, formed for example of fiberglass. An inner surface of the flotation device may include an opening that abuts a flowline, such a length of pipe suitable for use in carrying oil.
[0007] These and other objects, features and advantages of the present invention will become apparent in light of the following detailed description of preferred embodiments thereof, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a pictorial illustration of a syntactic foam buoyancy module;
[0009] FIG. 2 is a cut-a-way view of the buoyancy module illustrating lengthwise adjacent and radially adjacent cylindrical tubes;
[0010] FIG. 3 is a cross sectional illustration of the buoyancy module taken along line 3 - 3 in FIG. 2 ;
[0011] FIG. 4 is a perspective view of lengthwise adjacent and radially adjacent cylindrical tubes; and
[0012] FIG. 5 is a flow chart illustration of a method for manufacturing the buoyancy module.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIG. 1 is a pictorial illustration of a syntactic foam buoyancy module 10 , which in this embodiment is shown as a drilling riser buoyancy module. However, one of ordinary skill in the art will recognize that buoyancy module may be used in applications other than drilling riser buoyancy modules, such as for example distributed buoyancy modules. The module 10 includes a protective exterior shell 12 (e.g., a 0.5 inch thick polymer shell) that surrounds a buoyancy core. The module 10 includes a first module 13 a and a second module 13 b that are mounted around a flowline (not shown), and held together around the flowline by removable clamps 15 (e.g., a synthetic fiber band such as Kelvar).
[0014] FIG. 2 is a cut-a-way view of the buoyancy module 10 , with a portion of the protective exterior shell 12 cut-a-way to expose a buoyancy core 14 . The core 14 comprises a plurality of lengthwise adjacent and radially adjacent cylindrical tubes, e.g., 16 - 20 , wherein interstices between the plurality of cylindrical tubes are filled with a composite matrix 22 of macrospheres and syntactic foam. Lengthwise ends 24 , 26 of each of the plurality of cylindrical tubes may be sealed so the interior of the tubes is void of the composite matrix 22 , and thus hollow.
[0015] In one embodiment, each of the cylindrical tubes 16 - 20 may be about 12 inches long and have a diameter of about 4 inches. The shorter the length of the tubes, the better for fault tolerance in the event one of the tubes cracks/fractures as a result of hydrostatic pressure cracking/fracturing the cylinder. Conversely, the longer the cylinder the easier for manufacture, which shall be discussed below. Thus the cylinder length and diameter are a trade-off depending upon the application of the buoyancy module. The cylindrical tubes sidewalls may have a wall thickness of about 0.0625 inches and be constructed of filament wound carbon or glass fibers with an epoxy resin binder. In an alternative embodiment, cylindrical tubes sidewalls may be constructed of thermoplastic.
[0016] As an example of an advantages offered by the invention, conventional riser buoyancy modules may have a density of about 25.0 to 28.0 pcf (lbs per cubic foot) when rated for a service depth of 5,000 feet. Modules of the tubular construction will have a density of about 20.0 to 22.0 pcf, affording a significant reduction in the weight of the drilling system.
[0017] Although the cross section of the tubes is preferably cylindrical, it is contemplated that other cross sectional shapes may also be used for the tubes. For example, it is contemplated that the tubes may have an octagonal cross-section. In general, the tube may be any rigid, lightweight, elongated hollow body, which also includes for example rectangular or hexagonal.
[0018] FIG. 3 is a cross sectional illustration of the buoyancy module taken along line 3 - 3 in FIG. 2 . Interstices between the tubes 16 - 20 are filled with the composite matrix 22 of macrospheres and syntactic foam, which contains microspheres and a resin binder (e.g., a semi-rigid resin binder such as epoxy, polyester, or polyurethane).
[0019] The macrospheres are generally spherical shaped and have a diameter of about 0.25 to 0.5 inches. The walls are preferably fiberglass or carbon composite and have thickness dependent upon the intended operational depth. Specifically, the greater the intended operational depth of the buoyancy module, the greater the wall thickness required to sustain the hydrostatic pressure at that depth. For example, at depths where the hydrostatic pressure is a thousand psi or less, the wall thickness may be quite thin (e.g., 0.01 inches). In contrast, at ten thousand feet where the hydrostatic pressure approaches 5,000 psi the wall thickness is increased significantly (e.g., 0.03 inches). It is contemplated that other high strength advanced composite type fibers (e.g., other carbon fibers, aramid, etc.) may also be used rather than fiberglass.
[0020] The microspheres interspersed within the resin binder are typically about 100 microns in diameter (i.e., 0.004″) hollow spheres generally containing a gas which may be atmospheric air, although it may be richer in nitrogen than atmospheric air. The microspheres may have a wall thickness of about one micron. As known, the microspheres are manufactured by blowing glass in a furnace in the presence of blowing agents that cause the glass to bubble.
[0021] FIG. 4 is a perspective view of the lengthwise adjacent and radially adjacent cylindrical tubes 16 - 20 .
[0022] FIG. 5 is a flow chart illustration of a method for manufacturing the buoyancy module. The method of manufacturing includes step 52 in which a mold that provides a cavity the shape of which provides a positive shape of the object to be molded, is coated with a release agent. In step 54 the coated mold is then lined with a fabric fiberglass material 56 . The mold is then lined with the protective exterior shell 12 in step 6 . The fiberglass material and the liner are put in dry. In step 58 the tubes are then placed into the mold such that they are lengthwise adjacent and radially adjacent, and fill the mold. The macrospheres are then introduced in step 60 into the mold and vibrated to fill interstices between the tubes. In step 62 syntactic foam is injected under vacuum to fill in space between the macrospheres and tubes. The mold is then placed in an oven to cure in step 64 .
[0023] In an alternative embodiment the tubes may be of different lengths, diameters and wall thickness. For example, it is contemplated that the tubes located at the peripheral surfaces of the buoyancy module may have a thicker wall surface, be of a shorter length, et cetera, in comparison to tubes located within interior regions of the buoyancy module.
[0024] The buoyancy module may be used for riser modules, fairings, riser drag reduction devices, distributed buoyancy, ROV floats, et cetera.
[0025] Although the present invention has been shown and described with respect to several preferred embodiments thereof, various changes, omissions and additions to the form and detail thereof, may be made therein, without departing from the spirit and scope of the invention. | A flotation device comprises three-dimensional cellular structure comprising a plurality of lengthwise adjacent and radially adjacent hollow cylindrical tubes, wherein interstices between the plurality of cylinders are filled with a composite matrix of macrospheres and syntactic foam. | 1 |
BACKGROUND OF INVENTION
This invention is directed to a flotation system for a wave harvesting device. The flotation system includes a conical shaped float having a submergible wave energy harvesting device attached to its apex such that the apex of the conical shape is downwardly oriented and the base of the conical shape is upwardly oriented.
With the introduction of utilization of electrical energy in the late 1800s, man has sought a number of ways to generate electricity. One of the earliest ways examined for generating electrical power was wave energy. Not too much longer thereafter, however, petroleum became very available, and this, in combination with hydroelectrical electrical generation, soon relegated wave energy to the position of being only a curiosity.
With the recent realizations that fossil fuel sources are of a limited supply, alternative forms of electrical energy generation have been sought. In my U.S. Pat. No. 4,462,211, I describe an apparatus for harvesting wave energy. The apparatus or device described therein takes advantage of the fact that wave energy for the most part is a surface phenomena, and, depending upon the depth of the water, water below the surface does not necessarily move in association with the wave motion on the top of the surface of the body of water.
The device I describe in my U.S. Pat. No. 4,462,211, utilizes two counter-rotating turbines which, in turn, rotate counter-rotating shafts leading from the turbines to the surface of the water.
The counter-rotating turbines of the device of my patent, U.S. Pat. No. 4,462,211, are raised and lowered at a depth below the surface of the water by wave action of a float floating on the surface of the water to which the shafts are attached. At the surface, motion from one of the shafts is reversed and combined with rotation of the other shafts and is transferred to a generator for the generation of electrical energy.
The wave harvesting device described in my patent is attached to an essentially flat surface float. As described in my U.S. Pat. No. 4,462,211, the turbines and the shafts of that device essentially remain in a vertical orientation irrespective of movement of the float as it follows the wave action on the surface of the body of water.
Dating back to antiquity, many designs for floats have been utilized. While platform floats, such as the one I describe in my U.S. Pat. No. 4,462,211, have a large surface area, at all times they have a constant displacement. Because of this constant displacement and their own inertia, when they are subjected to a rising wave, they tend to sink into the wave. And when they are subjected to a descending wave, the wave tends to drop out from beneath them. This same effect is true of other floats or buoys which also have a substantially constant displacement. This mitigates the wave action, tending to decrease the energy harvesting action of any device attached to these floats.
Because waves vary in their length from nothing in calm water to very long waves, a flat float is subjected to varying horizontal forces. In order to maintain the integrity of the float during the most severe conditions, ribs, keels, bulkheads, or other supporting structures must be engineered into flat floats. Inevitably, with the addition of strength also comes the addition of weight, and the float must support not only the wave energy harvesting device beneath it, but its own structural weight. This further mitigates the efficiency of the float.
BRIEF DESCRIPTION OF THE INVENTION
In view of the above, it is evident that there is a need for new and improved floats and flotation systems which can appropriately suspend a wave energy harvesting device in a body of water. It is therefore a broad object of this invention to fulfill this need. It is a further object of this invention to provide for floats and flotation systems which are capable of responding to waves of minimal height efficiently to move a wave energy harvesting device. Additionally, it is an object of this invention to provide a float and a flotation system which, because of the engineering principles contained therein, is inherently stable, strong, light, and responsive to a variety of wave conditions.
These and other objects, as will become evident from the remainder of this specification, are achieved in a float for supporting a submerged device in a body of water which comprises: a buoyant conical member capable of floating on said body of water with its base above the surface of said body of water and its apex submerged in said body of water; cap means located on said base of said conical member, said cap means for essentially sealing the interior of said conical member to ingress of water into said interior of said conical member; device connecting means located on said conical member, said device connecting means for connecting said device to said conical member, said device connecting means located on said conical member whereby said device submerged in said body of water extends from the apex of said conical member.
Further, these objects are achieved in a flotation system for supporting a submerged device in a body of water which comprises: a central float body, at least three supplemental float bodies, a plurality of tether means equal in number to the number of said supplemental float bodies and a plurality of anchor means equal in number of said supplemental float bodies; each of said tether means connecting between one of said supplemental float bodies and said central float body; each of said anchor means connecting to one of said supplemental float bodies.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be better understood when taken in conjunction with the drawings wherein:
FIG. 1 is a pictorial representation of my flotation system coupled with a wave energy harvesting device as it would appear when appropriately anchored in a large body of water;
FIG. 2 is a side elevational view in partial section of the central float of the device of FIG. 1;
FIG. 3 is a side elevational view in section about the line 3--3 of FIG. 2; and
FIG. 4 is a plan view in section about the line 4--4 of FIG. 3.
The device shown in the drawings and described in this specification utilizes certain principles and/or concepts as are set forth in the claims appended hereto. Those skilled in the engineering arts will realize that these principles and/or concepts are capable of being utilized in a variety of embodiments which may differ from the exact embodiment shown for illustrative purposes. For this reason, this invention is not to be construed as being limited solely to the illustrative embodiment, but is only to be construed in view of the claims.
DETAILED DESCRIPTION
FIG. 1 shows a wave energy harvesting device 10 essentially as is described and shown in my U.S. Pat. No. 4,462,211, the entire disclosure of which is herein incorporated by reference. This device 10 utilizes two counter-rotating cylinders 12 and 14 each which includes a turbine, not numbered or shown, located in the interior. The turbine within cylinder 12 is attached to outer shaft 16, and the turbine within cylinder 14 is attached to an inner shaft 18. As is described in my above referred to patent, the turbine blades in the turbines within the cylinders 12 and 14, are set at opposite angles of attack to water either moving up through the two cylinders 12 and 14, or down through the cylinders 12 and 14. Because of this, as the device 10 is raised or lowered within a body of water, generally depicted by the numeral 20, the cylinder 12 and the shaft 16 attached thereto rotate in one direction, and the cylinder 14 and the shaft 18 attached thereto rotate in the opposite direction.
The two shafts, 16 and 18, are attached to a central float body 22. As the central float body raises and lowers with respect to wave action on the surface of the body of water 20, the cylinders 12 and 14 are concurrently raised and lowered at a depth beneath the surface of the body of water 20. The turbine blades, as are described in my above referred to patent, flip or re-orient themselves depending upon whether the water is moving up through the two cylinders 12 and 14, or down through the two cylinders 12 and 14. This in turn depends upon whether or not the wave energy device 10 is being raised or lowered. In any event, in response to movement of the central float body 22 up and down as waves pass by it, the wave energy harvesting device 10 is activated so as to rotate shaft 16 in one direction and the shaft 18 in the opposite direction.
Because the shafts 16 and 18 of the wave energy harvesting device 10 are rotating, the device 10, including the shafts 16 and 18, are essentially held in a vertical orientation. The central float body 22, however, follows the crests, slopes, and troughs of the wave, and pitches and yaws in response to this wave movement. It is therefore necessary to pivotally mount the shafts 16 and 18 to the float body 22, as well as rotatably mount the shafts 16 and 18 to the float body 22 to account for the rotation of the shafts.
As is described in my above referred to patent, the shafts 16 and 18 are appropriately journalled together at the lower end of the wave energy harvesting device 10. Further, as is also described in my patent, the rotation direction of one of the shafts is reversed at the joining point of the shafts upper extremity such that rotation in a single direction can be outputted to an appropriate electrical generating device. The attachment of the upper ends of the shafts to the generating device is also as is described in my above referred to patent. For the remainder of this application it is sufficient to note that shaft 18 is appropriately journalled within shaft 16 and rotates opposite of the rotation of shaft 16.
As is best seen in FIGS. 3 and 4, outer shaft 16 has a circular bearing 24 attached thereto which rides within a bearing race 26. The bearing race 26 forms one part of a gimble or universal joint.
The bearing race 26 is appropriately suspended by trunnions, collectively identified by the numeral 28, in a circular collar 30. The collar 30 is suspended by trunnions, collectively identified by the numeral 32, in a further circular collar 34. The trunnions 28 are positioned 90° with respect to the trunnions 32, allowing for pivoting of the shafts 16 and 18 in any direction with respect to the collar 34.
The central float body 22 has an outer conical wall 36. It is truncated near its apex or bottom, as is seen in FIGS. 2 and 4, and the collar 34 is fixed within the inside radius of the apex end of the conical wall 36. In view of this, the shafts 16 and 18, and the wave energy harvesting device 10 appropriately suspended therefrom, are free to both rotate with respect to conical wall 36 of the central float body 22 by virtue of the bearing 24 and bearing race 26, and pivot by virtue of the collars 30 and 34 and the trunnions 28 and 34.
Completing the exterior of the central float body 22 is cap member 38. The cap member 38 is appropriately sealed to the conical wall 36 around its periphery. A hatch 40 is positioned on top of the cap 38 allowing access to the hollow interior of the central float body 22. The hatch 40 would be appropriately sealed when in its closed position so as to seal the interior of the central float body 22 to any wave action which may crest over the top of the central float body 22 preventing flooding of the interior of the central float body 22.
A super structure 42 can be attached on top of the cap 38. The super structure 42 would include an appropriate radar reflector 44, a visual and/or audio warning device 46, and, if appropriate, an identification banner 48. This would provide for identification of the central float body 22 both in fair and inclement weather by any vessels which may be in the immediate area. Since radar reflectors, such as radar reflector 44, visual and audio warning devices such as the device 46, and banners 48, are in common useage, for brevity of this specification, these will not be described further.
Located within the interior of the central float body 22 is an interior conical wall 50 having a much smaller conical angle than the conical angle of the central float body 22. The conical wall 50 completely surrounds the shafts 16 and 18. The bottom of the conical wall 50 is joined to the bearing race 26, and, as such, will always be in a fixed position with respect to the shafts 16 and 18. However, since the bearing 24, attaching to the outer shaft 16, pivots within the bearing race 26, the outer shaft 16 (as well as the inner shaft 18) will rotate with respect to the interior conical wall 50.
An appropriate electrical generator 52 is positioned on the top of the interior of the conical wall 50. The generator 52 is supported within the interior of the central float device 22 by the conical wall 50. Since, however, the conical wall 50, and the generator 52 attached thereto, are fixed with respect to the rotation of the shafts 16 and 18, the generator 52 does not rotate within the interior of the float body 22 and the rotational energy of the rotating shafts 16 and 18 can be utilized to drive the generator. An appropriate electrical connection, such as cable 54, leads from the generator 52 to the exterior of the central float body 22. The opening, wherein the cable 54 passes through the central float body 22, would, of course, be appropriately sealed against water ingress into the interior of the central float body 22. The cable 54 would also be of such a nature to operator within the aqueous environment.
An annular flange 56, which is of a diameter greater than the generator 52, is located at the attachment point of the generator 52 onto the interior conical wall 50. This flange serves as an internal walkway for maintenance work in the generator 52.
The bottom of the interior conical wall 50 is sealed to the conical wall 36 utilizing an annular seal 58. A sealing ring 60 maintains the seal 58 against the interior of the conical wall 50, and a further sealing ring 62 maintains the annular seal 58 against the interior of the conical wall 36. The annular seal 58 is shaped so as to include an annular crest, shown at arrow 64, allowing for flexing of the annular seal 58 in response to movement of the shafts 16 and 18, and the interior conical wall 58, with respect to the wall 36 and the remainder of the central float body 22.
The central float body 22 floats on the surface of the body of water 20 and is thus exposed to wave action. The cylinders 12 and 14 of the wave energy harvesting device 10 are positioned well below the surface of the body water 20, below a point wherein the wave action extends. In response to vertical rising and falling of the central float body 22 by wave action, motion of the central float body 22 is transferred via shafts 16 and 18 by virtue of the attachment of the shaft 16 to the bearing 24. This moves the wave energy harvesting device 10 upwardly and downwardly within the body of the water 20. This causes rotation of the shafts 16 and 18 as is explained in my above referred to patent. This rotation is then transferred to the generator 52 to generate an appropriate electrical current.
Pitching and yawing of the central float body 22, however, is not transferred to the shafts 16 and 18 and to the wave energy harvesting device 10 because of the gimble formed by the collars 30 and 34 and the trunnions 28 and 32. The central float body 22 can pitch and toss in the waves as the crest and troughs of the waves move across it. As the float body 22 pitches and yaws in the waves, the conical wall 36 moves back and fourth about the interior conical wall 50, and the generator 52 attached thereto. The cable 54 is provided with sufficient scope within the interior of the float body 22 to allow for movement of the conical wall 36 away from and toward the generator 52.
The crest 64 in the annular seal 58 allow for flexing of the annular seal 58 in response to the pitching and yawing of the float body 22 in the waves. This maintains a water tight seal at the bottom of the float body 22 to the interior conical wall 50 and the bearing race 26 to which it is attached. The bearing race 26, in turn, forms a water tight seal with the bearing 24 allowing the bearing 24, and the shaft 16 attached thereto, to rotate within it, but preventing ingress of water into the interior of the interior conical wall 50. Alternately, not shown, the seal between the bearing 24 and the bearing race 26 would be less than water tight, and an upper seal above the surface of the water could be formed between the top of the interior conical wall 50 and the outer shaft 16.
Since the water pressure against the annular seal 58 is only dependent upon the depth of the seal 58 from the surface of the body of the water 20, there is very little hydraulic pressure on this seal. This allows for use of flexible rubber, or other suitable material, for the annular seal 58.
Additionally, since the interior of the float 22 is sealed by the hatch 40, the interior of the float 22 is essentially pressurized against entering of water through the submerged apex end of the float 22.
Referring back to FIG. 1, the central float body 22 is preferably suspended in a fixed position on the surface of the body of the water 20 utilizing supplemental floats, collectively identified by the numeral 66 in FIG. 1. Tether lines, collectively identified by the numeral 68, are attached to appropriate eyelets, identified by the numeral 70, positioned on the exterior of the conical wall 36 of the central float body 22.
Preferably, three supplemental floats 66 are utilized and are positioned in a triangular arrangement around the central float body 22. Connectors, collectively identified by the numeral 72, connect the supplemental floats 66 to one another to form this triangular orientation. The connectors 72 can either be stiff connectors which maintain the floats 66 at fixed distances from one another, or can be flexible allowing the floats to approach and then spread from one another depending upon the action on the surface of the body of the water 20. In any event, each of the supplemental floats 66 is connected by an anchor line, collectively identified by the numeral 74, to an appropriate anchor, collectively identified by the numeral 76, which is lodged in the earth surface beneath the body of water 20. If the connectors 72 are flexible, the scope of the anchor lines 74 can be such to limit the inward travel of the supplemental floats 66 towards one another.
As is shown in FIG. 1, a triangular arrangement utilizing three supplemental floats 66 is preferred. At least two supplemental floats 66 could be utilized and a greater number, as for instance four, could also be utilized. However, the triangular arrangement, as is shown in FIG. 1, assures both centralization of the central float body 22 within its holding anchor 76, and economy of materials. As is shown in FIG. 1, the central float body 22 is free to move within the triangular orientation formed by the supplemental float 66 and is maintained in positioned by the tether line 68.
If stiff members are utilized for the connectors 72, when the float body 22 moves, one or the other of the tether lines 68 are tense, maintaining the float body 22 in its desired positioned within the triangular orientation formed by the supplemental floats 66, but allows for full vertical movement of the float body 22 in response to the waves, crests, and troughs. Further, this allows for any pitching and yawing of the float body 22 in response to the wave action without any interference from the anchor lines 74.
As is evident from the symmetrical shape of the central float body 22, vertical movement of the float body 22 is independent of the direction of the advancing waves, and is immediately responsive to change in direction of these advancing waves.
Further, as noted before, because of the attachment of shafts 16 and 18 at the apex of the central float body 22, the float body 22 can pitch and yaw with respect to wave action while still maintaining shafts 16 and 18 essentially vertically oriented. Additionally, irrespective of the pitch or yaw of the float body 22, its vertical movement is always transferred to the shaft 16 and 18 so as to drive the wave energy harvesting device 10.
The system depicted in FIG. 1 is never unstable since all loads are located at the fulcrum at the apex of the central float body 22 wherein the interior conical wall 50 and the shafts 16 and 18 pivot with respect to the central float body 22.
Because of the conical shape of both the wall 36 and the wall 50, the structure is extremely rigid with a minimum of structural components which maximizes the buoyant force of the central float body 22 and, thus, allows for the use of a smaller central float body 22 to raise and lower the wave energy harvesting device 10.
The conical angle of the central float body 22 can be varied to account for different local environments. It is obvious that in certain locations waves of 2 feet may be the norm, wherein, in other locations, waves of 6 feet may be the norm. By increasing or decreasing the conical angle, that is the angle between the sides of the central float body 22, as for instance as seen in FIG. 3 comparing wall 36A to wall 36B, the buoyant force of the central float body 22 can be "tuned". Further, because of the conical shape of the central float body 22, it is more responsive to wave action than other shapes of floats.
Archinedes principle states that the buoyant force of a body is equal to the weight of the fluid it displaces. If a body is not wholly submerged in the fluid, the buoyant force is equal to the volume of fluid which is displaced by the submerged portion of the body. If conical walls 36 have a circular base, neglecting the truncated end at the apex of the float body 22, the submerged volume of the float body 22 will be 1/3πr 2 s, where r is the radius of the body at the waterline, and s is the altitude from the waterline to the apex of the conical wall.
As an example, if a central float body 22 is chosen so as to have a 60° conical angle, and the wave energy harvesting device 10 is of a sufficient mass so as to submerge the central float body 22 to a point wherein the waterline is 10 meters above the submerged apex of the central float body 22, the radius of the submerged portion at the waterline would equal 5.77 meters. The submerged portion of the central float body 22 would displace approximately 349 meters 3 of water exerting a buoyant force of approximately 788,000 lbs. If a two meter wave then travels across the float body 22 and, under the inertia of the wave energy harvesting device 10, the central float body 22 remains fixed with respect to its horizontal position, the waterline would then move up to the 12 meter mark and the radius at this waterline would now be 6.93 meters. The volume of water displaced by the submerged portion of the central float body 22 is now approximately 603 meters 3 which would exert a buoyant force of approximately 1,363,000 lbs. This represents a 73% increase in the buoyant force. It is evident that, because of the conical shape of the central float body 22, the buoyant force is dependent upon the depth of submersion of the central float body 22.
Because of the effects described in the previous paragraph, movement of a very small wave beneath the central float body 22 easily overcomes the inertia of the totality of the float body 22, and the wave energy harvesting device 10 attached thereto, to make it very responsive to the wave action, moving the wave energy harvesting device 10 upwardly and downwardly to rotate the shafts 16 and 18 in the presence of extremely small waves. This accounts for the increase efficiency of the flotation system of this invention with respect to other floats.
It is also evident that, by changing the conical angle of the float body 22, a greater or a lesser buoyant force can be achieved for a particular size wave. In those areas which experience small waves, the buoyant force would be optimized by increasing the conical angle of the central float body 22; and in those areas wherein waves of greater height are commonplace, the conical angle of the central float body 22 could be decreased allowing the vertical movement of the central float body 22 to be less responsive to the large wave heights to essentially tune the wave energy harvesting device 10 with respect to local wave conditions.
The cable 54 leading from the generator 52 is shown as a submerged cable in FIG. 1. However, other forms of energy transmission could be utilized, such as a floating cable or even storage batteries located within the interior of the central float body 22 or in a nearby float tethered to the flotation system of this invention. | A float for supporting a submerged wave energy harvesting device includes a conical member which is buoyant on the surface of the body of water with its base located upwardly above the surface of the body of water and its apex submerged just below the surface of the body of water. The wave energy harvesting device extends downwardly from the apex of the conical member and is connected to the conical member utilizing a connecting member which allows for pivoting of the conical member with respect to the wave energy harvesting device as the conical member rocks or otherwise moves in response to wave motion on the surface of the body of water. An electrical generator is located within the interior of the conical member and is connected to the wave energy harvesting device so as to be powered by the wave energy harvesting device. Supplemental positioning floats each connected to an anchor can be positioned in a geometrical configuration around the conical member with a tether connected between the conical member and each of the supplemental floats to maintain both the conical member and the wave energy harvesting device in a fixed position with respect to an ocean floor, a lake bed, or the like. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 07/665,021, filed Mar. 5, 1991, now abandoned.
INTRODUCTION
1. Field of the Invention
This invention relates to a high performance computer data storage device including a combination of solid state storage and a rotating magnetic disk device.
2. Description of Prior Art
A number of computer data storage systems exist which make some use of solid state memory devices as a caching controller for placement between a computer host device and rotating magnetic disk device. A typical caching system uses a single solid state memory unit as a holding area for data stored on a string of magnetic disks, thereby allowing certain information to be stored in performance as compared to the use solely of relatively lower speed disk memories, i.e. the percentage of times a desired piece of data is contained in the high speed cache memory, thereby allowing faster access as compared with when that data is only stored in a disk drive. A block diagram of such a system is shown in FIG. 1. Host computer 101 communicates with the entire string 102 of disks 102-1 through 102-N via cache unit 103 via Host interface 104, such as Small Computer Systems Interface (SCSI). All data going to or from disk string 102 passes through the cache-to-disk data path consisting of host interface 104, cache unit 103, and disk interface 105. Cache unit 103 manages the caching of data and services requests from host computer 101. Major components of cache unit 103 include microprocessor 103-1, cache management hardware 103-2, cache management firmware 103-3, address lookup table 103-4, and solid state cache memory 103-5.
The prior art cache system of FIG. 1 is intended to hold frequently accessed data in a solid state memory area so as to give more rapid access to that data than would be achieved if the same data were accessed from the disk media. Typically, such cache systems are quite effective when attached to certain host computers and under certain workloads. However, there exist some drawbacks and, under certain conditions, such cache systems exhibit a performance level less than that achieved by similar, but uncached, devices. Some of the factors contributing to the less than desirable performance of prior art cached disk devices are now described.
The single cache memory 103-5 is used in conjunction with all disks in disk string 102. Data from any of the disks may reside in cache memory 103-5 at any given time. The currently accessed data is given precedence for caching data is cached regardless of the disk drive on which it resides. When fulfilling a host command, the determination of whether or not the data is in cache memory 103-5, and the location of that data in cache memory 103-5, is usually via hashing schemes and table search operations. Hashing schemes and table searches can introduce time delays of their own which can defeat the purpose of the cache unit itself.
Performance is very sensitive to cache-hit rates. Due to caching overhead and queuing times, a low hit rate in a typical string oriented cache system can result in overall performance that is poorer than that of configured uncached string of disks.
The size of cache memory 103-5 relative to the capacity of disk drives 102 is generally low. An apparently obvious technique to remedy a low hit rate is to increase the cache memory 103-5 size. However, it has been found that there is an upper limit to the size of cache memory 103-5 above which adding more capacity has limited benefits. With limited cache memory 103-5 capacity, a multitude of requests over a variety of data segments exhausts the capability of the cache system to retain the desirable data in cache memory 103-5. Often, data that would be reused in the near future is decached prematurely to make room in cache memory 103-5 for handling new requests from the host computer 101. The result is a reduced cache hit rate. A reduced hit rate increases the number of disk accesses; increased disk accesses increases the contention on the data path. A self-defeating cycle is instituted.
"Background" cache-ahead operations are limited since the data transferred during such cache ahead operations over the same data path as, and often conflicts with, the data transferred to service direct requests from the host computer 101. The data path between cache unit 103 and disk string 102 can easily be overloaded. All data to and from any of the disks in disk string 102, whether for satisfying requests from host computer 101 or for cache management purposes, travels across the cache-to-disk path. This creates a bottleneck if a large amount of prefetching of data from disk string 102 to cache memory 103-5 occurs. Each attempt to prefetch data from disk string 102 into cache memory 103-5 potentially creates contention for the path with data being communicated between any of the disk drives of disk string 102 and host computer 101. As a result, prefetching of data into cache memory 103-5 must be judiciously limited; increasing the size of the cache memory 103-5 beyond a certain limit does not produce corresponding improvements in the performance of the cache system. This initiates a string of related phenomena. Cache-ahead management is often limited to reading succeeding data into cache from disk on each host read command which is a cache read miss. This technique helps to minimize the tendency of cache-ahead to increase the queuing of requests waiting for the path between cache memory 103-5 and disk string 102. However, one of the concepts on which caching is based is that data accesses tend to be concentrated within a given locality within a reasonably short time frame. For example, data segments are often accessed in sequential fashion. Limiting the cache-ahead operations to being a function of read misses can have the negative effect of lowering the cache hit rate since such limitation may prevent or degrade the exploitation of the locality of data accesses.
A variety of algorithms and configurations have been devised in attempts to optimize the performance of string caches. A nearly universally accepted concept involves the retention and replacement of cached data segments based on least-recently used (LRU) measurements. The decaching of data to make room for new data is managed by a table which gives, for each cached block of data, its relative time since it was last accessed. Depending on the algorithm used, this process can also result in some form of table search with a potential measurable time delay.
Cache memory 103-5 is generally volatile; the data is lost if power to the unit is removed. This characteristic, coupled with the possibility of unexpected power outages, has generally imposed a write-through design for handling data transferred from host computer 103 to the cached string. In such a design, all writes from host computer 103 are written directly to disk; handled at disk speed, these operations are subject to all the inherent time delays of seek, latency, and lower transfer rates commonly associated with disk operations.
Cache unit 103 communicates with the string of disk drives 102 through disk interface 105.
SUMMARY OF THE INVENTION
Computer operations and throughput are often limited by the time required to write data to, or read data from, a peripheral data storage device. A solid state storage device has high-speed response, but at a relatively high cost per megabyte of storage. A rotating magnetic disk, optical disk, or other mass media provides high storage capacity at a relatively low cost per megabyte, but with a low-speed response. The teachings of this invention provide a hybrid solid state and mass storage device which gives near solid state speed at a cost per megabyte approaching that of the mass storage device. For the purposes of this discussion, embodiments will be described with regard to magnetic disk media. However, it is to be understood that the teachings of this invention are equally applicable to other types of mass storage devices, including optical disk devices, and the like.
This invention is based on several features: a rotating magnetic disk media, an ample solid state storage capacity, a private channel between the disk and solid state storage devices, microprocessors which perform unique data management, a unique prefetch procedure, and simultaneous cache, disk, and host operations. The hybrid storage media of this invention performs at near solid state speeds for many types of computer workloads while practically never performing at less than normal magnetic disk speeds for any workload.
A rotating magnetic disk media is used to give the device a large capacity; the solid state storage is used to give the device a high-speed response capability. By associating the solid state media directly with a single magnetic disk device, a private data communication line is established which avoids contention between normal data transfers between the host and the device and transfers between the solid state memory and the disk. This private data channel permits virtually unlimited conversation between the two storage media. Utilization of ample solid state memory permits efficient maintenance of data for multiple, simultaneously active data streams. Management of the storage is via one or more microprocessors which utilize historical and projected data accesses to perform intelligent placement of data. No table searches are employed in the time-critical path. Accesses to data stored in the solid state memory are at solid state speeds; accesses to data stored on the magnetic disk are at disk device speeds. All data sent from the host to the device is handled at solid state speeds.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a block diagram of a typical prior art cached disk computer data storage system;
FIG. 2 is a block diagram depicting one embodiment of a cached disk computer data storage device constructed in accordance with the teachings of this invention;
FIG. 3 is a block diagram depicting one embodiment of a controller which implements the described invention;
FIG. 4 is a flow chart depicting the operation of one embodiment of this invention;
FIG. 5 is a flow chart depicting a more detailed description of the operation of the host command step of FIG. 4;
FIG. 6 is a flow chart depicting the operation of one embodiment of the analyze host I/O command operation of FIG. 5;
FIG. 7 is a flow chart depicting in more detail the operation of the setup track address list operation of FIG. 6;
FIG. 8 is a flow chart depicting in more detail the address translation of FIG. 7;
FIG. 9 is a flow chart depicting the cache read hit operation depicted in FIG. 5;
FIG. 10 is a flow chart depicting in more detail the cache read miss operation depicted in FIG. 5;
FIG. 11 is a flow chart depicting the cache write hit operation of FIG. 5;
FIG. 12 is a flow chart depicting the cache write miss operation of FIG. 5;
FIG. 13 is a flow chart depicting the seek cache miss operation of FIG. 5;
FIG. 14 is a flow chart depicting the decache LRU operation of FIGS. 6, 13 and 15;
FIG. 15 is a flow chart depicting the cache ahead operation of FIG. 4;
FIG. 16 is a flow chart depicting the operation of the cache ahead determination operation of FIG. 15;
FIG. 17 is a flow chart depicting the operation of the initiate background sweep operation of FIG. 4;
FIG. 18 is a flow chart depicting the step of background sweep initiation at host I/O completion depicted in FIG. 4;
FIG. 19 is a flow chart depicting the generate background event operations depicted in FIGS. 17, 18, and 20;
FIG. 20 is a flow chart depicting the operation of the continued background sweep step of FIG. 4;
FIG. 21 is a flow chart depicting the power down control operations;
FIG. 22 is a flow chart depicting the final background sweep operation depicted in FIG. 21;
DESCRIPTION OF THE TABLES
Tables F-1 through F-4 describe the organization of Tables T-1 through T-4, respectively;
Table T-1 depicts an example of values in the address translation (ADT) table prior to the handling of the first I/O operation from the host CPU;
Table T-2 depicts an example of values in the Least-Recently-Used (LRU) table prior to the handling of the first I/O operation from the host CPU;
Table T-3 describes the least recently used (LRU) table;
Tables T-3a through T-3e depict the ADT table after various numbers of I/O operations; and
Table 4 depicts a sample of I/O commands extracted from computer system operations during normal usage. These I/O commands, and the intervening commands, were the basis for the sample predicted LRU and ADT tables as shown in Tables T-1 through T-3.
DETAILED DESCRIPTION OF THE INVENTION
Glossary of Terms
ADDRESS TRANSLATION: The conversion of a sector address into a track address and sector offset within the track.
CACHE-AHEAD FACTOR; PROXIMITY FACTOR: At each track hit or rehit, data sufficient to satisfy a number of I/O's may remain in front of, and/or behind, the current location of the data involved in the current I/O. When either of these two remaining areas contain space for less than a set number of I/O's, the cache-ahead is activated. That minimum number of potential I/O's is the cache-ahead factor, or the proximity factor.
ADDRESS TRANSLATION TABLE; ADT TABLE: The table which maintains the relationship between disk track identifiers and solid state memory addresses; also holds other information as required.
CACHE: The solid state memory area which holds frequently accessed user data with the cache system of this invention, taken as a whole.
CPU SECTOR: See Logical Sector.
DISK; MAGNETIC DISK; ROTATING MAGNETIC DISK: A rotating magnetic media disk drive.
DISK SECTOR ADDRESS: The address of a physical sector on the magnetic disk.
DISK SERVER: The logical section of the cache system of this invention which handles the writes to, and reads from, the rotating magnetic disk.
DISK TRACK ADDRESS; TRACK ADDRESS: The address of the first sector of data in a given track on disk. These addresses correspond to physical locations on the rotating magnetic disk. Each sector address as specified in an I/O operation can be converted into a track address and a sector offset within that track.
DMA: Direct Memory Access; that is, memory-to-memory transfer without the involvement of the processor.
DRAM: Dynamic random access memory. The chip or chips that are used for solid state memory devices.
EDAC: Error Detection And Correction.
EEPROM: Electrically Erasable Programmable Read-Only Memory.
EPROM: Erasable Programmable Read-Only Memory.
HOST: The computer to which the cache system of this invention is attached.
HOST SERVER: The portion of the cache system of this invention which interfaces with the host computer.
LRU: Least-Recently-Used, as pertains to that data storage track which has not been accessed for the longest period of time.
LRU TABLE; LEAST-RECENTLY-USED TABLE: The table containing the information which allows the controller to determine which solid state memory data areas may be reused with the least impact on the cache efficiency.
MRU: Most-Recently-Used, as pertains to that data storage track which has been accessed in the nearest time past.
PHYSICAL TRACK; DISK TRACK: A complete data track on a disk; one complete magnetic band on one platter of the disk device.
PROXIMITY FACTOR: See CACHE AHEAD FACTOR.
RECYCLE: The term used to describe the retention of a track in cache beyond its arrival at the LRU position; such retention to be based on the fact the track was reused at some time since it was placed in cache as a result of a read miss, a caching operation, or a cache-ahead operation, or since it was last given preference for retention in cache by the recycling mechanism.
SCSI: Small Computer System Interface; the name applied to the protocol for interfacing devices, such as a disk device to a host computer.
SCSI CONTROL CHANNEL: A physical connection between devices which uses the SCSI protocol, and is made up of logical controllers connected by a cable.
SECTOR: The logical sub-unit of a disk track; the smallest addressable unit of data on a disk.
SOLID STATE MEMORY, SOLID STATE DEVICE; SSD: Storage media made up of solid state devices such as DRAMs.
SSD TRACK ADDRESS: The address in the solid state memory at which the first byte of the first sector of a given disk track resides.
TRACK; LOGICAL TRACK; LOGICAL BLOCK: A logical data track on disk, or its equivalent in SSD; may or may not be identical to a physical track on disk (one complete magnetic band on one platter of the disk unit). It is noted that an I/O operation may involve more than one logical block.
System Overview
In accordance with the teachings of this invention, a computer peripheral data storage device is provided comprising a combination solid state memory and rotating magnetic disk; such device having the large capacity of magnetic disk media with near solid state speed at a cost per megabyte approaching that of magnetic disk media. For the purposes of this discussion, embodiments will be described with regard to magnetic disk media. However, it is to be understood that the teachings of this invention are equally applicable to other types of mass storage devices, including optical disk devices, and the like.
The device of this invention derives its large storage capacity from the rotating magnetic disk media. Its high speed performance stems from the combination of a private channel between the two storage media, multiple microprocessors utilizing a set of unique data management algorithms, a unique prefetch procedure, simultaneous cache, disk, and host operations, and an ample solid state memory. This hybrid storage media gives overall performance near that of solid state memory for most types of computer workloads while practically never performing at less than normal magnetic disk speeds for any workload.
To the host computer, the device of this invention appears to be a single, directly addressable entity. By the combination, within the device, of a solid state memory and one or more magnetic disk device, private data communication lines are established within the device which avoids contention between normal data transfers between the host and the device, and transfers between the solid state memory and the disk media. This private data channel permits unrestricted data transfers between the two storage media with practically no contention with the communication between the host computer and the described device. Utilization of ample solid state memory permits efficient retention of data for multiple, simultaneously active data streams. Management of the storage is via microprocessors which anticipate data accesses based on historical activity. Data is moved into the solid state memory from the disk media based on management algorithms which insure that no table searches need be employed in the time-critical path. Host computer accesses to data stored in the solid state memory are at near solid state speeds; accesses to data stored on the magnetic disk are at near disk device speeds. All data sent from the host to the device is transferred at solid state speeds limited only by the channel capability.
Hardware Description
A device constructed in accordance with the teachings of this invention is depicted in FIG. 2. Memory device 200 is a self-contained module which includes three points of contact with other devices. Its primary contact is with host computer 201 via host interface 204. Host interface 204 comprises, for example, a dedicated SCSI control processor which handles communications between host computer 201 and memory manager 205. An operator interface is provided via the console 207, which allows the user to exercise overall control of the memory device 200. Other points of contact are to terminal 207 (such as a personal computer) for interrogating system status or the operating condition of memory device 200, and a telephone dial-in line 202 which can access via computer/terminal 207.
Memory manager 205 handles all functions necessary to manage the storage of data in, and retrieval of data from, disk drive 210 (or high capacity memory devices) and solid state memory 208, the two storage media. The memory manager 205 consists of one or more microprocessors 205-1, associated firmware 205-2, and management tables, such as Address Translation (ADT) Table 205-3 and Least Recently Used (LRU) Table 205-4.
Solid state memory 208 is utilized for that data which memory manager 205, based on its experience, deems most useful to host computer 201, or most likely to become useful in the near future.
Magnetic disk drive 210 is the ultimate storage for all data, and provides the needed large storage capacity. Disk interface 209 serves as a separate dedicated control processor (such as an SCSI processor) for handling communications between memory manager 205 and disk drive 210.
Information about functional errors and operational statistics are maintained by diagnostic module error logger 206. Access to module 206 is obtained through dial-in line 202 or console 207. Console 207 serves as the operator's access to the memory device 200 for such actions as powering the system on and off, reading or resetting the error logger, or inquiring of system statistics.
The memory device 200 includes power backup system 203 which includes a rechargeable battery. Backup system 203 is prepared to maintain power to memory device 200 should normal power be interrupted. If such a power interruption occurs, the memory manager 205 takes whatever action is necessary to place all updated data stored in solid state memory 208 onto magnetic disk 210 before shutting down memory device 200.
FIG. 3 depicts a hardware controller block diagram of one embodiment of this invention. As shown in FIG. 3, hardware controller 300 provides three I/O ports, 301, 302, and 303. I/O ports 301 and 302 are differential SCSI ports used to connect hardware controller 300 to one or more host computers 201 (FIG. 2). I/O port 303 is a single-ended SCSI port used to connect controller 300 to disk drive 210 (which in this embodiment is a 5.25" magnetic hard disk drive). Disk drive 210 provides long-term non-volatile storage for data that flows into controller 300 from host computers 201. "Differential" and "single-ended" refer to specific electrical characteristics of SCSI ports; the most significant distinction between the two lies in the area of acceptable I/O cable length. The SCSI aspects of I/O ports 301, 302, and 303 are otherwise identical.
Cache memory 308 (corresponding to memory 208) is a large, high-speed memory used to store, on a dynamic basis, the currently active and potentially active data. The storage capacity of cache memory 308 can be selected at any convenient size and, in the embodiment depicted in FIG. 3, comprises 64 Megabytes of storage. Cache memory 308 is organized as 16 Megawords; each word consists of four data bytes (32 bits) and seven bits of error-correcting code. Typically, the storage capacity of cache memory 308 is selected to be within the range of approximately one-half of one percent (0.5%) to 100 percent of the storage capacity of the one or more magnetic disks 210 (FIG. 2) with which it operates. A small portion of cache memory 308 is used to store the tables required to manage the caching operations; alternatively, a different memory (not shown, but accessible by microcontroller 305) is used for this purpose.
Error Detection and Correction (EDAC) circuitry 306 performs error detecting and correcting functions for cache memory 308. In this embodiment, EDAC circuitry 306 generates a seven-bit error-correcting code for each 32-bit data word written to cache memory 308; this information is written to cache memory 308 along with the data word from which it was generated. The error-correcting code is examined by EDAC circuitry 306 when data is retrieved from cache memory 308 to verify that the data has not been corrupted since last written to cache memory 308. The modified Hamming code chosen for this embodiment allows EDAC circuitry 306 to correct all single-bit errors that occur and detect all double-bit and many multiple-bit errors that occur.
Error logger 307 is used to provide a record of errors that are detected by EDAC circuitry 306. The information recorded by error logger 307 is retrieved by microcontroller 305 for analysis and/or display. This information is sufficiently detailed to permit identification by microcontroller 305 of the specific bit in error (for single-bit errors) or the specific word in error (for double-bit errors). In the event that EDAC circuitry 306 detects a single-bit error, the bit in error is corrected as the data is transferred to whichever interface requested the data (processor/cache interface logic 316, host/cache interface logic 311 and 312, or disk/cache interface logic 313). A signal is also sent to microcontroller 305 to permit handling of this error condition (which involves analyzing the error based on the contents of error logger 307, attempting to scrub (correct) the error, and analyzing the results of the scrub to determine if the error was soft or hard).
In the event that EDAC circuitry 306 detects a double-bit error, a signal is sent to microcontroller 305. Microcontroller 305 will recognize that some data has been corrupted. If the corruption has occurred in the ADT or LRU tables, an attempt is made to reconstruct the now-defective table from the other, then relocate both tables to a different portion of cache memory 308.
If the corruption has occurred in an area of cache memory 308 that holds user data, microcontroller 305 attempts to salvage as much data as possible (transferring appropriate portions of cache memory 308 to disk drive 210, for example) before refusing to accept new data transfer commands. Any response to a request for status from the host computer 201 will contain information that the host computer 201 may use to recognize that memory device 200 is no longer operating properly.
Microcontroller 305 includes programmable control processor 314 (for example, an 80C196 microcontroller available from Intel Corporation of Santa Clara, Calif.), 64 kilobytes of EPROM memory 315, and hardware to allow programmable control processor 314 to control the following: I/O ports 301, 302, and 303, cache memory 308, EDAC 306, error logger 307, host/cache interface logic 311 and 312, disk/cache interface logic 313, processor/cache interface logic 316, and serial port 309.
Programmable control processor 314 performs the functions dictated by software programs that have been converted into a form that it can execute directly. These software programs are stored in EPROM memory 315.
In one embodiment, the host/cache interface logic sections 311 and 312 are essentially identical. Each host/cache interface logic section contains the DMA, byte/word, word/byte, and address register hardware that is required for the corresponding I/O port (301 for 311, 302 for 312) to gain access to cache memory 308. Each host/cache interface logic section also contains hardware to permit control via microcontroller 305. In this embodiment I/O ports 301 and 302 have data path widths of eight bits (byte). Cache memory 308 has a data path width of 32 bits (word).
Disk/cache interface logic 313 is similar to host/cache interface logic sections 311 and 312. It contains the DMA, byte/word, word/byte, and address register hardware that is required for disk I/O port 303 to gain access to cache memory 308. Disk/cache interface logic 313 also contains hardware to permit control via microcontroller 305. In this embodiment, I/O port 303 has a data path width of eight bits (byte).
Processor/cache interface logic 316 is similar to host/cache interface logic sections 311 and 312 and disk/cache interface logic 313. It contains the DMA, half-word/word, word/half-word, and address register hardware that is required for programmable control processor 314 to gain access to cache memory 308. Processor/cache interface logic 316 also contains hardware to permit control via microcontroller 305. In this embodiment, programmable control processor 314 has a data path width of 16 bits (half-word).
Serial port 309 allows the connection of an external device (for example, a small computer) to provide a human interface to the system 200. Serial port 309 permits initiation of diagnostics, reporting of diagnostic results, setup of system 200 operating parameters, monitoring of system 200 performance, and reviewing errors recorded inside system 200. In other embodiments, serial port 309 allows the transfer of different and/or improved software programs from the external device to the control program storage (when memory 315 is implemented with EEPROM rather the EPROM, for example).
Formats of Control Tables
Format of Address Translation (ACT) Table
The Address Translation Table, along with the LRU table, maintains the information required to manage the caching operations. There are two sections in the ADT table, the indexed, or tabular portion, and the set of unindexed, or single-valued items.
The unindexed portion of the ADT table contains two types of data fields; the first are those items which are essential to the cache management, the second category contains those data items which maintain records of system performance.
The first group of unindexed items, or those requisite to the cache management, includes the following single-valued items.
1) ADT-CNL. The number of tracks on the cached disk spindle; also equals the number of lines in the ADT table. This is set at the time the system is configured and is not changed while the system is in operation.
2) ADT-HEAD-POS. The current position of the read/write head of the cache disk. This is updated every time the head is positioned.
3) ADT-SWEEP-DIR. The direction in which the current sweep of the background writes is progressing. This is updated each time the sweep reverses its direction across the disk.
4) ADT-MOD-COUNT. The total number of tracks in the cache which have been modified by writes from the host and are currently awaiting a write to disk by the Disk server. This is increased by one whenever an unmodified cache track is updated by the host, and it is decreased by one whenever a modified cache track is copied to the cache disk.
The second group of unindexed items are those which record system performance, and are all used to compute the current operating characteristics of the system. They include the following single-valued items.
1) ADT-READ-HITS. The number of cache read-hits encountered since the last reset. This value is set to zero by a reset operation from the terminal. It is incremented by one for each read I/O which is entirely satisfied from data which is resident in the cache memory.
2) ADT-READ-MISSES. The number of cache read-misses encountered since the last reset. This value is set to zero by a reset operation from the terminal. It is incremented by one for each read I/O which is cannot be entirely satisfied from data which is resident in the cache memory.
3) ADT-WRITE-HITS. The number of cache write-hits encountered since the last reset. This value is set to zero by a reset operation from the terminal. It is incremented by one for each read I/O for which the corresponding track or tracks are found to be in cache memory.
4) ADT-WRITE-MISSES. The number of cache write-misses encountered since the last reset. This value is set to zero by a reset operation from the terminal. It is incremented by one for each read I/O for which at least one of the corresponding tracks is not found to be in cache memory.
There is one line in the tabular portion for each data track on the spindle. A line is referred to by its line number, or index. That line number directly corresponds to a track number on the disk. When the host wants to access or modify data on the disk, it does so by referencing a starting sector address and indicating the number of sectors to be accessed or modified. For caching purposes, the starting sector address is converted into a track identifier and offset within that track.
A disk sector address is converted into a track number and a sector offset by dividing it by the number of sectors per track. The remainder is the offset into the track. The quotient is the track identifier and is the index into the ADT table. Using this index, the condition of the specified disk track can be determined directly from data in the ADT table; no search is required to determine cache-hits or misses.
Each ADT line contains the following items:
1) ADT-SLOT. There is a one-to-one correspondence between lines in the ADT table and the logical tracks on the disk. If the logical track on the disk corresponding to a given ADT table line is cached, the ADT-SLOT field of that ADT line contains the number which corresponds to the logical block in the cache which contains a copy of the data which resides in the corresponding logical track on the disk. By design, the value in ADT-SLOT also points to the line in the LRU table related to the cached disk track. If the data contained in the track on the disk is not in cache, the value in this field is meaningless and is set to zero. It is by means of this field that cache-hits can be serviced completely without any table search.
2) ADT-CACHED. A flag indicating whether or not the corresponding disk track is stored in the cache. This marker is updated each time a track is entered into or removed from the SSD area.
3) ADT-MODIFIED. A flag indicating whether or not the corresponding cached track has been modified by a write operation from the host, and thus, needs to be copied from the cache to the disk.
4) ADT-LOCKED. A flag indicating whether or not the corresponding cached track is currently the target of some operation, such as being acquired from the disk, being modified by the host, or being written to the disk by the cache controller.
Format of Least Recently Used (LRU) Table
The LRU table maintains the information relative to the times when cached tracks of data were last accessed. This information is necessary for the system to always be aware of which cache slots are available for overwriting whenever uncached data tracks must be placed in cache. Its contents also provide redundancy for the data kept in the ADT table, thus contributing to system reliability.
There are two sections in the LRU table, the indexed, or tabular portion, and the set of unindexed, or single-valued items. The unindexed portion of the LRU table contains data required to manage the caching process. The tabular portion is composed of pointers for LRU chaining purposes, pointers into the ADT table, and the recycle control markers.
It is by means of this LRU information and the ADT table information that the system determines which cached track to overwrite when a cache area is needed for an uncached disk track. The unindexed items are requisite to the cache management, and includes the following single-valued items.
1) LRU-CNL. The number of track-equivalents slots in the cache area; this is equal to the number of lines in the LRU table.
2) LRU-LRU. The LRU-LRU table element points to the cache area track-slot containing the cached data which has been left untouched for the longest time. It is updated when new activity for the referenced slot makes it no longer the least-recently-used. The referenced slot is the top candidate for overwriting when new data must be written into the cache.
3) LRU-MRU. The LRU-MRU table element points to the cache area track-slot containing the cached data which has been most recently reference by the host. LRU-MRU is updated every time a track is touched by either a read or a write from the host. At that time, the address of the accessed track is placed in LRU-MRU and the LRU chains are updated in the indexed portion of the LRU table.
There is one line in the tabular portion for each cache area slot in the cache data area. A line is referred to by its line number, or index. That line number directly corresponds to a slot in the cache data area.
Each LRU table line contains three pointer fields plus a recycle control field:
1) LRU-TRACK. The pointer to the ADT line which references the disk track currently resident in the corresponding cache slot. By design, this value is also the identifier of the disk track whose data currently resides in the corresponding cache slot, if any.
2) LRU-LAST. This is part of the bidirectional chaining of the cache data slots. LRU-LAST is the pointer to the next-older (in usage) cache slot. If this slot is the oldest, LRU-LAST will contain a zero.
3) LRU-NEXT. This is the other half of the bidirectional chaining of the cache data slots. LRU-NEXT is the pointer to the next newer (in usage) cache slot. If this slot is the newest, LRU-NEXT will contain a zero.
4) LRU-RECYCLE. A single bit marker which indicates whether or not the corresponding track is a candidate for recycling. It is set to 1 (on) whenever the track is reused; it is set to 0 (off) when the track is recycled (moved to the MRU position). It is initially set to 0 when a track is brought into cache as a result of a cache-ahead decision. For a track brought in to satisfy a cache miss, it is set to 1.
EXAMPLES OF TABLES
Initial ADT Table
When a system is first powered on, the ADT table is in an indeterminate state. In order to become operational, initial values must be entered into their appropriate table elements. Initial values for unindexed fields of the ADT table are as follows:
The ADT-CNL field must be set to the size of the cache disk as a number of tracks.
the ADT-HEAD-POS field is set to zero to indicate the head is currently at the edge of the disk. This may, or may not, be true, but it does not matter, it will become correct on the first access to the disk.
The ADT-SWEEP-DIR field is arbitrarily set to one ("1") to indicate the head is moving in an upward (based on track addresses) direction. This will be corrected at the initiation of the first background sweep.
The ADT-MOD-COUNT field is set to zero to reflect the fact that no modified tracks are waiting in cache to be copied to disk.
The ADT-READ-HITS field is set to zero to reflect the fact that no cache hits have occurred during read operations.
The ADT-READ-MISSES field is set to zero to reflect the fact that no cache misses have occurred during read operations.
The ADT-WRITE-HITS field is set to zero to reflect the fact that no cache hits have occurred during write operations.
The ADT-WRITE-MISSES field is set to zero to reflect the fact that no cache misses have occurred during write operations.
All indexed fields of all lines of the ADT table are initially set to zero to indicate that no tracks are resident in cache.
Initial LRU Table
When a system is first turned on, the LRU table is in an indeterminate state. In order to become operational, initial values must be entered into their appropriate table elements. While there are many acceptable ways to initialize the chaining fields, a simple one has been selected, and is described here.
Initial values for unindexed fields of the LRU table are as follows:
The LRU-CNL field must be set to the size of the cache, as a number of track-equivalent slots.
The LRU-LRU field is set to one to represent the lowest numbered cache slot as being the oldest. This is an arbitrary choice in keeping with the chaining values selected, below.
The LRU-MRU field is set equal to LRU-CNL to represent the highest cache slot as being the most recently used. This is an arbitrary choice in keeping with the initial chaining values selected, below.
Initial values for indexed fields of the LRU table are as follows:
The LRU-TRACK field of every line of the LRU table is set to zero to indicate that no disk data tracks are currently held in cache.
The LRU-LAST field of every line of the LRU table is set to that line's index minus one. This action, along with the settings for the LRU-NEXT values, produces a chained list suitable for the cache start-up operation.
The LRU-NEXT field of every line, except the highest, of the LRU table is set to that line's index plus one. The LRU-NEXT field of the highest line is set to zero. These settings, along with the settings for the LRU-LAST values, produce a chained list suitable for the cache start-up operation.
The LRU-RECYCLE field of every line of the LRU table is set to zero to indicate that no slot is currently a candidate for recycling.
Operational state ADT tables
The operational state ADT table examples illustrate the conditions after the very first (sample) I/O has occurred and after the system has reached a fully active condition. These fully active examples show the effects of several I/O's on the state of the ADT table contents. Also included in these examples is the effect of a background sweep which wrote modified tracks from cache to disk. A detailed description of these specific sample operations appears under the LRU table discussion, below.
Operational state LRU tables
The operational state LRU table examples illustrate the conditions after the very first I/O has occurred and after the system has reached a fully active condition. These fully active examples show the effects of several I/O's on the state of the LRU table contents.
Description of Sample I/O's
For purposes of illustration, a sample of I/O's where chosen to be discussed in detail. Those chosen for discussion are I/O numbers 1, 1000, 1001, and 1002 taken from a trace of actions at an operational site; they are detailed in Table 4 as projected into the described system. The following discussions of the sample I/O's include the effects on both the ADT and the LRU tables.
Actions related to I/O operation number 1:
1. This I/O is a read involving disk track numbers 46 and 47; since nothing is in cache, it must be a cache-miss, and the tracks must be brought into cache. The ADT table is modified to show the locations of the tracks in the cache. The LRU table is updated to indicate the presence of the two tracks in cache, the chains are relinked to show the tracks as the MRU and next-to-MRU tracks, and they are both marked for recycling. They are marked for recycling since they will have been used at least once by the time they reach the LRU position in the chain.
2. Based on the I/O size and the difference from the end of the data requested in I/O operation number 1 to the end of track 47, a prefetch of track 48 is initiated. That activity is not reflected in the ADT and LRU tables since it is initiated as a background operation after the completion of the current I/O.
After 999 I/O's have occurred, the ADT and LRU tables have reached a certain status. Based on that status, the following actions relate to I/O operation number 1000:
1. This I/O is a read involving track 56 which is not in cache; it must be brought into cache and put at the MRU position in the LRU chain. To make room for this track, the old LRU track was decached.
2. A read I/O operation does not affect the need for a background sweep. There are three tracks in cache that need to be copied to disk; this condition remains unchanged by the current I/O.
3. Several cache slots have been marked for recycling, including the slot at the LRU end of the chain and the slot it points to. Before any prefetch is initiated, these will be moved to the MRU and next-to-MRU positions and their recycle markers will have been removed.
4. Since track 57 is already in cache, no prefetch is needed for it.
5. The size of the I/O (68 sectors) and the current I/O's proximity to the first sector in track 56 indicate that track 55 should be prefetched by a cache-ahead action. That prefetch will be initiated as a background operation. Based on the LRU chain and the recycling situation, track 55 will be cached into slot 3. For the moment it will occupy the MRU position in the chain.
Actions related to I/O operation number 1001:
1. Prefetching of track 55, which was initiated by I/O 1000 has now been completed.
2. I/O number 1001 is a write involving tracks 61 and 62 which are both resident in the cache. The LRU and ADT table references to them are updated.
3. This I/O action modified two cached tracks, bringing the total number of tracks which need written to disk up to the trigger point for the background sweep.
4. The background sweep is initiated and starts writing the modified tracks from cache to disk.
5. Since the background sweep is using the disk spindle, no cache-ahead is initiated, even though the system would consider the prefetch of track 60 into cache.
Actions related to I/O operation number 1002:
1. The background sweep completed writing all modified tracks from cache to disk; it then went into the dormant state.
2. I/O 1002 was a write involving track 214 which is already resident in cache. The track is marked in the ADT table as having been modified. In the LRU table, track 214 in slot number 13 is rechained to the MRU position.
3. A prefetch of track 215 is initiated since the position of the current I/O in track 214 is near enough to the end of the track to warrant a cache-ahead operation. This activity does not appear in the ADT and LRU tables for I/O 1002 since it will occur in the background after the completion of the current I/O.
4. Since a prefetch of track 215 has been initiated, track 213 is not considered for prefetching.
FIRMWARE
Firmware Overview
The memory controller of this invention goes into a semi-dormant state when there is no activity that it needs to handle. As depicted in the flow chart of FIG. 4, there are three types of occurrences that may cause the controller to become active:
1. The host computer sends a command;
2. The background sweep completes an event;
3. The background sweep times out.
Insofar as possible, the host computer commands are given priority over other memory device activities. Thus, when a command is received from the host, it is immediately turned over to the Host Command Handler (described elsewhere). At the completion of the activity called for by that command, the memory controller determines if the background sweep is active. If it is not active, the background status is inspected and action is taken as appropriate, as described later with regard to the background check. Following the background status check, the cache-ahead status is checked, as described later with regard to the cache-ahead management. The controller then waits for the next host command. The controller may not be completely inactive at this time, inasmuch as either the background sweep or the cache-ahead may have initiated or continued some disk activity. If the background was found to be active, its activity is continued until such time as it has no more immediate work to do, as described later with regard to background continuation.
When the background sweep completes a command, the controller is given an interrupt with a signal that indicates the sweep needs its attention. At that time, the controller initiates the next sweep event, if any is waiting, and sets up a subsequent sweep event, also based on need, as described later with regard to the background continuation. At the completion of each sweep event, the controller determines if there is a need to continue the sweep. If no such need exists, the background sweep is placed in the dormant state. In either case, when the controller has completed its housekeeping, it becomes inactive awaiting its next task.
The background sweep can be activated in either of two ways; it will be activated when a set number of cached tracks have been modified and are in need of being written from cache to disk. The sweep may also be activated by a timeout. A timeout occurs whenever the sweep is inactive, and there exists any modified track waiting to be written from cache to disk which has been waiting more than a preset amount of time. When a timeout occurs, the controller is signaled that the sweep requires its attention. The controller initiates the background sweep (see description of background initiation) and, after completing the appropriate housekeeping, awaits the next command or event requiring its attention. The background sweep itself continues in operation until there is no more immediate need for its services. At that time it is returned to the dormant state.
Host-Command Management
Whenever a command is received from the host computer, it is given the highest possible priority and handled as depicted in FIG. 5. To determine what actions are required, the command must be analyzed. A portion of the firmware is dedicated to that purpose (see description of host command analysis). The analysis of the command determines the type of command (read, write, seek, or other) and, where meaningful, will make a cache hit/miss determination. The analysis also sets up a table of one or more lines which will be used later in servicing the command.
If the command is a read and it can be serviced entirely from cache (i.e. a cache hit), the command is serviced by the read-hit portion of the controller (see description of read-hit handling).
If any portion of the read cannot be serviced from cached tracks (i.e. a cache miss), the command is turned over to the read-miss portion of the controller (see description of the read-miss handling).
If the command is a write and all tracks involved in the operation are already in cache, the command is serviced by the write-hit portion of the controller (see description of write-hit handling).
If any portion of the write involves an uncached track or tracks, the command is turned over to the write-miss portion of the controller (see description of the write-miss handling).
If the command is a seek, and the target track is already cached, no action is required. If the target track is not cached, the command is turned over to the seek-miss portion of the controller (see description of seek-miss handling).
Analyze Host I/O Command
As depicted in FIG. 6, the analysis of a host command includes creation of a track address list which contains the locations of each track involved in the operation (see description of track address list setup). For each such track, the list contains the track's current location in cache, if it already resides there; or where it will reside in cache after this command and related caching activity have been completed. In the case that a track is not already cached, the space for it to be put into in cache in located, and the current track resident in that space is decached. The analysis includes setting the cache hit/miss flag so that the controller logic can be expedited.
Set Up Track Address List
As shown in FIG. 7, the controller segment which sets up the track address list uses the I/O sector address and size to determine the disk track identifying numbers for each track involved in the I/O operation (see description of address translation). The number of tracks involved is also determined, and for each track, the portion of the track which is involved in the operation is calculated.
Address Translation
FIG. 8 describes the operation for this translation. A sector address can be converted into a track address by dividing it by the track size. The quotient will be the track number, and the remainder will be the offset into the track where the sector resides.
Cache Read-Hit Operation
Refer to FIG. 9. A cache read hit is satisfied entirely from the cached data. In order to reach this module of the controller, the command will have been analyzed and the track address table will have been set up. With this preliminary work completed, the host read command can be satisfied by using each line of the track address table as a subcommand control. Since all affected tracks are already in cache, all required data can be sent directly from the cache to the host. In addition to transferring the data to the host, this module will rechain the affected tracks to become the most-recently-used tracks in the LRU table.
Cache Read-Miss Operation
A cache read miss (FIG. 10) is satisfied in part or wholly from the disk. In order to reach this module of the controller, the command will have been analyzed and the track address table will have been setup. With this preliminary work completed, the host read command can be satisfied by using each line of the track address table as a subcommand control. For tracks which are already in cache, the data can be sent directly from the cache to the host. For tracks not resident in the cache, the data is sent from the disk to the host, and simultaneously to the cache. For any partial tracks sent to the host, the whole track will be sent to cache. In addition to transferring the data to the host, this module will rechain the affected tracks to become the most-recently-used tracks in the LRU table.
Cache Write-Hit Operation
A cache write hit (FIG. 11) is handled entirely within the cache. In order to reach this module of the controller, the command will have been analyzed and the track address table will have been set up. With this preliminary work completed, the host write command can be satisfied by using each line of the track address table as a subcommand control. Since all affected tracks are already in cache, all data can be sent directly from the host to the cache without any concern for post-transfer caching of partial tracks. In addition to transferring the data to the cache, this module will rechain the affected tracks to become the most-recently-used tracks in the LRU table.
Write Miss Operation
A cache write miss is handled entirely within the cache, but requires post-transfer caching of data from the disk into cache of any partial tracks that were involved, as depicted in FIG. 12. In order to reach this module of the controller, the command will have been analyzed and the track address table will have been set up. With this preliminary work completed, the host write command can be satisfied by using each line of the track address table as a subcommand control. Since this is a cache-miss, some or all of the affected tracks are not in cache; however, all data can be sent directly from the host to the cache.
The cache controller has the responsibility for post-transfer caching of any partial tracks. In actuality, only the first and/or last tracks involved in the transfer can be partial tracks; all interior tracks must be full tracks, and thus require no post-transfer staging in any case. For those tracks requiring post-transfer caching, the controller sets up a list of caching events to bring any required track segments into cache to maintain the integrity of the cached tracks. In addition to transferring the data to the cache, this module rechains the affected tracks to become the most-recently-used tracks in the LRU table.
Seek Cache Miss
As shown in FIG. 13, the controller has the option of ignoring a seek command since the controller will ultimately be responsible for fulfilling any subsequent, related I/O command. For a seek command for which the target track is already in cache, no controller action is needed or appropriate. For a seek command for which the target track is not in cache, the controller, if the disk to which the seek is directed is not busy, will cache that target track. This action is based on the assumption that the host would not send a seek command unless it was to be followed by a read or a write command. If the disk to which the seek is directed is busy when a seek command is received from the host, the seek command is ignored.
Decache a Track
For every cache-miss I/O that occurs, and for every cache-ahead operation, some previously cached track or tracks of data must be decached. The primary function of the LRU table is to allow the controller to expeditiously determine which cached track of data is the best candidate for decaching. The decaching module depicted in FIG. 14 chooses the track to be decached. Normally, the track with the longest elapsed time since its last usage will be the track to be decached. This is the track which is pointed to by the LRU-LRU element of the LRU table. The LRU-LRU pointer is maintained in such a way as to always point to the least-recently-used track.
The first condition is that the track must be inactive; that is, it is not at this instant the subject of any activity. It is highly unlikely that the LRU-LRU track would have any activity since most activities would reposition it out of the LRU-LRU spot. However, the possibility is covered by the decaching algorithm.
The second condition that must be satisfied before a track can be decached is that it not be in a modified state in cache. Again this is most improbable when the background sweep algorithm is considered. The background sweep algorithm continually attempts to keep the number of modified tracks to a very low number, on the order of a fraction of one percent of the total cached tracks.
Finally, the track to be decached must not be a candidate for recycling. Any track which has been reused since it was first cached or reused since it was last recycled is not decached. Instead, such a cached track is removed. In this manner, such a track is allowed to remain in cache for a longer time than a track which has not been reused since it was last recycled, or, in the case of a cache-ahead track, since the time it was first cached. The effect of this procedure is to allow unused cache-ahead tracks to move down through the LRU list at a faster rate than those which have been used, and to allow the more useful tracks to remain in cache for a longer time.
If, for any of the above reasons, the LRU-LRU track is unable to be decached, the LRU chain will point to the next-LRU candidate. While it is not unusual for the LRU track to be recycled, it will be an extremely unusual condition in which the decaching module will need to inspect more than one non-recycled LRU slot to find the slot to be decached.
When the actual candidate for decaching has been identified, both the LRU and ADT tables are updated to reflect that the chosen candidate is no longer cached. This is a minor amount of work; no disk activity is involved.
Cache-Ahead Management
The cache hit management operation is depicted in FIG. 15. As shown in FIG. 19, the background sweep has a lower priority than host activities, and as shown in FIG. 15, cache-ahead activities have a lower priority than background sweep activities. Since a background sweep has priority over cache-ahead activities, all cache-ahead steps are ignored if the background sweep is active or of a host request exists. If the background sweep is not active, the controller considers the possible need for cache-ahead after every host I/O regardless of whether the I/O was a read or a write, or whether the I/O was a cache hit or cache miss. However, since all cache-ahead action are a background type of activity, and only uses the private channel between disk and cache, they will have a very minimal negative impact on response time to host I/O activity. To further limit the impact, the cache-ahead steps are given a lower priority than any activities required to satisfy an incoming host I/O request and a lower priority than any background sweep activity.
A major factor in limiting the cache-ahead activity is the lack of need for its operation following most host I/O's. As depicted in FIG. 16, the I/O locality feature limits the cache-ahead activity to those circumstances where it is likely that a soon-to occur host I/O would access data beyond the track which satisfied the current I/O. The I/O locality algorithm uses the current I/O block size and its location within the affected track to determine how near the "edge" of the current tack the current I/O was located. If it is determined that a preselected number of like-sized sequential I/O's could be satisfied from this same track without need for an adjacent track, no cache-ahead is performed.
There are only two candidates for cache-ahead: they are the single track immediately following that involved in the host I/O and the track immediately preceding that of the host I/O. Since these tracks will often have already been cached by previous cache-ahead activity, the cache-ahead activity is largely a self-limiting process. To determine if the succeeding data track is already in cache, the ADT-CACHED field of the ADT table in the line next higher than that related to the current track is examined. It will indicate whether or not that succeeding track is in cache. Conversely, the ADT table line next lower to the current track is examined to determine if the preceding track is in cache.
For each host I/O, there is a beginning side of the data accessed by the host as represented, for example, by the I/O's first, or lowest numbered, sector address, and an ending side of the data accessed by the host as represented, for example, by the I/O's last, or highest numbered, sector address.
For each logical track area or block in cache, when it is assigned to a logical disk track, there is also a beginning side as, for example, represented by the first, or lowest numbered, sector address of the assigned logical disk track, and an ending side as, for example, represented by the last, or highest numbered sector address of the assigned logical disk track.
A forward proximity value can be calculated for any host I/O based on the size of that I/O in sectors and the distance between its ending side in cache and the ending side of the logical track area in cache to which the host I/O's logical disk track is assigned.
Likewise, a backward proximity value can be calculated for any host I/O based on the size of that I/O in sectors and the distance between its beginning side in cache and the beginning side of the logical track area in cache to which the host I/O's logical disk track is assigned.
Only one track is cached-ahead for any given host I/O: the track succeeding the host I/O is the primary candidate. If it is not already cached, and the forward proximity value compared to the proximity factor indicates the cache-ahead should occur, the forward track is scheduled for caching at this time. If the succeeding track is already cached, the track preceding the backward proximity value compared to the host I/O is considered; if it is not already cached, and the proximity factor indicates the preceding track should be cached, this preceding track is scheduled for caching at this time. Of course, if both the succeeding and preceding tracks are currently in cache, the cache-ahead module has no need to do any caching. Scheduled cache-ahead operations are carried out as background activities on a lower priority than any activities required to satisfy a host request and at a lower priority than any background sweep activities.
A very important benefit accrues from this forward and/or backward cache-ahead feature. If related tracks are going to be accessed by the host in a sequential mode, that sequence will be either in a forward or backward direction from the first one accessed in a given disk area. By the nature of the cache-ahead algorithm of this invention, an unproductive cache-ahead will only involve one track which lies in the wrong direction from the initial track in any given track cluster. This, coupled with the proximity algorithm, makes the cache-ahead behavior self-adapting to the direction of the accesses.
Background Sweep Management
When a write I/O from the host is serviced by the controller, the data from the host is placed in the cache. It is written from the cache to the disk in the background, minimizing the impact of the disk operations on the time required to service the I/O. The module that handles this background activity is the background sweep module. In the interest of efficiency, the background sweep module does not always copy data from cache to disk as soon as it is available. Rather, it remains dormant until some minimum number of modified tracks are waiting to be copied before going into action. In order to avoid having a single modified track wait an inordinately long time before being copied from cache to disk, the background sweep will also be activated by a timeout. Thus, if any modified track has been waiting a certain minimum time, and the sweep is not active, the sweep will be activated. After the sweep has copied all modified tracks from cache to disk, it returns to a dormant state.
Sweep Timeout
A timeout occurs when some cached data track has been modified and the corresponding track on disk has not been updated after a certain minimum time has elapsed. When a timeout occurs, by definition there will be at least one cached track which needs to be copied to disk. At this time, the background will be changed into the active state. The timeout module (FIG. 17) also causes the first background event to be set up (see description of background event generation), and if no conflict exists with the host for access to the disk, the execution of the event will be initiated. After this event is initiated, the next event, if one is known to be needed, is also set up and held for later execution. When these things have been done, the background sweep waits for circumstances to cause it to continue its operation or to return to a dormant state.
Sweep Initiation
At the completion of each host I/O operation, the sweep initiation module (FIG. 18) is entered. One of three cases may exist. The first case is that the sweep is dormant, and there are not a sufficient number of modified tracks waiting to be copied to disk to cause the sweep to be enabled at this time. In this case, which is the most common one, there is no action to be taken at this time.
In the second case, the sweep is active, and a background event is operating. In this situation, no new action is needed at this time.
In the final case, the sweep is active, but no background event is currently in operation. Under these conditions, a background event is generated (see description of Generate Sweep Event) and, if appropriate, its execution is initiated.
Generate Sweep Event
The need for the generation of a background sweep event is predicated on there being no other ongoing activity involving the disk. If the event generation module of FIG. 19 is entered when any such activity is in progress, no event is generated.
At times, the event generation module will find that there are no more modified tracks waiting to be copied to the disk. In this case, the background sweep is returned to the dormant condition. At other times, the background sweep is in the active mode, but has been temporarily interrupted to handle the higher priority activity of servicing a host I/O. Such interruption requires the background sweep to be restarted. It does this by finding the modified track which is nearest the disk head; initiating a seek to that track; and then setting up a write event for the track. This write event will not be initiated until later, but its existence signals the sweep continuation module (see description of continuation module) that, if possible, this write is the next thing to be done.
The effect of this method of handling background writes is to minimize the impact on the host operations. The controller has an opportunity to service host I/O misses between the background seek and the corresponding write operation. None of this has any significant effect on servicing host I/O cache hits since hits are always handled immediately. The disk is not involved in a hit.
Sweep Continuation
As depicted in the flow chart of FIG. 20, each background sweep event, whether a seek or a write, prepares a waiting event for the sweep's subsequent action. Thus, the initiation of a seek always prepares the subsequent, related write event; the initiation of a write prepares the subsequent, unrelated seek event, if another track is waiting to be copied to disk.
The continuation module is entered upon the completion of each sweep event. If the host has issued an I/O command which requires the disk (in other words, a cache-miss), the background sweep sequence is interrupted, and the waiting event is erased. This action is taken in order to expedite the servicing of the host's commands, and is taken regardless of the type of sweep event which is waiting. It can result in wasting background seek actions. This is acceptable; the aborted write will be handled later when time permits. Of course, once a sweep command has actually been initiated, it cannot be aborted.
If the sweep continuation module is entered after the sweep operations have been interrupted, it will use the event generation module (see description of event generation) to restart the sweep sequence.
Finally, if the continuation module finds that the just completed sweep operation was a write, and no more modified tracks are waiting to be copied to the disk, the sweep is put into the dormant state.
Power Down Control
As depicted in the flow chart of FIG. 21, this portion of the firmware is invoked when the system senses that the line power to it has dropped. Since some of the data in the system may be in the cache portion in a modified state and awaiting transfer to the disk, power must be maintained to the cache memory until the modified portions have been written to the disk. Thus, a failure of the line power causes the system to switch to the battery backup unit. The battery backup unit provides power while the memory device goes through an intelligent shutdown process.
If the host is in the process of a data transfer with the memory device when power drops, the shutdown controller allows the transfer in progress to be completed. It then blocks any further transactions with the host from being initiated.
The shutdown controller then must initiate a background sweep to copy any modified data tracks from the solid state memory to the disk so that it will not be lost when power is completely shut off to the control and memory circuits. After the sweep is completed (which will take only a few seconds), all data in the solid state memory will also reside on the disk. At this point the disk spindle can be powered down, reducing the load on the battery.
Most power outages are of a short duration. Therefore, the controller continues to supply battery power to the control circuits and the solid state memory for some number of minutes. If the outside power is restored in this time period, the controller will power the spindle back up and switch back to outside power. In this case, the operation can proceed without having to reestablish the historical data in the solid state memory. In any case, no data is at risk since it is all stored on the rotating magnetic disk before final shutdown.
Final Background Sweep
The final background sweep (FIG. 22) copies modified, waiting tracks from the solid state memory to the magnetic disk. There will usually be only a few such tracks to copy since the number that can reach this state is intentionally limited by the operations of the system. The final sweep makes use of logic developed for the normal operation of the background sweep.
The sweep is initiated in much the same manner as for a timeout during normal operation. If no tracks need to be copied, the sweep is left in the dormant state, and no further sweep action is required. If any tracks need copied, the sweep initiator sets up and initiates the first background seek, as well as sets up the related write event. At the completion of this first seek, control goes to the background continuation module which alternately executes the previously created, waiting event and generates the next event and puts it into a wait status. When no modified tracks remain to be copied, the sweep is finished.
Parameters and Particulars
This specification refers to items which are not given specific quantities or identities. These have been purposely left unquantified so as not to imply any absolute limits or restrictions. For purposes of illustration, and to provide known workable dimensions and identifies, the following ranges of values and identifiers are provided, along with a set which is satisfactory for a sample configuration.
BACKGROUND SWEEP TRIGGER, NUMBER OF MODIFIED TRACKS
Range: One to number of tracks on chosen disk.
Sample configuration: Five
BACKGROUND SWEEP TRIGGER, TIME
Range: One millisecond to unlimited.
Sample configuration: Five seconds.
EPROM MEMORY FOR MICROPROCESSOR
Size range: Non-specific.
Sample configuration: 64 kilobytes.
HARDWARE MICROPROCESSOR CONTROLLER
Candidates: Any suitable and available microprocessor.
Sample configuration: 80C196, 24 MHz (Intel Corp.).
POWER DOWN, CACHE HOLD TIME
Range: Zero seconds to limitation imposed by battery back unit.
Sample configuration: Five minutes.
ROTATING MAGNETIC DISK CAPACITY
Size range: Any available disk capacity.
Sample configuration: 675 megabytes formatted.
SCSI CONTROLLER
Candidates: Any suitable and available controller device.
Sample configuration: NCR 53C90A (National Cash Register Corp., Dayton, Ohio).
SECTOR SIZE
Size range: Any appropriate for the host system and the selected disk drive.
Sample configuration: 180 bytes.
SECTORS PER TRACK
Range: Any appropriate for selected disk and host system.
Sample configuration: 256.
SOLID STATE MEMORY SIZE
Size range: One megabyte to 100 percent of the capacity of the attached disk capacity.
Sample configuration: 32 megabytes.
TRACK SIZE
Size range: One sector to any size appropriate for the selected disk drive.
Sample configuration: 256 sectors.
TRACKS PER DISK
Range: Any available on chosen disk.
Sample configuration: 14628.
TABLE F-1______________________________________TABLE FORMATSADDRESS TRANSLATION (ADT) TABLE FORMAT -UNINDEXED ELEMENTSTABLEITEM DESCRIPTION______________________________________ADT-CNL Number of tracks on the cached disk spindle; equals the number of lines in the ADT table.ADT-HEAD-POS Position of read/write head of cache disk.ADT-SWEEP-DIR Direction of current DISK SERVER sweep; 1 = sweep is progressing from low-to-high. 0 = sweep is progressing from high-to-low.ADT-MOD-COUNT Total number of tracks in the cache which have been modified by writes from the host and are currently awaiting a write to disk by the Disk server.ADT-READ-HITS Number of cache read-hits encountered since last reset.ADT-READ-MISSES Number of cache read-misses encountered since last reset.ADT-WRITE-HITS Number of cache write-hits encountered since last reset.ADT-WRITE-MISSES Number of cache write-misses encountered since last reset.______________________________________
TABLE F-2______________________________________ADDRESS TRANSLATION TABLE FORMAT - INDEXEDELEMENTSTABLE MAXIMUM ITEMITEM VALUE DESCRIPTION______________________________________(INDEX) (ADT-CNL) ADT table index; equivalent to the corresponding disk track number. There is one ADT table line for each disk track.ADT-SLOT (LRU-CNL) Number of the cache slot which contains the disk track of data corresponding to this ADT index; also points to line in LRU table related to the disk track. If the disk track is not in cache, this field is meaning- less and is set to zero.ADT-CACHED 1 Flag indicating whether or not the corresponding disk track is stored in the cache. 0 = the track is not in cache. 1 = the track is in cache.ADT-MODIFIED 1 Flag indicating whether or not this (cached) track has been modified by a write operation from the host, and thus, needs to be written from the cache to the disk. 0 = This track (if cached) is unmodified and does not need to be written to disk. 1 = This track needs to be written to disk.ADT-LOCKED 1 Flag indicating whether or not this (cached) track is currently the target of some operation (locked), such as being acquired from the disk, being modified by the host, or being written to the disk by the cache controller. 0 = the (cached) track is not locked; it is available for any operations. 1 = the (cached) track is the target of an operation and is locked; it cannot, at this moment, become the tar- get of another operation.______________________________________
TABLE F-3______________________________________LEAST-RECENTLY-USED (LRU) TABLE FORMAT -UNINDEXED ELEMENTSTABLEITEM DESCRIPTION______________________________________LRU-CNL Number of lines in the LRU table; equal to the number of slots in the cache area.LRU-LRU Pointer to least-recently-used end of the LRU chain.LRU-MRU Pointer to most-recently-used end of the LRU chain.______________________________________
TABLE F-4______________________________________LEAST-RECENTLY-USED TABLE FORMAT - INDEXEDELEMENTSTABLE MAXIMUM ITEMITEM VALUE DESCRIPTION______________________________________LRU-TRACK (ADT-CNL) Disk track number for data stored in this cache slot; also points to line in ADT table related to the disk track.LRU-LAST (LRU-CNL) Pointer to preceding link in LRU chain; 0 = this is first (LRU) link in chain.LRU-NEXT (LRU-CNL) Pointer to following link in LRU chain; 0 = this is last (MRU) link in chain.LRU-RECYCLE 1 Recycle marker; 0 = this is not a candidate for recycling______________________________________
TABLE T-1______________________________________INITIAL ADT TABLEADT-CNL = 14628ADT-HEAD-POS = 0ADT-SWEEP-DIR = 1ADT-MOD-COUNT = 0ADT-READ-HITS = 0ADT-READ-MISSES = 0ADT-WRITE-HITS = 0ADT-WRITE-MISSES = 0DISK SSDTRACK SLOT CACHED MODIFIED LOCKED______________________________________1 0 0 0 02 0 0 0 03 0 0 0 04 0 0 0 05 0 0 0 06 0 0 0 0. . . . .. . . . .. . . . .(ADT-CNL) 0 0 0 0______________________________________
TABLE T-2______________________________________INITIAL LRU TABLECNL = 22LRU = 1MRU = 22SSD DISK LRU LRU LRUSLOT TRACK LAST NEXT RECYCLE comments______________________________________1 0 0 2 0 LRU;2 0 1 3 0 the LRU table3 0 2 4 0 is aritrarily4 0 3 5 0 chained to5 0 4 6 0 allow initial6 0 5 7 0 operations to7 0 6 8 0 proceed with8 0 7 9 0 a minimum of9 0 8 10 0 special handling10 0 9 11 0 during startup11 0 10 12 0 of the caching12 0 11 13 0 operations13 0 12 14 014 0 13 15 015 0 14 16 016 0 15 17 017 0 16 18 018 0 17 19 019 0 18 20 020 0 19 21 021 0 20 22 022 0 21 0 0 MRU; arbitrary.______________________________________
TABLE T-3a______________________________________ADT TABLE AFTER ONE I/O OPERATION(A read involving tracks 46 and 47)ADT-CNL = 14628ADT-HEAD-POS = 47ADT-SWEEP-DIR = 1ADT-MOD-COUNT = 0ADT-READ-HITS = 0ADT-READ-MISSES = 1ADT-WRITE-HITS = 0ADT-WRITE-MISSES = 0DISK SSD MODI- com-TRACK SLOT CACHED FIED LOCKED ments______________________________________1 0 0 0 02 0 0 0 03 0 0 0 04 0 0 0 05 0 0 0 06 0 0 0 0. . . . .. . . . .. . . . .46 1 1 0 0 from read- miss (2-track)47 2 1 0 0 from read- miss (2-track)48 0 0 0 049 . . . .(ADT- 0 0 0 0CNL)______________________________________
TABLE T-3b______________________________________LRU TABLE AFTER ONE READ I/O OPERATION(A read involving track 46)LRU-CNL = 22LRU-LRU = 3LRU-MRU = 2SSD DISKSLOT TRACK LAST NEXT RECYCLE comments______________________________________1 46 22 2 1 cached due to 2-track read-miss2 47 1 0 1 MRU; second track of read-miss3 0 0 4 0 new LRU4 0 3 5 05 0 4 6 06 0 5 7 07 0 6 8 08 0 7 9 09 0 8 10 010 0 9 11 011 0 10 12 012 0 11 13 013 0 12 14 014 0 13 15 015 0 14 16 016 0 15 17 017 0 16 18 018 0 17 19 019 0 18 20 020 0 19 21 021 0 20 22 022 0 21 1 0 old MRU______________________________________
TABLE T-3c______________________________________LRU TABLE AFTER 1000 I/O OPERATIONS(A read involving track 56)LRU-CNL = 22LRU-LRU = 19LRU-MRU = 21SSD DISKSLOT TRACK LAST NEXT RECYCLE comments______________________________________1 62 8 17 02 46 12 16 1 will be recycled3 215 18 6 04 41 15 22 05 8071 13 21 06 58 3 10 07 45 11 13 1 will be recycled8 61 9 1 09 48 14 8 010 43 6 15 011 44 17 7 1 will be recycled12 52 22 2 013 214 7 5 1 will be recycled14 65 20 9 015 42 10 4 016 57 2 20 017 63 1 11 018 213 19 3 1 will be recycled19 212 0 18 1 LRU, oldest usage; will be recycled20 66 16 14 021 56 5 0 0 MRU; newest usage22 67 4 12 0______________________________________
TABLE T-3d______________________________________LRU TABLE AFTER 1001 I/O OPERATIONS(A write involving tracks 61 and 62)LRU-CNL = 22LRU-LRU = 6LRU-MRU = 1SSD DISKSLOT TRACK LAST NEXT RECYCLE comments______________________________________1 62 8 0 0 new MRU2 46 12 16 13 55 18 8 04 41 15 22 05 8071 13 21 06 58 0 10 0 new LRU7 45 11 13 18 61 3 1 09 48 14 17 010 43 6 15 011 44 17 7 112 52 22 2 013 214 1 5 114 65 20 9 015 42 10 4 016 57 2 20 017 63 9 11 018 213 19 3 0 recycled19 212 21 18 0 old LRU; recycled20 66 16 14 021 56 5 19 0 old MRU22 67 4 12 0______________________________________
TABLE T-3e______________________________________LRU TABLE AFTER 1002 I/O OPERATIONS(A write involving track 214)LRU-CNL = 22LRU-LRU = 6LRU-MRU = 13SSD DISKSLOT TRACK LAST NEXT RECYCLE comments______________________________________1 62 8 13 02 46 12 16 13 55 18 8 04 41 15 22 05 8071 7 21 06 58 0 10 0 LRU; unchanged7 45 11 5 18 61 3 1 09 48 14 17 010 43 6 15 011 44 17 7 112 52 22 2 013 214 1 0 1 new MRU14 65 20 9 015 42 10 4 016 57 2 20 017 63 9 11 018 213 19 3 019 212 21 18 020 66 16 14 021 56 5 19 022 67 4 12 0______________________________________
TABLE 4______________________________________Sample I/O's for IllustrationThe LRU and ADT table examples are based on I/O samplestaken from an actual operating computer system andprojected into the system's environment.For each I/O, the following information is available:(I/O SIZE (COMPUTEDREF SECTOR IN TRACKNBR) ADDRESS SECTORS NUMBER) comment______________________________________1 11,742 68 46, 47 read starts in 46, ends in 47. . . .. . . .. . . .1000 14,190 68 56 read com- pletely in 561001 15,550 68 61, 62 write starts in 61, ends in 621002 54,582 68 214 write en- tirely in 214. . . .. . . .. . . .______________________________________
The invention now being fully described, it will be apparent to one or ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the appended claims. | A computer data storage device made up of both solid state storage and rotating magnetic disk storage maintains a fast response time approaching that of a solid state device for many workloads and improves on the response time of a normal magnetic disk for practically all workloads. The high performance is accomplished by a special hardware configuration coupled with unique procedures and algorithms for placing and maintaining data in the most appropriate media based on actual and projected activity. The system management features a completely searchless method (no table searches) for determining the location of data within and between the two devices. Sufficient solid state memory capacity is incorporated to permit retention of useful, active data, as well as to permit prefetching of data into the solid state storage when the probabilities favor such action. Movement of updated data from the solid state storage to the magnetic disk and of prefetched data from the magnetic disk to the solid state storage is done on a timely, but unobtrusive, basis as background tasks of the described device. A direct, private channel between the solid state storage and the magnetic disk prevents the conversations between these two media from conflicting with the transmission of data between the host computer and the described device. A set of microprocessors manages and oversees the data transmission and storage. Data integrity is maintained through a power interruption via a battery assisted, automatic and intelligent shutdown procedure. | 6 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 13/182,496 filed Jul. 14, 2011, which claims the benefit of the earlier priority filing date of the Provisional Application, U.S. patent application Ser. No. 61/365,076 filed Jul. 16, 2010.
FIELD OF THE INVENTION
[0002] The present invention relates generally to a compressed air device, and more particularly relates to a compressed air device that is compact and saves valuable space during operation and allows for the accurate, efficient, and expeditious adjustment of drive belts.
BACKGROUND OF THE INVENTION
[0003] The adjustment of belts on a piece of machinery can be a time consuming operation. This is especially so on a piece of equipment that is vital to the operation of a system or a business. For example, when the piece of equipment is supplying compressed air to a hospital, the hospital needs the compressed air to be pumped throughout the hospital continuously. The compressed air is pumped throughout the hospital by compressors that utilize drive belts. Because of the nature of the drive belts, they need to be changed periodically and this changing of the drive belts must be accurate, efficient, and expeditious. The present invention provides a device that is compact and allows the accurate, efficient, and expeditious adjustment of drive belts.
BRIEF SUMMARY OF THE INVENTION
[0004] According to an embodiment of the present invention, a device for expeditiously adjusting a drive belt is claimed that includes a base, a motor, at least one compressor mounted to the base, and an adjusting plate that is slidingly engaged to the base for adjusting the at least one compressor mounted to the base.
[0005] According to another embodiment of the present invention, the device for expeditiously adjusting a drive belt includes a plurality of sides forming a cavity therein.
[0006] According to yet another embodiment of the present invention, the device for expeditiously adjusting a drive belt includes a base that is generally triangular in shape.
[0007] According to yet another embodiment of the present invention, the device for expeditiously adjusting a drive belt includes an adjusting plate that is positioned underneath the base and engaged to the base with at least one fastener, whereby the adjusting plate is adjusted by the movement of the fastener.
[0008] According to yet another embodiment of the present invention, the device for expeditiously adjusting a drive belt includes at least one compressor that is engaged to the adjusting plate.
[0009] According to yet another embodiment of the present invention, the device for expeditiously adjusting a drive belt includes at base that is generally trapezoidal in shape.
[0010] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes a base having a plurality of sides, a motor, at least one compressor mounted to the base that is operated by the motor, an adjusting plate that is slidingly engaged to a side of the base and engaged to the base with a fastener, whereby the adjusting plate is adjusted along a side of the base by way of the fastener.
[0011] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes a base that is generally triangular in shape and consists of three sides forming a cavity therein for receiving the motor.
[0012] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes at least two sides of the base that each comprise at least two slots for receiving a portion of the at least one compressor. The adjusting plate is disposed beneath the at least two slots for receiving and engaging the portion of the at least one compressor and allowing the at least one compressor and the adjusting plate to move along the side of the base for adjusting the at least one compressor.
[0013] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes a first compressor and a second compressor, whereby the first compressor is mounted to one of the plurality of sides of the base and the second compressor is mounted to one of the plurality of sides of the base, and the motor is mounted to one of the plurality of sides of the base.
[0014] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes a belt that is disposed between the at least one compressor and the motor, whereby the belt is mounted to a drive wheel of the motor and a compressor wheel on the compressor for operating that at least one compressor.
[0015] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes a base that is generally trapezoidal in shape having a planar top portion for receiving the motor.
[0016] According to yet another embodiment of the present invention, a device for producing compressed air that expeditiously allows for the adjustment of a drive belt that includes at least one mounting foot that is engaged to the base for selectively securing the device to a structure.
[0017] According to yet another embodiment of the present invention, a device for producing compressed air that allows for the expeditious adjustment of a drive belt that includes a base having a substantially triangular shape with at least a first side having a top portion and a bottom portion, a second side having a top portion and a bottom portion, and a third side having a top portion and a bottom portion. The first side, second side, and third side collectively form a cavity therein. A motor is disposed within the cavity of the base and engaged to the first side of the base. A first compressor is slidingly engaged to the second side of the base and a second compressor is slidingly engaged to the third side of the base. At least one pair of slots is disposed on the second side of the base and at least one pair of slots is disposed on the third side of the base for receiving a fastener engaged to the first compressor and the second compressor. A first adjusting plate positioned on the bottom portion of the second side of the base that is engaged to the first compressor, and a second adjusting plate positioned on the bottom portion of the third side of the base that is engaged to the second compressor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers denote like method steps and/or system components, respectively, and in which:
[0019] FIG. 1 is a perspective view of the compressed air device;
[0020] FIG. 2 is a top view of the compressed air device;
[0021] FIG. 3 is a front view of the compressed air device;
[0022] FIG. 4 is a front view of the compressed air device depicting the translation of the compressors;
[0023] FIG. 5 is another front view of the compressed air device depicting the translation of a compressor;
[0024] FIG. 6 is a perspective view of the compressed air device;
[0025] FIG. 7 is a view of several components of the compressed air device;
[0026] FIG. 8 is view depicting the engagement of a compressor and adjusting plate to the compressed air device;
[0027] FIG. 9 is a perspective view of an adjusting plate; and
[0028] FIG. 10 is a perspective view of an another exemplary embodiment of a base for the compressed air device.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring now specifically to the drawings, an improved compressed air device is illustrated in FIG. 1 and is shown generally at reference numeral 10 . The device 10 includes a base 12 , a motor 14 , and at least one compressor 16 , as shown in FIGS. 1-6 . Preferably, the device 10 will include two compressors 16 that are mounted to the base 12 . The base 12 may have a plurality of sides. As illustrated in FIG. 1 , the base has a first side 18 , a second side 20 , and a third side 22 . Each side ( 18 , 20 , and 22 ) has a top portion and a bottom portion. The top portion of the sides ( 18 , 20 , and 22 ) is the exposed portion or the portion that is more easily accessible to a user when the device 10 is in the upright position. By way of example, the motor 14 is positioned on the top portion of the first side 18 , as illustrated in FIG. 1 and the compressors 16 are positioned on the top portion of the second side 20 and third side 22 . The bottom portion of the sides ( 18 , 20 , and 22 ) is the portion opposite the top portion.
[0030] The base 12 may have any form, but as illustrated in FIG. 1 , the base has a substantially triangular form. The term substantially triangular form means that the base includes three primary sides that may be adjacent to one another. In other words, the sides may intersect. The term substantially triangular form may also mean that the three primary sides do not intersect, but the planes of the sides intersect at a point or are an asymptote.
[0031] The sides ( 18 , 20 , and 22 ) of the base 12 are in a spaced apart relationship forming a void 24 within. As illustrated in FIG. 1 , the motor 14 is positioned within the void 24 and is engaged to the top portion of the first side 18 . The motor is fastened to the top portion of the first side by a bolt, screw, weld, or the like.
[0032] The second side 20 of the base 12 includes at least one pair of slots 26 . The third side 22 of the base 12 includes at least one pair of slots 26 . Preferably and as illustrated in FIG. 8 , the second side 20 and third side 22 of the base 12 includes two pairs of slots 26 disposed on each side ( 20 , 22 ). Each compressor 16 preferably contains a fastener that extends from the bottom of the compressor 16 . The fastener may be a belt, screw, threaded extension or the like. In the examples, a threaded extension is utilized as a fastener and extends from the compressor 16 and is inserted into the slots 26 . By way of example only and as shown in the figures, the compressor 16 includes four (4) threaded extensions or bolts that extend downward and are inserted into the slots 26 . Each bolt contains a threaded end for receiving a correspondingly threaded nut. The threaded extension also receives a correspondingly threaded nut.
[0033] The compressors 16 are slidingly engaged to the top portion of the second side 20 and the top portion of the third side 22 of the base 12 with the use of an adjusting plate 28 . As illustrated in FIGS. 8 and 10 , the adjusting plate 28 comprises a face 30 , a lip 32 , and a rib 34 . The face 30 of the adjusting plate 28 contains at least a pair of bores 36 for receiving the fastener that extends from the bottom of the compressor 16 . Preferably, the face 30 of the adjusting plate 28 contains two pairs of bores 36 for receiving the fastener that extends from the bottom of the compressor 16 . The lip 32 is positioned about 90° with respect to the face 30 . The lip 32 contains at least one threaded bore 38 . Preferably, the lip 32 contains two threaded bores 38 . The rib 34 of the adjusting plate 28 is optional, but can be added to provide strength and stability to the adjusting plate 28 .
[0034] During use, an adjusting plate 28 is positioned on the bottom side of the second side 20 of the base 12 , and an adjusting plate 28 is positioned on the bottom of the third side 22 of the base 12 , as shown in FIG. 8 . The bores 36 of the adjusting plate 28 are aligned with the slots 26 of the second side 20 and third side 22 of the base 12 . The fastener disposed on the bottom of the compressor 16 is received within the slot 26 of the sides ( 20 , 22 ) and the bore 36 of the adjusting plate 28 . As set forth above and by way of example only, the fastener is a threaded fastener engaged to the bottom side of the compressor 16 and when the threaded fastener is inserted through the slot 26 and bore 36 ; a nut may be selectively secured to the threaded fastener, thus allowing the compressor 16 to be selectively secured or engaged to the adjusting plate 28 .
[0035] The second side 20 and third side 22 of the base 12 contain a hole 40 positioned in close proximity to the area where the second side 20 and third side 22 are engaged, as shown in FIG. 7 . A threaded fastener 42 is received within the hole 40 . The threaded fastener may be a bolt, screw, or the like. As illustrated in FIGS. 3-8 , the threaded fastener 42 is designed to be inserted into the threaded bore 38 positioned on the lip 32 of the adjusting plate 28 . The threaded fastener 42 received within the hole 40 positioned on the second side 20 is received within the threaded bore 38 of an adjusting plate 28 positioned beneath the bottom side of the third side 22 . Likewise, the threaded fastener 42 received within the hole 40 positioned on the third side 22 is received within the threaded bore 38 of an adjusting plate 28 positioned beneath the bottom side of the second side 20 .
[0036] During use, the threaded fastener 42 is rotated, causing the adjusting plate 28 to translate or adjust along the side ( 20 , 22 ) of the base 12 . Preferably, the device 10 will include a pair of threaded fasteners 42 that are received within a pair of threaded bores 38 disposed on the lip 32 of the adjusting plate 28 . Therefore, when both of the threaded fasteners 42 are rotated, the adjusting plate 28 translates or adjusts along the side ( 20 , 22 ) of the base 12 , as illustrated in FIGS. 4 and 5 . It should be noted that the term translates or adjust means that the adjusting plate 28 moves relative to the side ( 20 , 22 ). By way of example only, as shown in FIG. 5 , the adjusting plate 28 moves a distance “d”, causing the center point of the compressor to move a distance “x” from the motor 14 . The side ( 20 , 22 ) is stationary and the adjusting plate 28 moves relative to the side ( 20 , 22 ). In one embodiment, as the threaded fasteners 42 are rotated in the clockwise position, the adjusting plate 28 moves upwards or towards the juncture where the second side 20 and third side 22 are engaged. As the threaded fasteners 42 are rotated counterclockwise, the adjusting plate 28 moves downward or toward the first side 18 . Since the compressors 16 are engaged to the adjusting plates 28 , the position of the compressors 16 are adjusted by the movement of the adjusting plate 28 .
[0037] As illustrated in FIG. 6 , the motor 14 includes a drive wheel 44 and each compressor 16 includes a slave wheel 46 . A belt 48 , as shown in FIGS. 2 and 3 , is positioned on the drive wheel 44 and the slave wheel 46 , allowing the motor 14 to supply rotational energy to the compressor 16 for operating the compressor 16 . For the device 10 to run efficiently, economically, and smoothly, the belts 48 must contain the optimum amount of tension. During the rotation of the threaded fasteners 42 , the compressors 16 are adjusted for providing the optimum amount of tension in the belts 48 , as illustrated in FIGS. 4 and 5 . Additionally, a protection shield may be positioned over the drive wheel 44 , slave wheel 46 , and the belts 48 to protect the safety of user of the device from getting limbs, hair, or clothing tangled with the gears ( 44 , 46 ) and belts 48 . The protection shield also reduces the amount of dirt or debris that enters the wheel ( 44 , 46 ) and belts 48 .
[0038] As illustrated in FIG. 1 , a mounting foot 52 may be engaged to the device 10 for selectively securing the device 10 to a structure. The mounting foot 52 may be selectively secured to the device 10 by fasteners, such as a bolt, and the mounting foot 52 may be selectively secured to the structure by a fastener, such as a bolt. As illustrated, the mounting foot 52 may be selectively secured to the first side 18 , second side 20 , or third side 22 of the base 12 .
[0039] In another alternative embodiment of the present invention as shown in FIG. 10 , the base 112 may have a generally trapezoidal shape. In other words, the base 112 may have four sides. The only difference between this embodiment and the embodiment described above is the fourth side 154 . The motor may be positioned on the fourth side 154 or within the cavity.
[0040] Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the following claims. | The present invention provides methods and systems for a device for producing compressed air that allows for the expeditious adjustment of a drive belt that includes a base having a substantially triangular shape with at least a first side having a top portion and a bottom portion, a second side having a top portion and a bottom portion, and a third side having a top portion and a bottom portion. The first side, second side, and third side collectively form a cavity therein. A motor is disposed within the cavity of the base and engaged to the first side of the base. A first compressor is slidingly engaged to the second side of the base and a second compressor is slidingly engaged to the third side of the base. | 5 |
BACKGROUND
1. Field of Invention
This invention relates generally to a device for aligning the sights on firearms utilizing the boresighting technique. More specifically, it relates to a bore adapter and laser sight mounting assembly which can utilize one of several commercially available laser light beam sighting devices.
2. Description of Prior Art
Before a firearm can be fired with any accuracy, the sights must be aligned with the central axis of the bore of the weapon. This process is commonly referred to as boresighting. Weapons that can be "broken down" so that the full extent of the bore is visible, are sighted by looking down the bore at a point some distance from the weapon, usually a target. Then the sights on the weapon are adjusted so they roughly correspond to the same point on the target. Finally, the weapon is fired several times, and fine adjustments are made. Weapons which can't be broken down are simply anchored then fired and adjusted until the sights are reasonably close to the spot where the bullet impacts the target. This is a laborious and expensive process. With optical scopes, infrared or laser sights, the process must be repeated each time the firearm receives a jolt or the sighting devices are moved or replaced.
Several types of devices have been developed which attempt to facilitate this process. One type includes an internal laser light emitter. It fits into the firearm chamber and directs a beam of light through firearm bore and onto a target. The scope may be aligned with the target using either visual sighting or a second fight emitting device mounted on the scope. An example of this system is illustrated in U.S. Pat. No. 3,782,832 entitled METHOD OF BORESIGHT ALIGNMENT OF A WEAPON, issued Jan. 1, 1974 to Hacskaylo. However, as with the previously described device, slight misalignment of the housing within the chamber will cause relatively large errors in the alignment of the bore with the target. Also, a laser fight emitter must be custom built for each caliber or firearm, making this device expensive for the average gun owner or military unit in the field who may possess firearms of several different caliber.
U.S. Pat. No. 5,001,836, issued Mar. 26, 1991 to Cameron et al, entitled APPARATUS FOR BORESIGHTING A FIREARM also includes a cartridge which fits into the chamber of a firearm. However, the light emitting device is external to the cartridge and light is fed to the cartridge via a fiber optic element. The device also includes a system of lenses and another light emitting source external to the firearm contained in a box or the like. Similar to U.S. Pat. No. 5,060,391 also issued Oct. 29, 1991 to Cameron et al. These apparatuses would be expensive and unwieldy to carry into the field, since they could be easily damaged if dropped. Also these devices are only designed for aligning optical sights.
U.S. Pat. No. 4,136,956 issued Jan. 30, 1979 to Eichweber, entitled INTEGRATED ATTACHING AND ALIGNING APPARATUS FOR LASER DEVICES IN GUN BARRELS utilizes a custom-designed laser light which fits into a tubular unit which is inserted into the muzzle of a firearm. The tubular unit is retained in the barrel by resilient material rings which will deteriorate over time due to contact with residual solvents and oils present in the barrel. This will cause the device to become misaligned. It also requires a custom-built laser light emitter, making the device expensive.
OBJECTS AND ADVANTAGES
Several objects and advantages of the present invention are:
(a) To provide a rugged, lightweight sighting aid for either military or civilian applications.
(b) To provide a device which is applicable for telescopic, laser, and open or aperture iron sights as well as night vision sighting devices.
(c) To provide a device which is applicable to use on rifles, pistols and machine guns.
(d) To provide an economical system for aligning all firearms owned by a gun owner or assigned to a military unit in the field in less time and without the necessity of firing round after round of ammunition. A typical collector could purchase fixed bore adapters for each caliber of firearm in his collection or one adjustable bore adapter, and would need only one mount and one laser beam sight in order to adjust the sighting devices for those weapons.
(e) To provide a device which will not scratch or mat the bore of a firearm.
(f) To provide bore adapters which always align with the axis of the bore. The adjustable bore adapter prongs are controlled with a single spring and automatically align the bore adapter with the central axis of the barrel. The fixed adapters would be fashioned for a specific caliber and would be aligned with its axis.
The advantages and novel features of the present invention will become more readily apparent from the following detailed drawings taken in conjunction with the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the of the fixed laser sight mount and the fixed bore adapter, along with a laser beam projection unit which could be utilized with the system.
FIG. 2 is a side view of the fixed bore adapter.
FIG. 3 is a side view of the fixed bore adapter within a rifle barrel.
FIG. 4 is a plan view of the rear of the fixed bore adapter.
FIG. 5 is a side view of the fixed bore adapter, fixed laser sight mount and a laser beam projection unit within a rifle barrel.
FIG. 6 is an exploded view of the adjustable laser sight mount.
FIG. 7 is an assembled view of the adjustable laser sight mount.
FIG. 8 is an exploded view of the adjustable bore adapter.
FIG. 9 is an assembled view of the adjustable bore adapter.
FIG. 10 is a side view of a laser light emitter, adjustable laser sight mount, and an adjustable bore adapter within a firearm barrel.
REFERENCE NUMERALS IN DRAWINGS
______________________________________20 fixed bore adapter 22 bore prongs24 mounting shaft 26 bore stop28 muzzle groove 30 fixed laser sight mount32 fitting socket 34 laser control wire slot36 laser sight socket 40 set screw50 laser light emitter 52 laser sight control wires60 firearm 61 laser mount guide slots62 laser mount elliptical 63 laser mount adjustment tabs driver slots70 adjustable laser sight 71 laser mount guide disk mount assembly72 laser sight grips 73 laser mount driver disk74 laser mount resilient 75 laser mount spring gripping pads76 laser mount spring 77 laser mount spring cap cap retainer78 laser mounting shaft 79 laser mount grip retainers81 bore adapter guide slots 82 bore adapter elliptical slots83 bore adapter 90 adjustable bore adjustment tabs adapter assembly91 bore adapter guide disk 92 adjustable bore prongs93 bore adapter driver disk 94 bore prong retainers95 bore adapter spring cap 96 bore adapter spring cap retainer97 bore adapter spring 98 adjustable bore adapter mounting shaft______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, wherein corresponding components are designated by the same reference numerals throughout the various figures. FIG. 1 illustrates a fixed bore adapter 20 having three prongs 22 which slide into a firearm barrel 60 and in concert with a muzzle stop 26, provide support for a laser sight mount 30 and a laser light emitter 50. FIG. 4 illustrates a rear-view of adapter 20 showing muzzle stop 26. A muzzle-groove 28 provides additional support by fitting around the curved end of a firearm muzzle. FIG. 4 also shows a cross-sectional view of prongs 22 illustrating their semi-circular shape which provides additional contact area within a bore.
Bore adapter 20 will be finished in such manner as to eliminate the possibility of damaging a firearm bore or muzzle with repeated insertions. FIG. 2 shows a side view of adapter 20. FIG. 3 illustrates a cutaway view of adapter 20 inserted into a firearm barrel 60. Bore adapters will be designed to fit the bore of each caliber of firearm i.e. 30--30, 38, 40 or 45.
In FIG. 1 laser sight mount 30 is affixed to a mounting shaft 24 of bore 20 and held in place by a set screw 40. Laser sight mount 30 accepts laser light emitter 50 with a slot 34 accepting laser control wires 52. FIG. 5 illustrates a typical assembly inserted in a firearm barrel 60 including laser light emitter 50.
The bore adapter and mount can be manufactured from metallic alloys, plastics, or any composite material which will be rugged, lightweight and resist deformation under extreme conditions. Ferrous alloys can be utilized for the adapter 20 to ensure a stronger hold on firearm barrel 60 by magnetizing the assembly.
An adjustable bore adapter FIG. 9 and an adjustable laser sight mount FIG. 7 are also provided for in the present invention and may be used together or in conjunction with fixed bore adapters or laser mounts. For instance, the adjustable bore adapter could be utilized in conjunction with a fixed laser sight mount, providing a single bore adapter which could fit the bore of several different calibers of firearms.
FIG. 7 illustrates an adjustable embodiment of a laser sight mount assembly 70. When laser mount adjustment tabs 63 are rotated counter clockwise, laser mount driver disk 73 rotates on laser mounting shaft 78. Laser mount elliptical driver slots 62 force laser sight grips 72 to slide outward in laser mount guide slots 61 of laser mount guide disk 71. When tabs 63 are released, laser mount spring 75 rotates disk 73 clockwise causing grips 72 to return to the center of the assembly. Spring 75 is protected by a laser mount spring cap 77 and the assembly is held together by laser mount cap retainers 76. Laser grip retainers 79 hold grips 72 in place. Resilient gripping pads 74 are affixed to inward facing surface of grips 72 using adhesive. FIG. 6 illustrates an exploded view of adjustable laser sight mount 70.
FIG. 9 illustrates an adjustable embodiment of a bore adapter assembly 90. When bore adapter adjustment tabs 83 are rotated clockwise, a bore adapter driver disk 93 rotates on an adjustable bore adapter mounting shaft 98. Bore adapter elliptical driver slots 82 force adjustable bore prongs 92 to slide inward in bore adapter guide slots 81 of a bore adapter guide disk 91. When tabs 83 are released, a bore adapter spring 97 rotates disk 93 counter clockwise, causing prongs 92 to slide outward. Spring 97 is protected by a bore adapter spring cap 95. Assembly 90 is held together by bore adapter spring cap retainers 96. Bore prong retainers 94 hold prongs 92 in place. FIG. 8 illustrates an exploded view of assembly 90.
OPERATION--FIGS. 1,2,4,5,7,9,10
As shown in FIG. 1, to operate the present invention, select a magnetized bore adapter 20 for the caliber of firearm to be boresighted. Select a laser sight mount 30 for laser light emitter to be used. Slide fitting socket 32 over bore adapter mounting shaft 24 of bore adapter 20. Tighten set screw 40. Thread laser sight control wires 52 into laser control wire slot 34 of fixed laser sight mount 30. Insert laser light emitter 50 into sight mount 30. Insert bore prongs 22 of magnetized bore adapter 20 into bore of firearm 60, making certain muzzle groove 28 of bore stop 26 fits snugly over end of muzzle. With assembly firmly seated within muzzle, laser light emitter 50 will align precisely with axis of bore.
To operate adjustable laser sight mount FIG. 6 and 7, rotate laser mount adjustment tabs 63 counter clockwise. The laser mount driver disk 73 will rotate. The laser mount elliptical driver slots 62 will force the laser sight grips 72 to slide outward in laser mount guide slots 61 of laser mount guide disk 71. Insert laser light emitter 50 into area between laser sight grips 72, making certain control wire 52 fits between grips 72 and release tabs 63. Laser mount spring 75 causes grips 72 to contract toward center of assembly, clamping onto laser fight emitter and holding it along the linear axis of laser sight mount assembly 70. Resilient gripping pads 74 adhere to laser light emitter 50 so that it doesn't slip from device.
To operate adjustable bore adapter 90 FIG. 8 and 9, rotate bore adapter adjustment tabs 83 clockwise. Bore adapter driver disk 93 will rotate, causing bore adapter elliptical slots 82 to force adjustable bore prongs 92 inward. Insert prongs 92 into bore of firearm and release tabs 83. Bore adapter spring 97 will force prongs 92 outward, centering bore adapter 90 axially within bore.
Slide laser mounting shaft 78 of adjustable laser sight mount 70 over adjustable bore adapter mounting shaft 98 of bore adapter 90. Tighten set screw 40. FIG. 10 illustrates assembled adjustable bore adapter 90 and adjustable laser sight mount 70.
Using laser control wires 52, switch on laser light emitter 50. Aim firearm at a target. Anchor the firearm to a table or other rest with a vice, rifle stand, sandbags or the like. Adjust the sights to correspond to the spot on the target where the laser light beam appears. Remove the bore adapter laser sight mount assembly from the firearm. Load a round into the firearm and test fire to determine if sights are properly correlated with the path of the bullet.
CONCLUSION, RAMIFICATIONS AND SCOPE
Accordingly, the reader will see that the apparatus is uncomplicated and the parts are few. The present invention can be manufactured of sturdy materials. Furthermore, the device has the following advantages.
It can be easily stored.
It is lightweight and can be carried into the field for hunters or military units.
It provides flexibility by permitting the use of many types of laser sights.
It is inexpensive because by permitting the use of many types of laser gun sights, even laser pointers may be used for adjusting sights for shorter distances. The least expensive alternative may be selected.
It is easy and inexpensive to upgrade, since purchasing a firearm of a different caliber only requires the purchase of another fixed bore adapter, not an entire assembly including laser beam emitter. If the adjustable bore adapter has been purchased, no additional hardware would be necessary.
For the same reason. Purchasing a different type of laser light emitter will not obsolete the assembly, since only another laser sight mount needs to be purchased.
If an adjustable laser sight mount and an adjustable bore adapter were purchased, no additional equipment would be necessary if a new laser light emitter or another caliber firearm were purchased.
All laser sight mounts may be used with all bore adapters so that the most economic and advantageous combination may be selected by the buyer.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the shape of the bore stop could be square or some other shape to accommodate different firearms, the shape of the driver disk and guide disk could be flattened on one side to accommodate different fixed sights; the bore adapter could be manufactured of a composite or other material and could also be universally adaptable to firearms of several different calibers.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | Apparatus for boresighting firearms which utilizes a number of commercially available laser gun sights as a light source. The system includes both fixed and adjustable bore adapters as well as fixed and adjustable laser sight mounts. Fixed bore adapters are designed for specific calibers. Adjustable bore adapters will function over a wide range of calibers. Fixed laser sight mounts will work only for laser gun sights of a specific diameter. Adjustable laser sight mounts will function with laser gun sights of any diameter. Fixed laser sight mounts may be utilized with adjustable bore adapters and fixed bore adapters may be used with adjustable laser sight mounts. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part based on PCT Application No. JP2008/053450, filed Feb. 27, 2008, which claims the benefit of Japanese Application No. 2007-048090, filed on Feb. 27, 2007, and Japanese Application No. 2007-284054, filed Oct. 31, 2007, all entitled “WIRING BOARD, ELECTRICAL SIGNAL TRANSMISSION SYSTEM AND ELECTRONIC DEVICE,” the content of which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] Embodiments of the present disclosure relate generally to wiring boards, and more particularly relate to differential circuits.
BACKGROUND
[0003] A wiring board may be used for mounting a semiconductor integrated circuit that is operated at high speed. A wiring board equipped with a differential circuit for transmitting a high frequency signal at high speed has been conventionally known. In a wiring board, a pair of differential lines can be configured in the wiring board at predetermined intervals in depth. The pair of differential lines may be electrically connected to a pair of surface layer line conductors provided on the main surface of the wiring board respectively via a pair of penetration conductors (vias) penetrating a thickness direction of the wiring board.
[0004] However, the heights of each of the penetration conductors are different from each other because they must penetrate the wiring board to different depths. Signals transmitted through the penetration conductors will travel different distances, and thus will have different transmission delay times (skew). When transmitting a differential signal, the different transmission delay times will cause each of the two signals to be out of phase, and transmission quality is deteriorated.
[0005] Accordingly, there is a need for a wiring board equipped with differential lines which reduce signal deterioration.
SUMMARY
[0006] A wiring board equipped with differential lines which compensate for differences in via lengths to minimize signal deterioration is disclosed. Two conductors are couple to different substrate levels through vias of different lengths. Compensation means are provided to correct for the phase difference caused by the different lengths.
[0007] A first embodiment comprises a wiring board. The wiring board comprises a dielectric substrate, and a first line comprising a first line conductor formed in the dielectric substrate and a first via conductor formed from one end of the first line conductor to a first main surface of the dielectric substrate. The wiring board further comprises a second line comprising a second line conductor formed in the dielectric substrate, a part of the second line conductor being aligned with the first line conductor. The second line also comprises an electric signal having opposite phase to an electric signal supplied to the first line conductor being supplied to the second line conductor, and a second via conductor formed from one end of the second line conductor to the first main surface of the dielectric substrate, the second via conductor being longer than the first via conductor, an electrical length of the second line being equal to an electrical length of the first line.
[0008] A second embodiment comprises an electric signal transmission system. The electric signal transmission system comprises a wiring board. The wiring board comprises a dielectric substrate, and a first line comprising a first line conductor formed in the dielectric substrate and a first via conductor formed from one end of the first line conductor to first main surface of the dielectric substrate. The first line further comprises a first surface layer line conductor provided along the first main surface of the dielectric substrate. The wiring board further comprises a second line comprising a second line conductor formed in the dielectric substrate, a part of the second line conductor being aligned with the first line conductor. The second line also comprises an electric signal having opposite phase to an electric signal supplied to the first line conductor being supplied to the second line conductor, and a second via conductor formed from one end of the second line conductor to the first main surface of the dielectric substrate, the second via conductor being longer than the first via conductor, an electrical length of the second line being equal to an electrical length of the first line. The second line further comprises a second surface layer line conductor provided along the first main surface of the dielectric substrate, a part of the second surface layer line conductor being aligned with the first surface layer line conductor. One end of the first surface layer line conductor is electrically connected to the first via conductor, and one end of the second surface layer line conductor is electrically connected to the second via conductor. The electric signal transmission system further comprises a second via conductor formed from one end of the second line conductor to the first main surface of the dielectric substrate, the second via conductor being longer than the first via conductor, an electrical length of the second line being equal to an electrical length of the first line. The electric signal transmission system further comprises a semiconductor integrated circuit electrically connected to the first surface layer line conductor and the second surface layer line conductor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments of the present disclosure are hereinafter described in conjunction with the following figures, wherein like numerals denote like elements. The figures are provided for illustration and depict exemplary embodiments of the disclosure. The figures are provided to facilitate understanding of the disclosure without limiting the breadth, scope, scale, or applicability of the disclosure. The drawings are not necessarily made to scale.
[0010] FIG. 1 illustrates an external perspective view of an exemplary wiring board according to an embodiment of the present disclosure.
[0011] FIG. 2 illustrates a schematic top plan view of the wiring board shown in FIG. 1 .
[0012] FIG. 3 illustrates a schematic top plan view of a wiring board according to one embodiment.
[0013] FIG. 4 illustrates a schematic top plan view of a wiring board according to one embodiment.
[0014] FIG. 5 illustrates a schematic top plan view of a wiring board according to one embodiment.
[0015] FIG. 6 illustrates a schematic external perspective view of a wiring board according to one embodiment.
[0016] FIG. 7 illustrates a schematic top plan view of the wiring board shown in FIG. 6 .
[0017] FIG. 8 illustrates a schematic top plan view of a wiring board according to one embodiment.
[0018] FIG. 9 illustrates a schematic external perspective view of a wiring board according to one embodiment.
[0019] FIG. 10 illustrates a schematic top plan view of the wiring board shown in FIG. 9 .
[0020] FIG. 11 illustrates a schematic cross sectional view in a line XI-XI in FIG. 9 .
[0021] FIG. 12 illustrates a schematic cross sectional view in a line XII-XII in FIG. 9 .
[0022] FIG. 13 illustrates a schematic cross sectional view in a line XIII-XIII in FIG. 9 .
[0023] FIG. 14 illustrates an external perspective view of an electrical signal transmission system according to one embodiment.
[0024] FIG. 15 illustrates a schematic elevation plan view of the electrical signal transmission system shown in FIG. 14 .
[0025] FIG. 16 illustrates a schematic enlarged elevation plan view of the part of the electrical signal transmission system shown in FIG. 15 .
[0026] FIG. 17 is a graph showing a frequency dependency property of the phase difference obtained in an exemplary example and in a comparative example.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0027] The following description is presented to enable a person of ordinary skill in the art to make and use the embodiments of the invention. The following detailed description is exemplary in nature and is not intended to limit the invention or the application and uses of the embodiments of the invention. Descriptions of specific devices, techniques, and applications are provided only as examples. Modifications to the examples described herein will be readily apparent to those of ordinary skill in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. The present invention should be accorded scope consistent with the claims, and not limited to the examples described and shown herein.
[0028] Embodiments of the invention are described herein in the context of practical non-limiting applications, namely, a circuit board. Embodiments of the invention, however, are not limited to such circuit board applications, and the techniques described herein may also be utilized in other electrical circuit applications. For example, embodiments may be applicable to integrated circuits and the like.
[0029] As would be apparent to one of ordinary skill in the art after reading this description, these are merely examples and the embodiments of the invention are not limited to operating in accordance with these examples. Other embodiments may be utilized and structural changes may be made without departing from the scope of the exemplary embodiments of the present invention.
[0030] FIG. 1 illustrates a perspective view of an exemplary wiring board according to an embodiment of the present invention. FIG. 2 illustrates a schematic top plan view of a wiring board 10 shown in FIG. 1 .
[0031] The wiring board 10 comprises a dielectric substrate 11 , a pair of inner layer line conductors 12 a and 12 b (first line conductor 12 a , and second line conductor 12 b ), three inner layer lands 13 a to 13 c , a pair of penetration conductors 14 a and 14 b (penetration conductor 14 a , and penetration conductor 14 b ), a pair of surface layer lands 15 a and 15 b (surface layer land 15 a , and surface layer land 15 b ), and a pair of surface layer line conductors 16 a and 16 b (first surface layer line conductor 16 a and second surface layer line conductor 16 b ).
[0032] In FIG. 1 , for the sake of easy understanding, the dielectric substrate 11 is seen through and the inner structure such as the inner layer line conductors 12 a and 12 b is shown by solid lines. A first line 9 a comprises the inner layer line conductor 12 a , the inner layer land 13 a , the penetration conductor 14 a , the surface layer land 15 a , and the surface layer line conductor 16 a . A second line 9 b comprises the inner layer line conductor 12 b , inner layer land 13 b , the penetration conductor 14 b , residual inner layer land 13 c , the surface layer land 15 b , and the surface layer line conductor 16 b.
[0033] A differential line 32 comprises the first line 9 a and the second line 9 b . The dielectric substrate 11 is equipped with at least three dielectric layers 17 a to 17 c (first layer 17 a , intermediate layer 17 b , and third layer 17 c ). The pair of inner layer line conductors (first line conductor 12 a and second line conductor 12 b ) are respectively positioned along upper surface 18 (first virtual plane, predetermined first virtual plane) and lower surface 19 (predetermined third virtual plane) of the intermediate layer 17 b.
[0034] Hereinafter, the laminated direction of the three dielectric layers 17 a to 17 c of the dielectric substrate 11 is referred to as the thickness direction Z. Further, among the directions perpendicular to the thickness direction Z of the dielectric substrate 11 , the direction extending along the long side of the dielectric substrate 11 when projected on a project plane perpendicular to the thickness direction Z is referred to as longitudinal direction X. Further, the direction perpendicular to both of the thickness direction Z and the longitudinal direction X is referred to as width direction Y.
[0035] The intermediate layer 17 b is positioned at the center of the three dielectric layers 17 a to 17 c in the thickness direction Z. Among the pair of inner layer line conductors 12 a and 12 b , the inner layer line conductor 12 a provided at the upper side in the thickness direction Z is the first line conductor 12 a , and the inner layer line conductor 12 b provided at the lower side in thickness direction Z is the second line conductor 12 b.
[0036] The first line conductor 12 a is positioned in the dielectric substrate 11 . For example, the first line conductor 12 a extends along the upper surface 18 of the intermediate layer 17 b that functions as a predetermined first virtual plane 18 . Further, the second line conductor 12 b is positioned in the dielectric substrate 11 . For example, the second line conductor 12 b extends along the lower surface 19 of the intermediate layer 17 b that functions as a predetermined third virtual plane 19 . Assuming that one of the surfaces of the dielectric substrate 11 at the upper side is a first main surface 11 a , the second line conductor 12 b is positioned at a side of a second main surface 11 b which is the lower surface 11 b of the dielectric substrate 11 , which is lower than the first line conductor 12 a . The upper and lower surfaces 18 , 19 of the intermediate layer 17 b are approximately parallel to each other. Herewith, a part of the second line conductor 12 b is approximately parallel with the first line conductor 12 a.
[0037] For example, as show in FIG. 1 , it is preferable that the distance between the first line conductor 12 a and the second line conductor 12 b is constant in the thickness direction Z. In order to provide the line conductors so as to be parallel to each other, it is necessary that the distance is constant regardless of the thickness direction Z. Note that the word “parallel” used in this document comprises “parallel” and “substantially parallel”. “Substantially parallel” means that the relationship is deviated from parallel by a level within which effects obtained by the embodiments of the invention are not influenced.
[0038] In FIG. 1 , the first line conductor 12 a and the second line conductor 12 b comprise an overlapped portion when viewed from the thickness direction Z. The overlapped portion extends along the longitudinal direction X. The differential line 32 includes the pair of inner layer line conductors 12 a and 12 b including the first line conductor 12 a and the second line conductor 12 b . The main part of the pair of inner layer line conductors 12 a and 12 b functions as the differential line 32 having constant differential impedance by comprising a uniform opposed structure in which the intermediate layer 17 b is interposed therebetween.
[0039] The inner layer lands 13 a and 13 b are provided at respective ends of the pair of inner layer line conductors 12 a and 12 b . The inner layer land 13 a is coupled to the first line conductor 12 a and is provided along the upper surface 18 of the intermediate layer 17 b . Further, the inner layer land 13 b is coupled to the second line conductor 12 b and is provided along the lower surface 19 of the intermediate layer 17 b . With the inner layer lands 13 a and 13 b , connection reliability between the pair of inner layer line conductors 12 a and 12 b and the pair of penetration conductors 14 a and 14 b can be assured. The inner layer land 13 a is coupled to the first line conductor 12 a , and the inner layer land 13 b is coupled to the second line conductor 12 b . The inner layer land 13 a and the inner layer land 13 b are positioned at approximately the same position in the longitudinal direction X when viewed from the thickness direction Z, and are provided to have an interval in the width direction Y. In this embodiment, the inner layer land 13 a coupled to the first line conductor 12 a and the inner layer land 13 b connected to the second line conductor 12 b are disposed at positions that are approximately linear symmetry with respect to the axis line L 1 of the portion at which the pair of inner layer line conductors 12 a and 12 b are overlapped (see FIG. 2 ). Further, the residual inner layer land 13 c is positioned along the upper surface 18 of the intermediate layer 17 b , and provided at the vicinity of just above the inner layer land 13 b connected to the second line conductor 12 b . In this embodiment, the three inner layer lands 13 a to 13 c are formed to have approximately the same shape and size to each other, and for example, formed to have a circular shape.
[0040] Ends of the pair of penetration conductors 14 a and 14 b are coupled to the inner layer lands 13 a and 13 b respectively. The inner layer lands 13 a and 13 b are connected to the pair of inner layer line conductors 12 a and 12 b respectively. A pair of the penetration conductors 14 a (first via conductor) and 14 b (second via conductor) are provided to extend to a second virtual surface that is closer to the first main surface 11 a of the dielectric substrate 11 than the upper surface 18 (first virtual plane 18 ) of the intermediate layer 17 b . In this embodiment, the second virtual surface is set at the first main surface 11 a of the dielectric substrate 11 . Accordingly the pair of the penetration conductors 14 a and 14 b are provided to extend from the pair of the inner layer line conductors 12 a and 12 b to the first main surface 11 a of the same surface layer which is the first main surface 11 a of the dielectric substrate 11 . Among the pair of penetration conductors 14 a and 14 b , the penetration conductor that is provided from the first main surface 11 a of the dielectric substrate 11 to one end of the first line conductor 12 a and that is electrically coupled to the first line conductor 12 a is the first via conductor 14 a . Further, among the pair of penetration conductors 14 a and 14 b , the penetration conductor that is provided from the first main surface 11 a of the dielectric substrate 11 to one end of the second line conductor 12 b and that is electrically coupled to the second line conductor 12 b is the second via conductor 14 b . The second via conductor 14 b is provided from the inner layer land 13 b whose one end is provided on the lower surface 19 of the intermediate layer 17 b to the first main surface 11 a of the dielectric substrate 11 via the inner layer land 13 c provided on the upper surface 18 of the intermediate layer 17 b . In this manner, since the second via conductor 14 b is provided via the inner layer land 13 c positioned at the upper surface 18 of the intermediate layer 17 , connection reliability to the first main surface 11 a of the dielectric substrate 11 can be improved. In this embodiment, each of the pair of penetration conductors 14 a and 14 b is formed to have a cylinder shape extending along the thickness direction Z, and is formed to have approximately the same cross sectional shape and size.
[0041] The pair of surface layer lands 15 a and 15 b are provided along the first main surface 11 a of the dielectric substrate 11 , and are respectively electrically coupled to the other ends of the pair of penetration conductors 14 a and 14 b . A pair of surface layer line conductors 16 a (first surface layer line conductor) and 16 b (second surface layer line conductor) are provided along the first main surface 11 a of the dielectric substrate 11 , and respectively electrically connected to the pair of surface layer lands 15 a and 15 b . In this embodiment, the shape and the size of the pair of surface layer lands 15 a and 15 b are formed so as to be approximately the same, and for example but without limitation, formed in a circular plate shape. The cross sections of the penetration conductors 14 a and 14 b in the thickness direction Z are formed smaller than the cross sections of the three inner layer lands 13 a , 13 b and 13 c and the cross sections of the pair of surface layer lands 15 a and 15 b . Herewith, when the penetration conductors 14 a and 14 b are formed, even when the positions of the penetration conductors 14 a and 14 b are misaligned with respect to the three inner layer lands 13 a , 13 b and 13 c and the pair of surface layer lands 15 a and 15 b , the penetration conductors 14 a and 14 b , and the three inner layer lands 13 a , 13 b and 13 c and the pair of surface layer lands 15 a and 15 b which should be coupled therewith can be coupled, and reliability can be improved.
[0042] Among the pair of surface layer line conductors 16 a and 16 b , the surface layer line conductor whose one end is electrically coupled to the first via conductor 14 a is the first surface layer line conductor 16 a . Further, among the pair of surface layer line conductors 16 a and 16 b , the surface layer line conductor whose one end is electrically connected to the second via conductor 14 b is the second surface layer line conductor 16 b . At least a part of a center line L 16 a of the first surface layer conductor 16 a and at least a part of a center line L 16 b of the second surface layer line conductor 16 b are provided so as to be approximately parallel. As shown in FIG. 2 , the pair of surface layer line conductors 16 a and 16 b is formed to bend closer to each other and apart from each of the pair of surface layer lands 15 a and 15 b . In this manner, the pair of surface layer line conductors 16 a and 16 b can extend to be approximately parallel to each other along a predetermined direction. The predetermined direction may be the longitudinal direction X in this embodiment, when the distance between the center lines L 16 a and L 16 b thereof becomes not less than a predetermined distance.
[0043] The pair of surface layer line conductors 16 a and 16 b constitutes the differential line 32 . In this embodiment, the electrical lengths of the surface layer line conductors 16 a and 16 b are selected to be equal to each other. Herein, the cross sectional shapes and the sizes of the surface layer line conductors 16 a and 16 b are selected to be equal to each other, and the line lengths of the first and second surface layer line conductors 16 a and 16 b are selected to be equal.
[0044] The dielectric substrate 11 may be made from, for example but without limitation, an inorganic material or a resin material. The inorganic material, may comprise, for example but without limitation, alumina (Al 2 O 3 ) ceramics, mullite (3Al 2 O 3 .2SiO 2 ) ceramics, glass ceramics, and the like. The resin material, may comprise, for example but without limitation, a fluorine resin, a glass epoxy resin, a polyphenylene ether (PPE) resin, liquid crystalline polyester (LCP), polyimide (PI), and the like. The shape and the size of the dielectric substrate 11 are appropriately set in accordance with the application. Particularly, the thickness is set depending on the frequency of transmission signal or impedance design.
[0045] The material of the conductor wirings such as the pair of inner layer line conductors 12 a and 12 b , the inner layer lands 13 a to 13 c , the pair of surface layer lands 15 a and 15 b , the pair of surface layer line conductors 16 a and 16 b , is constituted by a conductor layer of a metal suited for the application of high speed signal transmission. For example, ceramics can be used as the material of the dielectric substrate 11 . The ceramics may comprise, for example but without limitation, copper, molybdenum-manganese, tungsten, and the like which, for example, can be used to form the conductor lines. Method of manufacturing of the dielectric substrate 11 comprises for example but without limitation, a thick film print method, various thin film forming methods, a plating method, and the like. The width and the thickness of each conductor wiring is set depending on the frequency of transmission signal or impedance design.
[0046] The wiring board 10 of the embodiment is manufactured, for example, as described below. When the three dielectric layers 17 a to 17 c are constituted by, for example but without limitation, alumina ceramics, green sheets of alumina ceramics are prepared, which becomes the three dielectric layers 17 a to 17 c . Through holes for providing the pair of penetration conductors 14 a and 14 b are formed by performing a predetermined blanking processing thereto. Then, a conductor paste such as, for example but without limitation, tungsten, molybdenum, or the like is filled in the through holes by a screen printing method. Patterns of the conductor wiring are printed by the screen printing method and applied at predetermined positions of the three dielectric layers 17 a to 17 c . Then, the three dielectric layers 17 a to 17 c on which the pattern is formed are overlapped and the layers are burned at 1600 degrees. Then, the wiring board 10 of this embodiment can be manufactured, for example but without limitation, by performing a nickel plating and gold plating on the exposed pair of the surface layer line conductors 16 a and 16 b.
[0047] Next, the first line conductor 12 a and the second line conductor 12 b are explained in detail. The electrical length of the first line conductor 12 a is set larger than the electrical length of the second line conductor 12 b . Further, the pair of inner layer line conductors 12 a and 12 b is formed to have, for example, band shapes whose cross sectional shapes and the sizes are approximately equal to each other. In this embodiment, the pair of inner layer line conductors 12 a and 12 b has approximately the same cross sectional shape to each other. Consequently, in order to set the electrical length of the first line conductor 12 a so as to be larger than the electrical length of the second line conductor 12 b , line length of the first line conductor 12 a is set larger than line length of the second line conductor 12 b.
[0048] The first line conductor 12 a is equipped with a first line parallel portion 20 in which a center line L 12 a of the first line conductor 12 a and a center line L 12 b of the second line conductor 12 b are approximately parallel, and a residual first line separation portion 22 . The second line conductor 12 b is equipped with a second line parallel portion 21 in which the center line L 12 a of the first line conductor 12 a and the center line L 12 b of the second line conductor 12 b are approximately parallel, and a residual second line separation portion 23 . In this embodiment, the center line of the first line parallel portion 20 and the center line of the second line conductor 12 b are disposed (at approximately the same position) so as to be overlapped in plan view (when viewed from the thickness direction Z). Since the widths of the pair of inner layer line conductors 12 a and 12 b are approximately same as each other, as shown in FIG. 2 , the first line parallel portion 20 and the second line parallel portion 21 are disposed at approximately the same position when viewed from the thickness direction Z. One end of the residual first line separation portion 22 is electrically coupled to the first via conductor 14 a . Further, one end of the residual second line separation portion 23 is electrically connected to the second via conductor 14 b.
[0049] The electrical length of the first line parallel portion 20 is set equal to the electrical length of the second line parallel portion 21 . In this embodiment, the “electrical length” can be rephrased by the length of the line in the case where the cross sectional shapes and the sizes of the lines are the same. The length of the line is the length from an exterior electrical input/output portion to another external electrical input/output portion. Notably, even when the cross sectional shapes or the sizes of the lines whose electrical lengths are compared are not the same, it is possible to compare the electrical lengths of the two lines by comparing phase changes from input portions to output portions of the two lines to be compared. Specifically, electric signals having the same phase are input to the input portions of the two lines, and phase sizes changed from the input portions are respectively compared at each of the output portions. When the changed phase sizes are the same, the electrical lengths are the same. In this document, “electrical lengths are equal” means that the difference of the lengths of two conductors of differential line is within the range of 5% of pulse width (or frequency of analog wave). In this embodiment, the pair of inner layer line conductors 12 a and 12 b have the approximately the same cross sectional shape and size. Consequently, in order to set the electrical length of the first line parallel portion 20 and the electrical length of the second line parallel portion 21 so as to be equal, the line length of the first line parallel portion 20 and the line length of the second line parallel portion 21 are set so as to be approximately the same length. Further, the electrical length of the residual first line separation portion 22 is set larger than the electrical length of the residual second line separation portion 23 .
[0050] In other words, a first electrical length is from an end of a part in which an opposing structure of the differential line 32 is uniform with the first line conductor 12 a provided on the upper surface 18 of the intermediate layer 17 b . A second electrical length is from an end of a part in which an opposing structure of the differential line 32 is uniform with the second line conductor 12 b provided on the lower surface 19 of the intermediate layer 17 b . The first electrical length is set larger than the second electrical length.
[0051] As shown in FIG. 2 , the residual first line separation portion 22 and the residual second line separation portion 23 are provided so as to be bent in the directions to be separated to each other, i.e., bent toward the width direction Y, and so as to extend toward the corresponding inner layer lands 13 a , 13 b . The curvature of the residual first line separation portion 22 is set smaller than the curvature of the residual second line separation portion 23 . By setting the curvature of the residual second line separation portion 23 so as to be smaller than the curvature of the residual second line separation portion 23 , the line length of the residual first line separation portion 22 can be set larger than the line length of the residual second line separation portion 23 .
[0052] Further, in this embodiment, a total electrical length of the residual first line separation portion 22 and the first via conductor 14 a and a total electrical length of the residual second line separation portion 23 and the second via conductor 14 b are set to be equal, and the electrical length of the first line 9 a and the electrical length of the second line 9 b are set to be equal. In the wiring board 10 of FIG. 1 , the length of the second via conductor 14 b connected to the second line conductor 12 b provided on the lower surface 19 of the intermediate layer 17 b via the inner layer land 13 b is longer than the length of the first via conductor 14 a connected to the first line conductor 12 a provided on the upper surface 18 of the intermediate layer 17 b via the inner layer land 13 a by the thickness of the intermediate layer 17 b . The pair of inner layer line conductors 12 a , 12 b has approximately the same cross sectional shape to each other, and the first via conductor 14 a and the second via conductor 14 b have approximately the same cross sectional shape and size to each other. In order to set the total electrical length of the residual first line separation portion 22 and the first via conductor 14 a and the total electrical length of the residual second line separation portion 23 and the second via conductor 14 b so as to be equal, the total line length of the residual first line separation portion 22 and the first via conductor 14 a and the total line length of residual second line separation portion 23 and the second via conductor 14 b are set so as to be equal. In other words, the difference between the electrical length of the residual first line separation portion 22 and the length of the residual second line separation portion 23 is set equal to the difference of the line lengths of the first via conductor 14 a and the second via conductor 14 b . Accordingly, the curvature of the residual first line separation portion 22 and the curvature of the residual second line separation portion 23 are set based on the difference of the line lengths of the first via conductor 14 a and the second via conductor 14 b.
[0053] The first line conductor 12 a and the second line conductor 12 b are provided along the upper and lower surfaces 18 and 19 of the intermediate layer 17 b . A height of the first via conductor 14 a is smaller than a height of the second via conductor 14 b . In this embodiment, the electrical length of the first line conductor 12 a is set larger than the electrical length of the second line conductor 12 b . Accordingly, since the electrical length of the first line conductor 12 that is connected to the first via conductor 14 a is set larger than the electrical length of the second line conductor 12 b , the total electrical length of the first line conductor 12 a and the first via conductor 14 a can be set equal to the total electrical length of the second line conductor 12 b and the second via conductor 14 b . Herewith, skew of an electric signal generated by the difference of the electrical lengths of the first and second via conductors 14 a and 14 b can be restrained by the first and the second line conductors 12 a and 12 b . In this manner, since the electrical length of each of the first and second lines 9 a and 9 b as the differential line 32 can be set so as to be equal to each other, phase shift amounts of electromagnetic waves as transmission signals also become equal. Consequently, skew at an output end of the differential line 32 can be reduced, which makes it possible to restrain deterioration of the waveform quality of transmission signal.
[0054] Further, in this embodiment, the first line conductor 12 a is equipped with the first line parallel portion 20 and the residual first line separation portion 22 , and the second line conductor 12 b is equipped with the second line parallel portion 21 and the residual second line separation portion 23 . The center lines of the first line parallel portion 20 and the second line parallel portion 21 are approximately parallel, and the center lines of the residual first line separation portion 22 and the residual second line separation portion 23 are not approximately parallel. Further, one end of the residual first line separation portion 22 is electrically connected to the first via conductor 14 a , and one end of the residual second line separation portion 23 is electrically coupled to the second via conductor 14 b . Accordingly, an electric signal supplied to the first line parallel portion 20 is transmitted to the first vial conductor 14 a via the residual first line separation portion 22 . Similarly, an electric signal supplied to the second line parallel portion 21 is transmitted to the second via conductor 14 b via the second line separation portion 23 . The electrical length of the first line parallel portion 20 is set equal to the electrical length of the second line parallel portion 21 . Consequently, generation of skew of the electric signal transmitted by the first line parallel portion 20 and the residual second line parallel portion 21 can be restrained.
[0055] Further, the electrical length of the residual first line separation portion 22 is set larger than the electrical length of the residual second line separation portion 23 . Herewith, the electrical length of the residual first line separation portion 22 connected to the first vial conductor 14 whose height is smaller than that of the second via conductor 14 b is set larger than the electrical length of the residual second line separation portion 23 . Accordingly, the total electrical length of the residual first line separation portion 22 and the first via conductor 14 a can be set equal to the total electrical length of the residual second line separation portion 23 and the second via conductor 14 b . Herewith, skew of electric signal generated by the difference of the electrical lengths of the first and second via conductors 14 a and 14 b can be restrained only by the first and the second line conductors 12 a and 12 b . Skew of each electric signal output from each line conductor via each via conductor can be reduced by equalizing the electrical length of each of the first line 9 a and second line 9 b , which makes it possible to restrain deterioration of quality of the electric signal transmitted by each line conductor.
[0056] Further, in this embodiment, the total electrical length of the residual first line separation portion 22 and the first via conductor 14 a and the total electrical length of the residual second line separation portion 23 and the second via conductor 14 b are set to be equal. Herewith, skew of each electric signal output from each line conductor via each via conductor 14 a and 14 b can be reduced. In this manner, deterioration of the quality of the electric signal transmitted by each line conductor can be restrained.
[0057] In this embodiment, the first surface layer line conductor 16 a and the second surface layer line conductor 16 b provided along the first main surface 11 a of the dielectric substrate 11 are further provided. One end of the first surface layer line conductor 16 a is electrically connected to the first via conductor 14 a . Further, one end of the second surface layer line conductor 16 b is electrically connected to the second via conductor 14 b . Even when the first and second lines 9 a and 9 b include the first and second surface layer line conductors 16 a and 16 b provided on the surface of the dielectric substrate 11 , it becomes possible to restrain deterioration of the quality of the electric signal transmitted by each line conductor. The first and the second surface layer line conductors 16 a and 16 b are provided on the surface of the dielectric substrate 11 . Consequently, it becomes easy to supply an electric signal to the first and second lines 9 a and 9 b and to connect with an external electronic apparatus such as a semiconductor integrated circuit for receiving an electric signal from the first and second lines.
[0058] Further, in this embodiment, the center line L 16 a of at least a part of the first surface layer line conductor 16 a , and the center line L 16 b of at least a part of the second surface layer conductor 16 b are approximately parallel. Herewith, a space for providing the first surface layer line conductor 16 a and the second surface layer line conductor 16 b can be reduced, and the wiring board 10 can be downsized.
[0059] Further, in this embodiment, the differential line 32 is constituted by the residual line conductors except the pair of surface layer line conductors 16 a and 16 b so that the electrical lengths become equal to each other.
[0060] FIG. 3 is a plan view of a wiring board 10 A according to an embodiment of the invention. In the wiring board 10 A, the residual first line separation portion 22 is constituted so as to be bent toward the width direction Y, and so as to be bent toward the longitudinal direction X to extend toward the corresponding inner layer land. Also with the structure, the electrical length of the residual first line separation portion 22 can be set larger than the electrical length of the residual second line separation portion 23 .
[0061] FIG. 4 is a plan view showing the wiring board 10 B according to an embodiment of the invention. In the embodiment shown in FIG. 4 , the shapes for increasing the electrical length of the first line conductor 12 a than the electrical length of the second line conductor 12 b are different as compared with the pair of the inner layer line conductors 12 a , 12 b of the first embodiment.
[0062] In this embodiment, the first line parallel portions 20 and the second line parallel portions 21 are portions having center lines extending in a predetermined direction, for example, in the longitudinal direction X. The first line parallel portions 20 and the second line parallel portions 21 are respectively formed at portions including the both ends of the first and second inner layer line conductors 12 a , 12 b in the extending directions. Further, the residual first line separation portion 22 and the residual second line separation portion 23 are the residual portions. Accordingly, the residual first line separation portion 22 is constituted so as to be sandwiched by the first line parallel portions 20 in the extending direction of the first inner layer line conductor 12 a . The residual second line separation portion 23 is constituted so as to be sandwiched by the second line parallel portions 21 in the extending direction of the second inner layer line conductor 12 b . Accordingly, the electrical length of the residual first line separation portion 22 is set larger than the electrical length of the residual second line separation portion 23 . Also with the structure, the similar operations and effects as those of the wiring board 10 can be provided.
[0063] FIG. 5 is a plan view showing the wiring board 10 C according to an embodiment of the invention. In the embodiment shown in FIG. 5 , the shapes for increasing the electrical length of the first line conductor 12 a than the electrical length of the second line conductor 12 b are different as compared with the pair of inner layer line conductors 12 a , 12 b of the first embodiment.
[0064] In this embodiment, the first line parallel portions 20 and the second line parallel portions 21 are portions that are linear symmetry in a predetermined direction, for example, in the longitudinal direction X when viewed from the thickness direction Z. The residual first line separation portion 22 and the residual second line separation portion 23 are residual portions. The residual first line separation portion 22 is constituted to be sandwiched by the first line parallel portions 20 . The residual second line separation portion 23 is constituted so as to be sandwiched by the second line parallel portions 21 . Accordingly, the electrical length of the residual first line separation portion 22 is set larger than the electrical length of the residual second line separation portion 23 . Specifically, the residual first line separation portion 22 is bent to have a convex shape with respect to the residual second line separation portion 23 , and the line length of the residual first line separation portion 22 is set larger than that of the second line separation portion. Also with the structure, the similar operations and effects as those of the wiring board 10 can be provided.
[0065] FIG. 6 is a perspective view showing the wiring board 10 E according to an embodiment of the invention. FIG. 7 is a plan view showing the wiring board 10 E of FIG. 6 . In the embodiment, the shapes for equalizing the electrical length of the first line 9 a and the electrical length of the second line 9 b are different as compared with the pair of inner layer line conductors 12 a and 12 b and the pair of surface layer line conductors 16 a and 16 b of the wiring board 10 .
[0066] In this embodiment, the electrical length of the first surface layer line conductor 16 a is larger than the electrical length of the second surface layer line conductor 16 b , and the electrical length of the first inner layer line conductor 12 a is smaller than the electrical length of the second inner layer line conductor 12 b . Herewith, skew of electric signal generated by the difference of the electrical lengths of the first and second via conductors 14 a and 14 b is restrained by the first and second inner layer line conductor 12 a and 12 b and the first and second surface layer line conductors 16 a and 16 b . With the formation of the structure, the similar effects as that of the aforementioned embodiments can be provided. In addition, degrees of freedom of drawing of the first and second lines 9 a and 9 b can be improved as compared with the case where skew is restrained by using only the first and second inner layer line conductors 12 a and 12 b , and the case where skew is restrained by using only the first and second surface layer line conductors 16 a and 16 b.
[0067] More specifically, the first via conductor 14 a is provided with a gap from the second inner layer line conductor 12 b at one side of the first main surface 11 a of the second inner layer line conductor 12 b . In this embodiment, the first and second inner layer line conductors 12 a and 12 b are formed to have straight shapes to extend in the longitudinal direction X. Further, the second surface layer conductor 16 b is also formed to have a straight shape to extend in the longitudinal direction X. The first and second inner layer line conductors 12 a and 12 b are formed so as to be overlapped when viewed from the thickness direction Z. Further, the center lines L 12 a and L 12 b of the first and second inner layer line conductors 12 a and 12 b , the center line L 16 b of the second surface layer line conductor 16 b , and the center axis lines of the first and second via conductors 14 a and 14 b extending in the thickness direction Z of the dielectric substrate 11 are formed to be included in a same virtual plane that is parallel to the thickness direction Z. The first surface layer line conductor 16 a are formed to include a line parallel portion 40 that extends in parallel with the second surface layer line conductor 16 b and a line curved portion 41 that is continued with the line parallel portion 40 and the first surface layer land 15 a and that have a portion that is curved toward the surface layer land 15 a from the line parallel portion 40 .
[0068] The center axis line L 16 a of the line parallel portion 40 and the center line L 16 b of the second surface layer line conductor 16 b are formed so as to be approximately parallel. The line curved portion 41 is curved in the direction to approach the center line L 16 b of the second surface layer line conductor 16 b as is separated from the line parallel portion 40 . A total electrical length of the line curved portion 41 and the electrical length of the first via conductor 14 a is set equal to the total of the electrical length of the second via conductor 14 b and the electrical length obtained by subtracting the electrical length of the first inner layer line conductor 12 a from the electrical length of the second inner layer line conductor 12 b.
[0069] In this embodiment, a part of the second inner layer line conductor 12 b and the first via conductor 14 a are overlapped in the thickness direction Z of the dielectric substrate 11 , so that the space of the dielectric substrate 11 at one side of the first main surface 11 a can be effectively used, and the space required for providing the first and second lines 9 a , and 9 b can be reduced. Further, the wiring board 10 E can be downsized.
[0070] Further, connection pads 42 a and 42 b used for connecting with an exterior electronic apparatus are formed at the other ends of the first and second surface layer line conductors 16 a and 16 b . The sizes of the connection pads 42 a and 42 b in the width direction Y are larger than the residual parts of the first and second surface layer line conductors 16 a and 16 b . Herewith, it becomes easy to connect the first and second surface layer line conductors 16 a and 16 b and an exterior electronic apparatus such as a semiconductor integrated circuit.
[0071] FIG. 8 is a plan view showing a wiring board 10 F according to an embodiment of the invention. The wiring board 10 F is formed by a plurality of aforementioned wiring boards 10 E aligned in the width direction Y, and a plurality of differential lines 32 are provided. When each of differential lines 32 is formed like the wiring board 10 E, the width W 1 of a pair of differential lines 32 in the width direction Y can be reduced when the plurality of differential lines 32 are aligned in the width direction Y. Herewith, the distance between the inner layer line conductors 12 a , and 12 b in the width direction Y and the distance between the surface layer line conductors 16 a , and 16 b in the width direction Y of adjacent differential lines 32 can be reduced, and more differential lines 32 can be formed in a unit area. Accordingly, the wiring board 10 F can be downsized in the case where a number of differential lines 32 are aligned.
[0072] FIG. 9 is a perspective view showing the wiring board 10 D of according to an embodiment of the invention. FIG. 10 is a plan view showing the wiring board 10 D of FIG. 9 . FIG. 11 is a cross sectional view showing the wiring board 10 D shown in FIG. 9 taken along the line XI-XI of FIG. 9 . FIG. 12 is a cross sectional view showing the wiring board 10 D shown in FIG. 9 taken along the line XII-XII of FIG. 9 . FIG. 13 is a cross sectional view showing the wiring board 10 D shown in FIG. 9 taken along the line XIII-XIII of FIG. 9 . The wiring board of this embodiment further includes a ground conductor 24 as compared with the wiring board 10 .
[0073] The wiring board 10 D is configured to further include first to fourth ground conductor layers 25 to 28 that function as the ground conductor 24 . With reference to FIGS. 9 to 11 , the first ground conductor layer 25 is provided along the first main surface 11 a of the dielectric substrate 11 in the thickness direction Z. The first ground conductor layer 25 is provided to cover the pair of surface layer line conductors 16 a , and 16 b from the outer side. The second ground conductor layer 26 is provided along the upper surface 18 of the intermediate layer 17 b . With reference to FIG. 12 , the second ground conductor layer 26 is provided to cover the first line conductor 12 a from the outer side. The third ground conductor layer 27 is provided along the lower surface 09 of the intermediate layer 17 b . With reference to FIG. 13 the third ground conductor layer 27 is provided to cover the second line conductor 12 b from the outer side. With reference to FIG. 9 , the fourth ground conductor layer 28 is provided along the second main surface 11 b of the dielectric substrate 11 in the thickness direction Z. The ground conductor 24 can be formed by using a material and a construction method similar to those in the case of the aforementioned line conductors.
[0074] Since each ground conductor layer 25 to 28 is respectively provided to cover each line conductor in this manner, leakage of the high frequency wave signal transmitted by the line conductor to an exterior portion can be restrained. Herewith, even when another differential line is provided, mutual interference can be restrained. Further, the fourth ground conductor layer 28 can function as an electrode for external connection for inputting/outputting an electric signal to and from and for supplying power source to an electronic component mounted on the wiring board 10 D.
[0075] FIG. 14 is a perspective view showing the electric signal transmission system 29 of according to an embodiment of the invention. FIG. 15 is a front view showing the electric signal transmission system 29 . FIG. 16 is an enlarged front view showing a part of the electric signal transmission system 29 shown in FIG. 15 . In this embodiment, the wiring board 10 of the first embodiment is employed. In this embodiment, the electric signal transmission system 29 is constituted to include the wiring board 10 having eight inner layer line conductors 12 a , 12 b , and a semiconductor integrated circuit 30 mounted on the wiring board 10 . The wiring board 10 may be any of the wiring boards 10 A, 10 B, 10 C, 10 D, 1 E, 10 F.
[0076] The semiconductor integrated circuit 30 can be operated at high speed, and can be mounted on the upper surface 18 of the wiring board 10 . The semiconductor integrated circuit 30 may comprise, for example but without limitation, a semiconductor element such as an integrated circuit (IC), large scale integration (LSI), and the like, and an optical semiconductor element such as a semiconductor laser (LD), a photo diode (PD), and the like. The semiconductor integrated circuit 30 can be electrically connected with surface layer line conductors 16 a and 16 b via a conductor bump constituted by solder, gold (Au), or the like or the electrode pad 31 for connecting the semiconductor integrated circuit 30 . Accordingly, an electric signal of high quality can be transmitted to the semiconductor integrated circuit 30 from the wiring board 10 .
[0077] Further, embodiments of the invention may be provided by an electronic apparatus equipped with the electric signal transmission system 29 . The electronic apparatus may comprise, for example but without limitation, a personal computer, a game apparatus, a mobile phone, a graphic board, a server, and the like. The electronic apparatuses are equipped with a semiconductor integrated circuit used in an especially high frequency band. The electronic apparatuses may comprise, an electronic apparatus equipped with the semiconductor integrated circuit used in the frequency band of at least 10 GHz. Generally, when such a semiconductor integrated circuit is included, deterioration of electric signal caused by transmission becomes large in proportion to the frequency band. However, with the electronic apparatus of according to an embodiment of the invention, since the wiring board is also included, deterioration of electric signal cause by transmission can be restrained. Accordingly, electric signal of high quality can be transmitted even in the case of such a frequency condition.
[0078] In each of the embodiments of the invention, influence to electrical length by the three inner layer lands 13 a to 13 c is ignored, and the electrical lengths are equally set by the line lengths of the pair of inner layer line conductors 12 a and 12 b and the pair of penetration conductors 14 a and 14 b . If the three inner layer lands 13 a to 13 c are set to have shapes with which influence to the electrical lengths becomes equal, influence of the three inner layer lands 13 a to 13 c can be ignored and calculation of the electrical lengths can be simplified.
[0079] In each of the embodiments of the invention, the cross sectional shape and the size of the pair of inner layer line conductors 12 a and 12 b are equal to each other without limitation. However, at least any one of the line length and the width may be set so that the electrical lengths become equal. In each of the embodiments of the invention, the cross sectional shape of the pair of inner layer line conductors 12 a and 12 b may be, for example but without limitation, rectangular shape, circular shape, square shape, ellipse shape, and the like.
[0080] In each of the embodiments of the invention, the dielectric substrate 11 comprises at least three dielectric layers 17 a to 17 c . The dielectric substrate 11 may comprise any suitable structure. Further, the dielectric substrate 11 is not limited to have the structure in which dielectric layers are laminated and any structure may be employed such that the pair of inner layer line conductors 12 a and 12 b is provided in the dielectric substrate 11 , and the pair of inner layer line conductors 12 a and 12 b is provided on surfaces that function as the first virtual plane and the second virtual plane.
[0081] Hereinafter, an example and a comparative example will be described. In the example and comparative example, a phase difference between the lines of the differential line respectively designed is analyzed by using a finite element method. Note that the analysis condition of the finite element method was in the frequency band of 0 to 40 GHz.
Example
[0082] The differential line constituted by the two lines shown in FIG. 1 is designed by using a substrate, line conductors (hereinafter, referred to as inner layer wirings) in the substrate, line conductors of a substrate surface layer (hereinafter, surface layer wirings), and via conductors 14 a and 14 b.
[0083] The relative permittivity of the substrate was 4.2, and the thickness of the substrate was 0.334 mm. Further, the substrate was covered with a solder resist whose thickness was 0.025 mm.
[0084] The line width of each of the inner layer line conductors 12 a and 12 b was 0.05 mm, the thickness of each of the inner layer line conductors 12 a and 12 b was 0.011 mm, and the distance between the inner layer line conductors 12 a and 12 b was 0.104 mm. Further, the line width of each of the surface layer line conductors 16 a and 16 b wiring was 0.063 mm, the thickness of each of the surface layer line conductors 16 a and 16 b was 0.015 mm, and the distance between the lines was 0.05 mm. Further, the diameter of each of the via conductors 14 a and 14 b was 0.1 mm, and the diameter of the land was 0.18 mm. Under these conditions, the line lengths of the inner layer line conductors 12 a and 12 b are adjusted so that the electrical lengths of each of the differential lines 32 become equal.
[0085] Then, the phase difference between the differential lines of the example is calculated in the frequency band of 0 to 40 GHz.
Comparative Example
[0086] As the comparative example, a differential line 32 was designed under the same conditions as the embodiment shown in FIG. 1 except the inner layer wiring. Instead of the inner layer wiring 12 a of FIG. 1 , the inner layer wiring was designed to have the same line length as 12 b and to be symmetric with the inner layer wiring 12 b when viewed from the upper side.
[0087] FIG. 17 shows frequency dependency property of the phase difference obtained in the example and the comparative example. The vertical axis shows phase difference, and the horizontal axis shows frequency.
[0088] According to the data of FIG. 17 , when the frequency was not less than 2 GHz in the comparative example, a phase difference was generated. However, the phase difference of the differential line was virtually not generated in the example. Further, in the frequency range of 0 to 40 GHz, the maximum phase difference of the differential line of the example was 7 degrees. The value is small and not less than 5% of the pulse width, corruption of the pulse wave is small when compared with 13 degrees which is the maximum phase difference of the differential line of the comparative example, and increase of skew is restrained.
[0089] While at least one exemplary embodiment has been presented in the foregoing detailed description, the present invention is not limited to the above-described embodiment or embodiments. Variations may be apparent to those skilled in the art. In carrying out the present invention, various modifications, combinations, sub-combinations and alterations may occur in regard to the elements of the above-described embodiment insofar as they are within the technical scope of the present invention or the equivalents thereof. The exemplary embodiment or exemplary embodiments are examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a template for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention as set forth in the appended claims and the legal equivalents thereof. Furthermore, although embodiments of the present invention have been described with reference to the accompanying drawings, it is to be noted that changes and modifications may be apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of the present invention as defined by the claims.
[0090] Terms and phrases used in this document, and variations hereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as mean “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. | A wiring board equipped with differential lines which compensate for differences in via lengths to minimize signal deterioration is disclosed. Two conductors are couple to different substrate levels through vias of different lengths. Compensation means are provided to correct for the phase difference caused by the different lengths. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application relates to copending applications Ser. Nos. 604,189; 604,295; 604,294 and 604,293, all filed on Apr. 26, 1984 and relating to low temperature characteristics of liquid hydrocarbon fuels.
BACKGROUND OF THE INVENTION
This invention relates to fuel compositions having improved low temperature characteristics. More particularly this invention relates to compositions comprising distillate hydrocarbon fuels having minor amounts of heavy metal salts of certain branched chain carboxylic acids.
As is well known to those skilled in the art, diesel fuels present problems at low temperatures because of poor flow characteristics and clogging of fuel filters. Consequently there is a continuing need for more efficient means for solving these low temperature problems. The materials described herein are metal salts of specific monocarboxylic acids which when added to a diesel fuel significantly improve its filterability, cloud point and pour point.
European Patent Application No. 79200612.4, (Publication No. 010 807 Al) filed on Oct. 25, 1979, discloses derivatives of branched chain monocarboxylic acids. These are amides of ammonia and aliphatic or aromatic amines having at least 1 to 15 primary or secondary amino groups, or salts of alkali metals or alkaline earth metals. The anion of these derivatives is a branched chain monocarboxylic acid moiety commonly known as a telomer acid.
U.S. Pat. No. 4,283,314 discloses resin compositions having improved lubricating properties which employ branched chain high molecular weight ester derivatives of monocarboxylic acids. These monocarboxylic acids can be of the telomer acid type.
The telomer acids described in the aforementioned European Patent Application Publication No. 0 010 807 Al (AKZO CHEMIE) are commercially available through Akona, Inc., Asheville, N.C. European Patent Application Publication No. 0 010 807 Al and U.S. Pat. No. 4,283,314 are incorporated herein in their entirety by reference.
Additives effective in lubricating oils are not necessarily effective in distillate fuels. See Table 1, Example 1, a commercial telomer acid calcium salt (average side chain length or acid about C 14 ) made by Akzo Chemie shows no effect on any of the properties.
It is known that additives which affect pour point cannot be presumed to affect other low temperature properties such as cloud point or filterability, see commercial additive data (Example 3) of Table 1.
The characteristics of telomer acids and their derivatives have been widely explored by Akzo Chemie. Outstanding properties in the areas of clarity, lubricity, rheology, thermo-oxidative and UV stability have been found. The chemical and physical properties of telomer acids and their derivatives suggest advantages for their application in diverse areas such as polymer additives, metal lubricant additives, spin finishes, metal ion extraction complexing aids, printing inks, surface active formulations, coatings, hot melts, greases, specialty plasticisers and water repellants. But there is no prior art known to applicant which discloses or suggests that telomer acid derivatives would be useful in distillate diesel fuels.
One object of this invention is to provide an additive product which will operate to lower the cloud point and the pour point of hydrocarbon fuels and improve their fillterability.
A further object of the invention is to provide a process for preparing an additive product comprising a heavy metal salt of a branched chain carboxylic acid wherein metallic contaminants such as calcium and sodium are avoided, by reacting the heavy metal oxide and the carboxylic acid, in the presence of a water/immiscible organic solvent system, with a heavy metal sulfate.
SUMMARY OF THE INVENTION
Applicant has now discovered that the reaction product obtained by heating equivalent amounts of a heavy metal salt and a telomer acid under appropriate reaction conditions results in an additive product which improves the filterability and reduces the pour point and cloud point of hydrocarbon fuels. Other aspects of the invention will become apparent in the following disclosure.
DESCRIPTION OF THE INVENTION
The invention is directed to a method of improving the low temperature characteristics such as filterability, cloud point and pour point of distillate diesel fuels comprising adding a minor effective amount of a heavy metal salt of a branched chain carboxylic acid to said diesel fuel. Fuel compositions containing said metal salts comprise a major proportion of a liquid hydrocarbon fuel and a minor proportion of a heavy metal salt of a branched chain carboxylic acid wherein said acid is a telomer acid and to a method of making same.
Suitable distillates generally have an initial boiling point of about 350° F. and an end point of about 675° F. Suitable branched chain carboxylic acids are preferably telomer acids.
A telomer acid in accordance with the present invention is one which ordinarily has a branched chain structure of which at least 10 percent by weight conforms to the following generalized formula ##STR1## wherein a is 0 or 1, and
if a is 0, Z is H, and
if a is 1, Z is a CH 2 --group;
wherein
b is 0 or 1, and
if b is 0, Q is H and
if b is 1, Q is a CH 2 --group, and
wherein
x is 0 or 2, and
if x is 0, y is 2 and
if x is 2, y is 0; and
R is CH 3 (CH 2 ) n , where n is an integer of from about 3 to about 42.
Preferred telomer acids are those made from C 10 -C 20 olefins and are available commercially under the tradename Kortacid T-1801 through AKZONA, Inc. Asheville, N.C.
The telomer acids described herein may be prepared by the free radical addition of one mole of acetic anhydride to at least 3 moles of hexene and/or higher olefin having up to 30 or more carbon atoms (C 30 +) in the presence of a trivalent manganese compound or in any other convenient manner known in the art. The metal salts may be prepared in accordance with U.S. Pat. No. 4,283,314 or in any convenient manner known to the art. Usually equivalent amounts of metal and telomer acid are reacted. The equivalent amounts will vary with the particular heavy metal used. Reaction temperatures can vary from ambient, about 70° F., to about 300° F. Reaction times can average from about one to about 16 hours or longer.
Because of varying legal requirements for fuels around the world and adverse affects on performance in the presence of certain metals, the preparation of salts such as manganese (II) and iron (II) described herein below utilizes a method not contemplated in the Akzo patent. By reaction of an intermediate (not isolated) calcium salt in a two-phase water/immiscible organic solvent system with a sulfate of a heavy metal, all calcium is removed and the presence of sodium (a gum promoter) is avoided in the final additive product. The telomer acids in accordance with the invention generally have side chains of from about 8 to about 18 carbon atoms, i.e., they are prepared from olefins having about 10 to about 20 carbon atoms. Preferred are telomer acids having side chains of from about 12 to 16 carbon atoms.
Any suitable heavy metal may be utilized herein. By heavy metal is meant any appropriate metal having a greater atomic weight than sodium. Preferred metals include but are not limited to Mg, Mn, Fe and Co. Generally speaking, a metal oxide, metal salt or metal hydroxide is reacted in at least equivalent amounts with the telomer acid and the intermediate product thereof is reacted in at least equivalent amounts with, for example, a metal sulfate.
Any suitable organic solvent may be used including toluene, benzene, xylene, various alcohols, ketones and esters. Toluene is preferred.
The additives may be used effectively in the disclosed diesel fuels in an amount ranging from about 0.01 wt. % to about 5 wt. % based on the total weight of the fuel composition. In certain cases depending, inter alia, on the particular fuel and/or weather conditions, up to about 10 wt. % may be used.
EXAMPLE 9
The preparation of an Iron (II) Salt in accordance with the invention is as follows: A mixture of 9.1 g calcium oxide, 195 g (0.32 moles) Kortacid T-1402, purchased from Akzona, Inc., made from a C 14 olefin and acetic anhydride, 122 g water and 249.3 g toluene, were refluxed for two hours. Iron (II) sulfate heptahydrate (45.2 g, 0.16 moles) was added and held at reflux for two hours. The water was then removed by azeotropic distillation, the insoluble calcium and unreacted iron sulfates were removed by filtration and the toluene by distillation.
EXAMPLE 12
A manganese salt in accordance with the invention was prepared in a manner similar to Example 1 from an equivalent amount of manganese (II) sulfate monohydrate.
Excess metal sulfate may be used to insure removal of remaining trace amounts of calcium if desired. Mixed salts may be prepared in situ and mixtures of acids may be used if desired.
EVALUATION
A number of reaction products were prepared according to the disclosure herein. These materials were prepared by reacting the reactants shown in the Table in their equivalent chemical proportions. The additives and base fuel were blended at the levels indicated. Additives designated Example 1 and Example 2 were commercial materials derived from C 14 olefins. The first two numbers of the Kortacids indicate the number of carbon atoms in the olefin used (T1401 from C 14 ). Example 13 is a comparative commercial low temperature non-telomer fuel additive product known as Chevron 402 M.
CFPP, Cold Filter Plugging Point (IP 309/76: Institute of Petroleum Test 309/76). LTFT, Low Temperature Flow Test for Diesel Fuels, a filtration test under consideration by CRC (Coordination Research Council). LTFT Procedure: The test sample (200 ml) is gradually lowered to the desired testing temperature at a controlled cooling rate. After reaching that temperature the sample is removed from its cold box and filtered under vacuum through a 17 micrometer screen. If the entire sample can be filtered in less than 60 seconds it shall be considered as having passed the test. An F in this test indicates failure at the maximum acceptable temperature (-6° F.). Cloud Point and Pour Point were determined respectively by the D-250 and D-97 ASTM tests. All test results are shown in the Table.
Any suitable distillate fuel oil or diesel fuel oil may be used in accordance herewith. However, as mentioned hereinabove, fuels having an initial boiling point of about 350° F. and an end point of about 675° F. are preferred. The base diesel fuel used in these tests was a blend of 15% kerosene with 85% of a straight distillate having the following characteristics:
TABLE______________________________________Initial b.p. 366° F.End Point 663° F.Viscosity, 40° C. 2.185 cstConradson Carbon Residue 0.04%API Gravity 34.8 (Kort-Met- acid) Wt. °F. °F. Cloud Poural Acid % CFPP LTFT Point Point______________________________________Base Fuel -- -- 100 -3 1 11 -10Example 1 Ca 2.5 -4 F 14 -10compar-ativecommercialadditiveExample 2 Mg 1 -12 -11 5 -50compar-ativecommercialadditiveExample 3 Mg T1001 2.5 -6 5 -20Example 4 Mg T1402 1 -15 -9 -8 -35Example 5 Mg T1802 1 -16 -8 10 -45Example 6 Mg W2201 2.5 -10 -10Example 7 Mg W2601 2.5 InsolubleExample 8 Li T1402 1 -12 -8 4 -35Example 9 Fe T1402 1 -12 -8 10 -65Example 10 Fe T1801 .05 -8 -6 10 -15Example 11 Mn T1801 .05 -6 -6 12 -15Example 12 Mn T1402 1 -19 -9 -7 -65Example 13 .075 -6 F 15 -40compar-ativecommercialadditive______________________________________
The data of the Table clearly show the improved results obtained when additive compositions in accordance with the invention are used. Examples 3-5 and 9-12 are in accordance with the invention. The important data is that with respect to the Cold Filter Plugging Point and the Low Temperature Flow Test. It is noted that two of the commercial additives failed the LTFT test.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to, without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims. | Heavy metal salts of certain branched chain carboxylic acids significantly improve the filterability, pour point and cloud point of liquid hydrocarbyl fuels when incorporated therein. | 2 |
BACKGROUND OF THE INVENTION
This invention relates in general to devices for drilling holes in the ground and, more specifically, to a system for drilling holes at a considerable distance from the drill support structure.
A wide variety of earth drilling machines have been developed for drilling large and small diameter holes of various depths in different soils under widely varying conditions. While the prior systems have been able to overcome many drilling problems, none have been capable of efficiently drilling holes on unstable hillsides or unstable ground where no nearby stable surface for supporting a drilling rig is available.
Most commercial drilling rigs are designed to support a drilling head on a tower or boom extending vertically directly above the hole site. Typical of these are the arrangements disclosed by Burg et al. in U.S. Pat. No. 2,728,555 and Wilson in U.S. Pat. No. 3,191,450. Such devices are cumbersome, often requiring on-site assembly, and cannot be directly used on unstable ground or hillsides.
Portability of drill rigs has been improced by cantilevered crane- or truck-mounted drill rigs, such as are described by H. R. Smith in U.S. Pat. No. 1,895,901 and E. A. Smith in U.S. Pat. No. 1,971,922. In these cases, the drilling head can be extended in a cantilevered fashion beyond the end of the supporting vehicle. The extension distance is, however, quite limited, because, among other things, a horizontal bar extending from the vehicle to the drilling head must absorb the drilling torque. Also, the extension is primarily horizontal, so that drilling on hillsides above or below the support vehicle is difficult.
On a tower mounted drill, additional drilling pressure may be directly transmitted from the tower to the drill. On the cantilevered drill systems, the drilling pressure is limited to that provided by the drill and drilling head, which is often insufficient for rapid, efficient drilling in some soils.
Thus, there is a continuing need for improved systems for drilling at an increased distance from the support vehicle.
OBJECTS OF THE INVENTION
It is an object, therefore, of this invention to provide an earth drilling systems overcoming the above-noted problems.
Another object of this invention is to provide an earth drilling system capable of drilling at locations spaced a greater distance from the supporting vehicle above, below or to the side of the vehicle.
A further object of this invention is to provide a drilling system capable of bringing greater weight to bear on the drilling head.
SUMMARY OF THE INVENTION
The above objects, and other, are accomplished in accordance with this invention by a suspended drilling system comprising a plate pivotably attachable to the boom point of a crane or similar structure, a first tube (having an other-than-round cross-section) attached to said plate and vertically orientable, at least one second tube telescoped within said first tube, a frame attached to the lower end of said second tube, a means for raising and lowering said frame, a drill stem extending downwardly of the frame and an engine within the frame adapted to rotate the drill stem. Thus, holes can be drilled at any location which can be reached by the boom end.
The second tube, which acts as a torque tube to react drilling torque, is preferrably hollow and closed in a manner permitting it to be used as a fuel tank for the drilling engine. The weight of the fuel then presses down on the frame and drilling stem, to improve drilling speed and efficiency. Preferrably, the second tube consists of two or more telescoping tubes to provide variable length and variable fuel storage capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
Details of the invention, and of a preferred embodiment thereof, will be further understood upon reference to the drawing, wherein:
FIG. 1 is a perspective over-all view of the suspended drill system mounted on a crane;
FIG. 2 is a perspective view, partially exploded, illustrating the attachment of the suspended drill system to a crane boom point;
FIG. 3 is a perspective view, partially in section, showing the attachment plate means;
FIG. 4 is a perspective view showing the telescoping support tube arrangement;
FIG. 5 is a plan view, partially in section, of the support plate attachment means; and
FIG. 6 is a section view taken on line 6--6 in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is seen a conventional crane 10 having the suspended drilling system of this invention secured to boom point 12. While a conventional wheel mounted crane 14 is illustrated, any other support vehicle having an extendable boom may be used, if desired. Best results are generally obtained with a conventional crane, 75 ton or larger, as the support vehicle.
In the usual drilling operation, crane 10 is moved to a position with wheels 14 on stable, generally level, ground near the drill site, with boom 16 movable to position boom point 12 over the desired drilling site, which may be above or below the wheels 14 and may be on unstable ground.
As seen in FIGS. 1 and 2, the basic components of the suspended drilling systems are a plate 18 pivotably attachable to boom point 12, a first tube 20 secured to plate 18, a tube assembly consisting of a second tube 22 telescoped with first tube 20 and a third tube 23 telescoped within second tube 22, a frame 24 secured to the lower end of third tube 23, a drill stem 26 extending downwardly from frame 24 and an engine means 28 within frame 24 to rotate drill stem 26 during drilling. Of course, tubes 22 and 23 could be replaced by a single tube, if desired.
Clearly, as drill stem 26 is rotated, an equal and opposite torque is induced through engine 28 to frame 24 and then tubes 22 and 23. Prior art cantilevered drill systems use a horizontal bar from the drill mount to the support vehicle to react that torque, severely limited drill capabilities. In the present case, tubes 22, 23 and 20, which have telescoping other-than-round cross-sections, act as torque tubes to react this torque. While any tube cross-section may be used, e.g., rectangular, eliptical, hexagonal, etc., the square configuration shown is preferred for simplicity and effectiveness.
Any conventional drill stem 26 and driving engine 28 may be used, as desired. For example, a 453 diesel engine from the General Motors Corporation may be used, operating througn an Allison three-speed transmission with an eight-to-one ratio low gear and a six-to-one ratio rotary table 30.
Engine 28 may be controlled in any conventional manner. If desired, an operator could ride within frame 24 to directly control engine 28. However, it is generally preferred that engine 28 be controlled from the ground near the drill site or from the cab of crane 10 through a conventional electrical or hydraulic control panel (not shown) connected to engine 28 through control cables 32.
Frame 24 is moved upwardly and downwardly before and during drilling by conventional crane hoisting cables 34 acting through first block 36.
A second block 38, operated from crane 10 independently of first block 36, is moved vertically by cables 39 to raise or lower second tube 22 by connecting cable 40 between block 36 and a pad eye 42 on second tube 22, as seen most clearly in FIG. 2. Thus, third tube 23 rises and falls with frame 24 as controlled by cables 34 and second tube 22 (telescoped over tube 23 and within tube 20) is raised and lowered under the control of block 38 and its associated cables to maintain the desired telescoping relationship among the tubes.
In an extreme case, such as where the drilling site is much lower than the crane support level, three or more telescoping tubes could be used in place of tubes 22 and 23. In that case, each of the tubes (except the innermost, which is secured to frame 24) would be supported and moved vertically by an arrangement similar to block 38 and pad eye 42, hoisted by a crane hoist cable.
The means for supporting the telescoping tubes 22 and 23 and for mounting plate 18 on boom point 12 are shown in detail in FIGS. 4-6. Hook-shaped brackets 44 are secured, such as by welding, to first tube 20 and extend to and around edges of plate 18 (which is preferrably round). Brace bars 46 maintain the hook-shaped ends of brackets 44 in the proper spaced relationship. Reinforcements 45 may be welded to tube 20 is necessary. The ends of brackets 44 closely surround the edges of plate 18, but are not bonded thereto. A pin 50, having a head 52 secured thereto, is fastened (such as by welding) in a hole in the wall of tube 22 and extends loosely through the center of plate 18. Thus, plate 18 is rotatable relative to tube 20 about pin 50 with the edge support of brackets 44 and 48. This pivotability facilitates vertical drilling even where crane 10 is not on level ground, since the tubes automatically assume a vertical orientation under the force of gravity acting on the weight of tubes, frames, etc., depending therefrom.
Plate 18 is mounted on boom point 12 by means of a pair of bars 54 (as seen in FIGS. 2, 3, 5 and 6) which are secured to plate 18, such as by welding. A U-shaped slot 56 in the end of each bar 54 is sized to fit over the extended ends of axle 58 in boom point 12. Filler blocks 60 are inserted after slots 56 are moved over axles 58 and are held in place by bolts 62 (as seen in FIGS. 4-6).
This suspended drill system is mounted on crane by laying the tube assembly horizontally on the ground with plate 18 horizontal and bars 54 pointing upwardly. Boom point 12 is lowered until axle ends 58 enter slots 56. Blocks 60 are inserted into slots 56 and bolts 62 are installed. Boom 16 is then raised slowly, lifting plate 18 and allowing tubes 20, 22 and 23 to swing to a vertical position. Since plate 18 can pivot about axle 58 in one plane and about pin 50 in the perpendicular plance, tubes 22 and 23 will always automatically assume a vertical position for drilling. Boom 16 is moved to locate drill stem 26 over the desired drilling site. Cables 34 are actuated to lower frame 24 to bring the drill into ground contact. Once drilling is well started, cables 34 may be slacked off, permitting the full weight of the assembly, including fuel within tubes 22 and 23 to bear on the drill, increasing drill speed and efficiency. Block 38 is moved as necessary to maintain an optimum telescoping relationship among tubes 20, 22 and 23. Thus, rapid, effective and convenient drilling can be accomplished at difficult sites well spaced from the support vehicle.
Certain specific components, arrangements and proportions have been described in conjunction with the above description of a preferred embodiment. These may be varied, or other components used, where suitable, with similar results. For example, the boom may be truck or barge mounted, or the boom may be of the horizontal type.
Other applications, variations and ramifications of the present invention will occur to those skilled in the art reading this disclosure. These are intended to be included within the scope of this invention, as defined by the appended claims. | A suspended drill system for drilling vertical holes in the ground at a distance from a supporting crane. A pivotable plate, attached to a crane boom point, has a first tube having a non-round cross-section attached thereto. A second tube (or plural telescoping tubes) vertically slidable in said first tube has a frame attached at the lower end. The frame is movable vertically by the crane hoisting cable. A drill stem extends downwardly of the frame and is rotated for drilling by an engine within the frame. This system allows drilling in unstable ground at a considerable distance above, below, or to the side of stable ground supporting the crane. | 4 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a sliding member, especially, to the wear resistant sliding member processed with a surface treatment.
(2) Description of the Prior Art
In order to enhance wear resistivity of sliding members of machines, improvement of the sliding members themselves and surface reforming of sliding portions etc. are performed.
As for the surface reforming of sliding portions, methods for forming a hard coating on the surface of the sliding members by such methods as hard chromium plating, ceramic coatings, and hard anodic oxidation coatings etc. are well known. Recently, forming metallic coatings having a low melting point or organic polymer coatings on the sliding surface are adopted in order to give a lubricating property in addition to wear resistant property.
When hard coating is formed on the surface of the sliding members, wettability with lubricating oil or the holding property of the lubricating oil become problems. As for the reforming coating having a preferable holding property of the lubricating oil, the hard anodic oxidation coatings can be exemplified. Alumite layer formed by anodic oxidation on an aluminum alloy has a great number of fine vertical holes, and has a preferable holding property of lubricating oil because of impregnation of the lubricating oil into the vertical holes. However, if the diameter of the vertical hole is too small and viscosity of the lubricating oil is too high, the holding property of the lubricating oil is decreased. Accordingly, it is important to control the diameter of the fine vertical hole so as to obtain a proper size of the holes matched to the viscosity of the lubricating oil.
In order to make the wear resistant property compatible with the lubricating property, there is a method for forming a surface layer with organic material or soft metal having a preferable lubricating property, wherein hard particles are dispersed. However, the above described material has such a problem that the hard particles are separated from the matrix layer in accordance with the proceeding of abrasion and cause abrasive wear by entering into frictional planes. Accordingly, it is important to prevent separation of the hard particles from the matrix layer.
As for a rotary drum for videotape recorder composed of sliding members made from an aluminum-silicon alloy, a sliding member, which is improved in sliding characteristics by forming and projecting fine silicon crystalline particles having a particle size smaller than a submicron on a surface layer of the sliding portion of the drum whereon the tape slides, is proposed (JP-A-57-147155 (1982)). In this case, the hard silicon particles which are dispersedly formed at the surface of the aluminum sliding material enhance a gas (air) lubricating effect by projecting out from the surface of the aluminum matrix, but, on the other hand, there is such a problem that failure of the friction planes is easily caused by separation of the hard silicon particles.
One of the methods to solve such a problem is, for example, a method to form a porous surface structure by vacuum vapour deposition of zirconia at an elevated temperature higher than 500° C. However, almost all of the many pores formed by the above described method are independent pores and are not connected with each other. Additionally, as a process to treat the sliding member at high temperature is indispensable for forming the porous surface in the above described method, the method is not applicable to such members as a member which has previously been processed by heat treatment (quenching or annealing), a member which will cause distortion by heating or cooling, or a member composed from metal having a low melting point.
SUMMARY OF THE INVENTION
OBJECTS OF THE INVENTION
One of the objects of the present invention is to provide sliding members having preferable wear resistivity and lubricating characteristics.
One of other objects of the present invention is to provide a method for manufacturing the above described sliding members.
Furthermore, another object of the present invention is to provide a compressor for a freezer and/or an air conditioner etc. using the above described sliding members having preferable wear resistivity and lubricating characteristics.
METHODS SOLVING THE PROBLEMS
In order to solve the above described problems, the inventors studied on structures of sliding surfaces and lubricating characteristics thereof, and invented a sliding member having a structure which facilitates impregnation of lubricating liquid or solid into the sliding member and preferable retainment thereof, and preferable wear resistivity itself. The gist of the present invention is as follows:
(i) A sliding member wherein a base member has a columnar texture composed from at least one of metal nitrides, metal oxides, metal carbides, and metals at least on the surface of sliding portion, the columnar texture is composed of assemblies of fine columnar asperities, intervals among the columnar asperities are composed so as to form a mesh structure by mutual combination, and a gas/air or a lubricating agent is retained in the intervals.
A projected area of the interval mesh structure at the surface of the columnar texture is preferably 10-40% of the total surface area of the columnar texture. And, depth of the intervals in the mesh structure is preferably 0.1-5 μm.
An average diameter of the columnar asperities assembly composing the columnar texture is preferably 0.1-3 μm. Especially, 0.1-0.5 μm is preferable.
Besides, forming a substrate composed from at least one of metal nitrides, metal oxides, metal carbides, and metals between the columnar texture and the base member is preferable.
(ii) A method for manufacturing sliding members by irradiating an inactive gas ion beam to at least a surface of the sliding portion of the base member with simultaneous deposition of metals or metallic compounds on the base member by vapour deposition method so as to form a columnar texture comprising assemblies of fine columnar asperities of metals or metallic compounds.
(iii) A method for manufacturing sliding members by irradiating directive inactive gas ion beam and injecting an ion beam of oxygen, nitrogen, or carbon with simultaneous deposition of metals or metallic compounds on the base member by vapour deposition method so as to form a columnar texture comprising assemblies of fine columnar asperities.
As for the above described inactive gas ion beam, ion beams such as argon, xenon, or krypton gas ion beams are used. It is important that the inactive gas ion beam must be a directive gas ion beam. Because, only with the directive inactive gas ion beam, can a columnar texture comprising assemblies of fine columnar asperities, which is one of the features of the present invention, be formed.
A schematic perspective view of the columnar asperities related to the present invention is shown in FIG. 1. Formed on the surface of a sliding portion of the base member 2 the columnar texture 5 composed of columnar asperities 1 which are formed from at least one of the metal nitrides, the metal oxides, the metal carbides, and the metals. Among the asperities, the intervals 3 are formed, and the intervals are mutually connected so as to form a network. A lubricating agent retained among the intervals 3 will lubricate at sliding. Besides, it is preferable that the substrate 4 is formed between the base member 2 and the columnar texture 5.
As for a method for obtaining the columnar texture related to the present invention, the physical vapour deposition method is adequate, especially, the physical vapour deposition method with concurrent ion beam irradiation. Adopting a vapour deposition method or an ion beam spattering method as the physical vapour deposition method, an argon ion beam, a krypton ion beam, or a xenon ion beam is concurrently irradiated during the physical vapour deposition.
The diameter of the columnar asperities and intervals among the columnar asperities composing the columnar texture can be controlled by simultaneous injection of oxygen ions, nitrogen ions, or carbon ions. For instance, in order to enhance the spattering effect at the surface layer where the columnar texture is formed and to control the diameter and the width of the intervals of the columnar asperities in a case of concurrent irradiation with the argon ion beam, the ion energy of 500 eV-200 keV is preferable. In accordance with the above described concurrent irradiation of an ion beam with the physical deposition method, the columnar texture related to the present invention can be obtained by treating the sliding member at room temperature or a lower temperature than the temperature of heat treatment of the sliding member, and, as the columnar texture has a preferable adhesiveness, the method can be applicable to aluminum alloys.
Referring to FIG. 2, an example of manufacturing apparatus for the sliding members relating to the present invention is shown. The sliding member 12 whereon the columnar texture must be formed is set in the vacuum tank 10 of which vacuum is maintained by operation of the vacuum apparatus 11, depositing the metal or the metallic compound 14 on the sliding member by operating the vapour deposition apparatus 13 which is installed in the vacuum tank 10, and concurrently, irradiating or implanting the sliding member with ions by using the ion source 15. The raw material for the directive ion beam 19 projected from the ion source 15 is supplied as the inactive gas 17 or the inactive gas 17 mixed with an adequate amount of reactive gas such as nitrogen, oxygen, or carbon etc. by the mixer 16. The sliding member 12 is held in a temperature controllable holder (not shown in the drawing) furnished with a cooling mechanism and a heater.
A control range of temperature can be arbitrarily determined depending on required temperature for the basic plate, and as for basic plates made from aluminum alloys or resin which require low temperature, the temperature can be arbitrarily controlled between room temperature and 300° C. Preferable temperature for the above described process is around 100° C. Farther, the holder has a mechanism for arbitrarily changing the angle of the deposition plane, the irradiation plane and the implantation plane in accordance with the shape of the sliding member 12. The gas mixer 16 can set predetermined introducing amounts of the inactive gas 17 and the other gases 18, and can mix them together. Besides, vacuum in the vacuum tank 10 is preferably at most 0.005 Torr.
As for the materials of the above described sliding members, in addition to such metals as aluminum group alloys, carbon steels, stainless steels, nickel base alloys, and copper alloys, a sintered ceramic body can be used. Especially, as for the aluminum group alloy, the alloy can include Si in an amount of 1-45% by weight, IIIa group elements in an amount of 0.1-20% by weight, at least one of IVa group elements and Va group elements in an amount of 0.1-5% by weight, and the balance is substantially aluminum, can be used. Especially, Si in amount of 13-35% is preferable.
As for the IIIa group elements, Sc, Y, lanthanide series elements (La, Ce etc.), especially, misch metal are preferable, and an amount of 0.5-5% is preferable. As for the IVa group elements, Ti, Zr, and Hf in amount of 0.5-3% are preferable. Especially, a sintered alloy is preferable when Si is contained in amount of 18-30%.
In accordance with the present invention, as for concurrently usable lubricants, liquid lubricants, solid lubricants, or a mixture of the liquid and the solid lubricants can be adopted depending on intended use of the sliding members. As for the liquid lubricants, conventional mineral oil group lubricating oils, and synthetic lubricating oils (for example, silicone oils), etc. can be enumerated. And as for the solid lubricants, molybdenum disulfide, low melting point metals, or organic polymers (for example, polytetrafluoroethylene), etc. can be enumerated. The above described lubricants can be used in forms of powder, paste, solution, and suspended liquid.
In the columnar texture related to the present invention, assemblies of the columnar asperities are formed by crystal growth of hard materials, and intervals among the mutual columnar asperities are connected like a network. Owing to the fact that the intervals differ from simple vertical pores and are connected with each other, and gas bubbles in the intervals are easily squeezed out by impregnation with the above described lubricant and the intervals are filled with enough amount of the above described lubricant, preferable impregnating and retaining character for the lubricants are realized.
Farther, in case of lubricating the sliding portion with a gas such as a magnetic recording medium etc., the intervals have an effect to stabilize a laminar flow of the gas on the sliding plane.
The width of the intervals among the columnar asperities is optimized depending on viscosity, wettability, and combining strength etc. of the lubricant to be filled. For example, when viscosity of the lubricant is low, the width must be small in order to prevent flowing out of the lubricant. On the contrary, when the viscosity is high, the width must be large in order to retain a large amount of the lubricant.
The columnar asperity may be either a single crystalline growing body or a polycrystalline growing body. However, it is necessary that the area occupied by the columnar asperities group at surface of the columnar texture be sufficient for supporting a bearing pressure added to the sliding portion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective view of the columnar texture on a surface of a sliding member relating to the present invention,
FIG. 2 is a schematic illustration of a manufacturing apparatus relating to the present invention,
FIG. 3 is an illustration of a scanning electron microscopic photograph of the sliding member surface in the embodiment 1,
FIG. 4 is a graph indicating a relationship between average diameters of columnar asperities and occupied area fraction of intervals at the surface of the columnar texture versus argon content in irradiating ions,
FIG. 5 is an illustration of a scanning electron microscopic photograph of the sliding member surface in the embodiment 2,
FIG. 6 is a vertical cross section of a rotary compressor,
FIG. 7 is a cross section taken along line A--A of FIG. 6,
FIG. 8 is a vertical cross section of a sealed scroll compressor.
DETAILED DESCRIPTION OF THE EMBODIMENTS
(Embodiment 1)
A sliding member having the columnar texture as shown in FIG. 1 was prepared by using the apparatus shown in FIG. 2. As for the base member 2, a plate made from an aluminum alloy (Si: 25%, Cu: 3.6%, Mg: 0.7%, Fe: 0.2%, Fe: 0.5%, Zr:0.9%, Ce:2.0%, respectively by weight, and Al: Balance) having dimensions of 50 mm×50 mm×3 mm thick was used. A layer of titanium nitride of about 1 μm thick was formed as the substrate 4 by irradiating the surface of the base member 2 with nitrogen ions having energy of 10 keV with concurrent deposition of titanium onto the surface of the base member 2 in vacuum (0.005 Torr.). Subsequently, the columnar texture 5 was formed by growing the columnar asperities 1 to about 3 μm by irradiating the titanium layer with mixed ions including 90-40% nitrogen ions and 10-60% argon ions having energy of 20 keV with concurrent deposition of titanium in an increasing speed of thickness, 0.5 nm/second.
Referring to FIG. 3, a photograph of a surface of the sliding member relating to the present embodiment taken by an scanning electron microscope is shown. FIG. 4 is a graph indicating a relationship of the average diameter of the columnar asperities at the total surface of the columnar texture and the occupied fraction of the projected intervals area, which were measured by an image treatment of the photograph observed by the scanning electron microscope, versus the argon content in the irradiating ions.
In FIG. 4, a tendency that the occupied area fraction of the intervals increases in accordance with the increment of the argon content can be observed. However, when the argon content exceeded 50 %, an amount of spattering by the ions irradiation increased, and a growing speed of the columnar grains vertical to the surface of the base member were extremely decreased and the aimed columnar texture could not be obtained. Almost the same tendency was observed when krypton or xenon was used for the irradiating inactive gas ion beam. That means, any ion beams having a large spattering effect can be used as a substitute for the argon ion beam.
The aluminum plates whereon the columnar texture were formed were evaluated by reciprocative linear motion sliding tests. An aluminum alloy (Si content: 11%) of which one end was fabricated in a spherical shape having a diameter of 10 mm was selected as a counterpart, and was reciprocated at an interval of 10 mm on a testing sample at a speed of 10 mm/sec with a load of 100 g. Before testing, the testing sample and the counterpart were degreased with acetone, 0.1 milliliter of spindle oil was dropped onto the sliding portion of the testing sample which was horizontally held, the testing sample was moved from the horizontal position to a vertical position after elapsing one minute since the dropping of the spindle oil. The oil which flowed down and gathered at the lower end of the testing sample was wiped off ten minutes after the movement. Friction coefficients were measured without additional supply of the oil after starting of the measurement. Results of the above described testing are shown in Table 1.
TABLE 1______________________________________Testing Average diameter Area fraction Lubricating Slidingsample of columnar of intervals limit limitname asperities (μm) (%) (times) (times)______________________________________NO26 0.06 0 54 611AN05 0.08 8.4 62 587AN21 0.12 15.8 150 673AN25 0.21 38.3 198 627AN50 0.24 43.5 93 300______________________________________
In accordance with the above described testing, the friction coefficients under lubricating condition are less than about 0.02. On the contrary, the friction coefficient increases rapidly to a value about 0.2 when the lubricating oil on the sliding surface is exhausted. The value of the friction coefficient is equivalent to the friction coefficient between titanium nitride and the aluminum alloy under no lubricating oil. Farther, when the lubricating oil becomes a deficient condition by exposing the aluminum alloy of the sliding member on account of fracture and wearness etc. of the columnar texture, the friction coefficient increases to about 0.5.
In the Table 1, the lubricating limit was defined as numbers of sliding times before starting of friction coefficient increment on account of the above described effects, and the sliding limit was defined as numbers of sliding times before the friction coefficient exceeds 0.4.
In accordance with the Table 1, the testing sample having a small area fraction of the intervals also has a small lubricating limit because a filled amount of the lubricating oil is small. When both the average diameter of the columnar asperities and the area fraction of the intervals become large, the lubricating limit become small, because a retainable capacity of the sample for the lubricating oil reversely decreases, and the sample becomes apt to cause the deficient condition of the lubricating oil. Besides, the fracture of the columnar texture causes early exposure of the base material of the sliding portion, increasing the friction coefficient on account of metal-metal friction, and consequently, lowering values of the sliding limit.
As Table 1 shows, the testing samples AN21 and AN25 among the testing samples of titanium nitrides, AN10, AN21 AN25 in the present embodiment obtained preferable results under the sliding condition equivalent to the reciprocative linear motion sliding test using spindle oil, and it has been revealed that the sliding member related to the present invention has preferable wear resistivity and lubricating property.
In a case when the base member is composed of a soft material, the decrement of the intervals in the columnar texture by deformation of the sliding member under sliding condition can be suppressed by forming the substrate 4 with hard materials. Additionally, the formation of the substrate is effective for improving a bonding force between the columnar texture and the sliding member, but, the substrate can be omitted depending on the sliding condition.
The filling amount of the lubricating agent is proportional to the depth of the intervals, but when the interval is too deep, fracture of the columnar texture is facilitated during sliding. Accordingly, the depth of the interval is preferably at most 5 μm. On the other hand, when the depth of the interval is too shallow, retention of the lubricating agent becomes difficult. Accordingly, the depth of the interval is preferably at least 0.1 μm.
(Embodiment 2)
A sliding member was manufactured by irradiating the surface of an aluminum alloy (Si: 11%) plate having dimensions of 50 mm×50 mm×3 mm thick with oxygen ions having an energy of 10 keV concurrently with titanium vapour deposition in a vacuum so as to form a titanium oxide substrate of about 1 μm thick. Subsequently, a hard columnar texture was formed by irradiating the substrate with oxygen ions mixed with 20% argon ions having an energy of 10 keV concurrently with depositing titanium at a thickness increasing rate of 0.5 nm/sec so as to grow columnar asperities of titanium oxide to about 3 μm. Besides, the sliding member was cooled by a water cooling device of the holder.
FIG. 5 is a schematic illustration of a scanning electron microscopic photograph of a surface of the sliding member in the present embodiment.
Almost the same results were obtained by using krypton or xenon to an inert gas ion beam for irradiation, and an ion beam having a large spattering effect can be used instead of the argon ion beam.
(Embodiment 3 )
Hard columnar texture was formed by irradiating an aluminum alloy plate, which was used as the sliding member in the embodiment 2, with an argon ion beam at least 0.4 mA/cm having an energy of 20 keV concurrently with depositing chromium in a vacuum at a thickness increasing rate of 1.0 nm/sec so as to grow columnar asperities of chromium to about 3 μm. Besides, the sliding member was cooled by a water cooling device of the holder.
(Embodiment 4)
Hard columnar texture was formed by irradiating an aluminum alloy plate, which was used in the above embodiment 3, with an argon ion beam at least 0.5 mA/cm having an energy of 10 keV concurrently with depositing metallic silicon in vacuum at a thickness increasing rate of 0.7 nm/sec so as to grow columnar asperities of silicon to about 5 μm.
(Embodiment 5)
A solid lubricant was filled into the columnar texture of the sliding members having the columnar texture obtained by the embodiments 1-4. As for the solid lubricants, molybdenum disulfide, acrylic resin low polymer, tetrafluoroethylene resin, zinc, and silver were respectively filled, and, subsequently, cross sections of the columnar texture were observed by a scanning electron microscope in order to investigate filling conditions of the solid lubricants.
Molybdenum disulfide was filled by an application method and a spattering deposition method, respectively. Although only about 70% of the depth of the intervals in the columnar texture was filled by the above methods, the intervals were filled with molybdenum disulfide to 100% of the depth after the end of a sliding test in dry air, and lubricating characteristics were preferable. Acrylic resin low polymer and tetrafluoroethylene resin, which were respectively filled by an immersion method wherein the above resins were ionized as chloride ions and electromagnetically filled into the intervals, to 100% fill the intervals from the bottom of the intervals, and were found to have preferable lubricating characteristics in a sliding test in dry air without splitting of the columnar texture. Titanium nitride having the columnar texture filled respectively with zinc and silver by a plating method increased the friction coefficient to 0.4 in comparison with 0.2 for the friction coefficient of titanium nitride without filling the lubricants in a sliding test in dry air. But, the titanium nitride filled with the lubricants revealed preferable friction characteristics in a sliding test in vacuum. Because the sliding members having columnar texture of titanium oxide obtained in the embodiment 2 were not electroconductive, the solid lubricants could not be filled.
(Embodiment 6)
Bearing sliding tests were performed on shafts, all of which respectively had equivalent columnar texture to the embodiment 1 on their surface, of 20 mm in diameter made from respectively alloy steel, alumina ceramics, mixed ceramics of oxides and nitrides of silicon and aluminum, titanium alloy, and aluminum alloy. Using an apparatus shown in FIG. 8, the columnar texture of titanium oxide was formed at an external surface of sliding a portion of the shaft while rotating the shaft by a holder. On the other hand, as a bearing for the shaft, a slide bearing made from bearing steel of 25 mm in width was used.
Seizing life (hours) of the above described shaft to the bearing was determined under a condition of an eccentric load 10 kgf, and 1000 rpm without any oil supply after a sufficient amount of naphthene group lubricating oil was supplied before the sliding test.
The seizing life of the shafts was extended more than three times by forming the columnar texture in the present embodiments.
(Embodiment 7)
FIG. 6 is a vertical cross section of a rotary compressor using mainly for refrigerators, and air conditioners etc. FIG. 7 is a horizontal cross section of the rotary compressor (taken along the line A--A of FIG. 6).
The rotary compressor has a structure wherein the crank shaft 102 is supported by journal bearings including an upper bearing 106 and a lower bearing 107, and the crank pin portion 109 of the crank shaft supplies an eccentric rotation to the roller 108 by sliding motion of the journal bearings. The vane groove 111 and the top portion 110a of the vane 110 which are formed on the cylinder 105 for containing the roller 108 are respectively contacted to the external circumference of the roller 108 in a slidable manner so that the vane 111 can slide as a thrust bearing in a direction or a reciprocatory manner.
A field test was performed on ten testing machines wherein the same columnar texture as the test piece AN21 in the embodiment 1 was formed on surfaces of the sliding portions of the crank shaft 102 and the vane 110 of the compressor. An observation of the sliding portions after one year of operation of the testing machines revealed that all sliding portions of the ten testing machines had preferable appearance without showing any traces of seizure which were observed on shafts not treated by the method of the present invention. Accordingly, compressors for freezers having preferable durability can be provided by applying the sliding members of the present invention to the compressor.
(Embodiment 8)
FIG. 8 is a vertical cross section of a scroll compressor used mainly for an air conditioner etc.
A compressing portion of the compressor is composed of the stationary groove 202 formed in a scroll shape, the movable groove 203 formed in the same scroll shape, the crank shaft 206, and the detente 204. The crank shaft 206 is supported by journal bearings of the upper bearing 205 and the lower bearing 208, and the crank shaft 206 rotates so as to supply an eccentric moving to the movable groove 203. Rotary motion of the movable groove 203 to the stationary groove 202 is restricted by the detente 204, and, accordingly, a space formed between the movable groove 203 and the stationary groove 202 moves, and concurrently a volume of the space shrinks so as to compress a cooling medium gas.
A field test was performed on ten testing machines wherein the same columnar texture as the test pieces in the embodiments 1 and 2 was formed on surfaces of the sliding portions of the crank shaft 206 and the detente 204. An observation of the sliding portions after one year of operation of the testing machines revealed that all sliding portions of the ten testing machines had preferable appearance without showing any traces of seizure which were observed on shafts not being treated by the method of the present invention. Accordingly, compressors for freezers having preferable durability can be provided by applying the sliding members of the present invention to the compressors.
Furthermore, a columnar texture equivalent to that in the embodiment 1 was formed on the surface of the movable groove 203 of the compressor. Rotating torque transmitted to the crankshaft was reduced, and durability of the compressor increased.
The columnar texture formed on the surface of sliding members relating to the present invention facilitates filling and holding of gaseous, liquid, or solid lubricating materials, improves sliding planes in wear resistivity and seizure resistance, and decreases friction forces at sliding portions.
Furthermore, magnetic recording media and compressors etc. using sliding members of the present invention decrease friction forces at sliding portions, and more than double the durable life of the above described apparatus caused by wearness and seizure. | The object of the present invention is to provide sliding members having preferable lubrication and seizure resistance. Sliding members comprising a columnar texture which is composed from at least one of metal nitrides, metal oxides, metal carbides, and metals on a base member, wherein the columnar texture is composed of assemblies of fine columnar asperities, with intervals formed between the columnar asperities being connected to each other so as to form a net work, and with gaseous, liquid, or solid lubricants being maintained in the intervals. The mutually connected intervals in the columnar texture are superior in filling and holding of lubricants, and the above described superiorities improve lubrication and seizure resistance and extend sliding life. | 5 |
FIELD OF THE INVENTION
The present invention is generally related to an apparatus and system for cleaning baseball field bases and/or locations.
BACKGROUND OF THE INVENTION
During a baseball game, a player or players may slide onto bases in their bid to score home runs. In doing so, dirt, dust, debris and/or mud would normally end up on the base in question. In many instances, the game would have to be delayed because the umpire and/or cleaners would have to stop the game to go to the base to clean it. Additionally, as the game progresses, the base may accumulate dust and debris that land on the base. As a result, the base ends up being dirtied and hard to see over time by both players and umpires. Clean bases are needed as they are more visible by the players and most especially the umpires who need to make play calls.
As such, there is a need for an apparatus and system that would enable the efficient cleaning of the base thereby enabling players to see the base as they slide or dive toward it. There is also a need for an apparatus and system that enables remote cleaning of the base, which would obviate the need for an umpire and/or a cleaner to go out to the base during a game to clean the base.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an apparatus, system and method for cleaning the surface of a baseball field base where the apparatus may comprise of a base, and one or more apertures which are positioned within the base. In one aspect of an embodiment of the present invention, the apertures may be adapted to expel air and may also be connected to one or more sub-channels. In another aspect of an embodiment of the present invention, the one or more apertures may be positioned flush with the surface of the base. The envisioned apparatus may also comprise of one or more air chambers which are operatively connected with the one or more sub-channels. The apparatus may further comprise of a main channel connected with the one or more air chambers, where the main channel is supplied from an air compressor. The apparatus may also comprise of a main valve located between the one or more air chambers and the main channel, where the main valve regulates the air flow from the main channel to the one or more air chambers. The valve may also be further adapted to close the main channel.
In one aspect of an embodiment of the present invention, one or more sides of the base may comprise of a visual display. The visual display may be a variety of things, including, without limitation, an LED display, an advertising screen etc. or combination thereof. The visual display may also perform a variety of functions.
In one aspect of an embodiment of the present invention, the surface of the base may comprise of sensors which detect dust, debris and/or mud on the base. In another aspect of an embodiment of the present invention, the sensors may be adapted to effect a blast of air from the air compressor. In an alternate embodiment, the sensors may be programmed to activate the air compressor once a certain amount of dust, debris, mud etc. has been detected on the surface of the base.
In another aspect of an embodiment of the present invention, the air compressor may be programmed to supply air at predetermined times. As such, the air compressor may operate either independently of input or with input from a user using the apparatus or operating the system.
In yet another aspect of an embodiment of the present invention, the base may further comprise of a visual device for aiding a user in determining when to activate the air compressor. In yet another aspect of an embodiment of the present invention, the visual device may be used to detect the presence of dust, debris and/or mud on the base.
In a further aspect of an embodiment of the present invention, the one or more apertures may be positioned to ensure efficient cleaning of the base. In one embodiment, the apertures are inclined at different angles to effect direct and indirect air blasts to clean the base.
In another aspect of an embodiment of the present invention, a base cleaning system is envisioned. The system, in one aspect of an embodiment, may comprise of an air compressor, a controller, one or more bases, a plurality of conduits or channels used to supply air to the bases. In one aspect of an embodiment of the invention, the controller may be either stationary or wireless. In another aspect, the air compressor may operate at predetermined intervals. In another aspect, the predetermined intervals may be programmed at the controller.
In another aspect of an embodiment of the present invention, a method of operating a system for cleaning baseball locations is disclosed. In one aspect, the method may include the steps of detecting dust, debris, dirt, mud or other obstacles at one or more locations, activating an air compressor to supply air to the one or more locations, directing air from the air compressor to the one or more locations, regulating the flow of said supplied air at the one or more locations, and using the supplied air to clean the one or more locations.
In another aspect of an embodiment of the present invention, the method may further include the step of monitoring the one or more locations. This may be made possible by using a variety of visual devices including cameras.
In another aspect of an embodiment of the present invention, the method may further include the step of activating a pre-determined schedule for supplying air to the one or more locations.
In another aspect of an embodiment of the present invention, the method may further include the step of displaying information at the one or more locations.
In another aspect of an embodiment of the present invention, the method may further include the step of effecting an automatic blast of air at the one or more locations upon the detection of dust, debris, dirt, mud or other obstacles. In one aspect, detection of dust, dirt, debris or other obstacles may be made possible using a variety of sensory devices including, without limitation, infra-red devices.
In another aspect of an embodiment of the present invention, the method may further include the step of transmitting an activation signal wirelessly.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of aspects of embodiments of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the claims and drawings, in which like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit of a reference number identifies the drawing in which the reference number first appears.
FIG. 1 illustrates a general layout of a baseball field showing the field's bases according to an exemplary aspect of the present invention.
FIG. 2A illustrates a system according to an exemplary aspect of the present invention showing a fixed controller device & location.
FIG. 2B illustrates a system according to an exemplary aspect of the present invention showing the use of a wireless controller.
FIG. 3A illustrates a perspective view of a base according to an exemplary aspect of the present invention.
FIG. 3B illustrates a bottom view of a base according to an exemplary aspect of the present invention.
FIG. 3C illustrates a side view of a base according to an exemplary aspect of the present invention.
FIG. 3D illustrates a sectional view of a base according to an exemplary aspect of the present invention.
FIG. 4 illustrates a flow chart of an operational process flow according to an exemplary aspect of the invention.
FIG. 5 Illustrates a flow chart of another operational process flow according to an exemplary aspect of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is now described in more detail by reference to the exemplary drawings in detail wherein like numerals indicate like elements throughout the various views. This is for convenience only and is not intended to limit the application of the present invention. In fact, after reading the following description, it will be apparent to one skilled in the relevant art(s) how to implement the following invention in alternate embodiments.
Referring now to FIG. 1 , a general layout of a baseball field 100 according to an exemplary aspect of the present invention is shown. As seen, baseball field 100 has three regular bases 102 A, 102 B, 102 C, home base 102 D and pitcher's mound 102 E (“locations”) where all of these bases and the pitcher's mound may have the same configuration and structural form or makeup. It should be noted that the number of locations may vary or differ and may include other positions not identified as “bases” or “pitcher's mound.”
Referring now to FIG. 2A , a system 200 according to an exemplary aspect of the present invention showing a fixed controller device & location 202 is shown. Here, fixed controller device & location 202 is used to control the operation of air compressor 204 . In one aspect of an embodiment of the present invention, an operator (e.g. an umpire and/or cleaner) may activate the air compressor 204 once the operator realizes that a base or some bases have been obscured by dirt, debris and/or mud. In another aspect of an embodiment of the present invention, the dust, dirt, mud and/or obstacles may be detected using a variety and/or combination of sensors and monitoring devices any one of which may use infra-red technology. Once air compressor 204 is activated, it sends a supply of air through conduits 206 A- 206 E to bases 102 A through 102 D and pitcher's mound 102 E of baseball field 100 . In one aspect of an embodiment of the present invention, a visual device 208 may be strategically positioned to view bases 102 A through 102 D and pitcher's mound 102 E. As such, an umpire or cleaner would be able to readily determine whether a base or bases need to be cleaned or not. Visual device 208 may send its video feed back to fixed controller device & location 202 or to any designated location.
Referring now to FIG. 2B , an exemplary aspect of the present invention showing the use of a wireless controller 210 is shown. Here, the air compressor 204 may be controlled and/or activated by a wireless controller 210 . An operator may be anywhere with the wireless controller 210 which transmits a signal to data receiver 212 which may be in operative communication with air compressor 204 . Data receiver 212 then sends the desired control to air compressor 204 . In one aspect, the control may be for air compressor 204 to supply only one base or any number of bases 102 A- 102 D and/or pitcher's mound 102 E with air to clean their respective surfaces. In another aspect of an embodiment of the present invention, air compressor 204 may be activated at predetermined intervals. Air compressor 204 may also be pre-programmed to operate at certain designated times on a predetermined schedule.
In another aspect of an embodiment of the present invention, a smoke generator 214 , may be connected with air compressor 204 . As such, wireless controller 210 may send a signal for smoke generator 214 to generate smoke and send it to a base, desired base(s) and/or pitcher's mound 102 E through air compressor 204 . In another aspect of an embodiment of the present invention, a visual device 208 may also be present. In one aspect of an embodiment of the present invention, visual device 208 may be part of a base 102 . In another aspect of an embodiment of the present invention, visual device 208 may be a separate device from base 102 . Visual device 208 may aid an operator or user in determining when to activate the air compressor. In yet another aspect of an embodiment of the present invention, the visual device may also be used to detect the presence of dust, debris and/or mud on the base. In a further aspect of an embodiment of the present invention, visual device 208 may be used to monitor the accumulation and/or detection of dust, debris, mud or obstacles at the base.
Referring now to FIG. 3A a perspective view of a base 102 A according to an exemplary aspect of the present invention is shown. Here a plurality of apertures 302 is shown on the surface of base 102 A. It should be noted that discussion/description of the invention as it pertains to base 102 A is purely illustrative and not limiting as the same discussion/description may be applicable to bases 102 B- 102 D, pitcher's mound 102 E and/or any other location in the system. In one aspect of an embodiment of the invention, the apertures 302 may be equidistant from each other. In another aspect, the apertures 302 may be at random positions from each other. In yet another aspect, apertures 302 may be positioned to ensure cleaning of the surface of base 102 A including the positions between apertures. In yet another aspect, apertures 302 may be positioned at angular positions to ensure blasts of air at angles to clean the surface and also to collide and bounce back onto spots in between apertures 302 . In yet another aspect of the invention, the apertures 302 are positioned flush with the surface of base 102 A. In yet another aspect of an embodiment of the present invention, base 102 A is also installed in its position using ground supports 306 as shown.
Also seen in FIGS. 3A & 3C is visual display 304 . Visual display 304 may be a variety of things, including, without limitation, an LED display, an advertising screen etc. or combination thereof. Visual display 304 may also perform a variety of functions, including a display of a team's logo as shown in FIG. 3C . In another aspect of an embodiment of the present invention, visual display 304 may have a ticker tape with displayed advertisements.
Referring now to FIG. 3B , a bottom view of a base 102 A according to an exemplary aspect of the present invention is shown. Here conduit 206 A is shown entering base 102 A from the bottom. Conduit 206 A supplies air from air compressor 204 once air compressor 204 has been activated to operate and supply air to one or any number of bases 102 A- 102 D and/or pitcher's mound 102 E. Air then flows from conduit 206 A into base 102 A.
Referring now to FIG. 3D , a sectional view of a base 102 A according to an exemplary aspect of the present invention is shown. As shown, conduit 206 A supplies air from air compressor 204 passing through main valve 308 , which, in one aspect of an embodiment of the present invention, may function to regulate the air flow top air chamber 310 . Upon opening of main valve 308 , the air flows into air chamber 310 before subsequently exiting base 102 A via apertures 302 , which in turn cleans the surface of base 102 A. In one aspect of an embodiment of the present invention, the air supplied by air compressor 204 may remain in the conduit/conduits 206 until main valve 308 , as shown in FIG. 3D opens. The operation of main valve 308 may be automatic or manual. In another aspect of an embodiment of the present invention, main valve 308 may be controlled from controller device 202 . Once main valve 308 is opened, air flows into air chamber 310 . In another aspect of an embodiment of the present invention, there may more than one air chamber. In a further aspect, each air chamber may be supplied separately by a separate conduit or air channel while also having individual valves to regulate the flow of air from air compressor 204 . In a yet further aspect of an embodiment of the present invention, an automatic blast of air may be supplied to base 102 A upon detection of dust, dirt, mud and/or obstacles on its surface.
Referring now to FIG. 4 , a flowchart showing an operational process flow 400 according to an aspect of an embodiment of the present invention is shown. The process may begin in step 402 with the monitoring of the bases or locations. Monitoring, in one aspect of an embodiment of the present invention, may be implemented by a visual device such as visual device 208 . Following the monitoring of the location(s) in step 402 is step 404 where it is determined whether the monitored location(s) is obscured by dirt, dust, debris, mud and/or other obstacles. An umpire or operator viewing the video feed from visual device 208 may, in step 404 , determine that a certain location may need to be cleaned. Once this has been determined, air compressor 204 may be activated in step 406 to start supplying air to the location. Once activated, air compressor 204 then supplies the designated location(s) with a blast/supply of air or smoke as shown in step 408 . Upon reaching the designated location, the air flow to the location's air chamber 310 may be regulated by main valve 308 , an operation as shown in step 410 . The supplied air may then be utilized in step 412 , upon release, to clean the surface of the location. Following this cleaning operation, the umpire and/or operator may, in step 414 , make another determination as to whether the location needs additional cleaning or not. If additional cleaning is needed, the process proceeds back to step 406 with the umpire and/or operator activating air compressor 204 to supply more air to the location. If not, the process ends.
In one aspect of an embodiment of the present invention, the umpire and/or operator may activate air compressor 204 using controller device 202 or wireless controller 210 . In another aspect of an embodiment of the present invention, air compressor 204 may be activated to supply the designated location with smoke generated by smoke generator 214 . In another aspect of an embodiment of the present invention, LED display may be activated by controller device 202 or wireless controller 210 with the displayed information transmitted via wire and/or wirelessly.
Referring now to FIG. 5 , a flowchart showing another operational process flow 500 according to an aspect of an embodiment of the present invention is shown. The process may begin with the monitoring of the location(s) as shown in step 502 . The process then proceeds to step 504 where the system determines whether the activation of air compressor 204 has been programmed into the system or not. If it is determined that activation of air compressor 204 has been programmed, the process proceeds to step 506 where the activation schedule for air compressor 204 is implemented. If no activation schedule has been pre-programmed for air compressor 204 , then the process proceeds to step 508 where the monitor (be it either the umpire and/or an operator) makes a determination as to whether the location(s) require cleaning. If the answer to this decisional block is in the affirmative, then air compressor 204 is activated as shown in step 510 . If not, then the process proceeds to step 502 for continued monitoring. An activation schedule may, in one aspect of an embodiment of the present invention, dictate when air compressor 204 is to be activated, duration of air compressor 204 's operation, amount of air to be supplied etc.
Once air compressor 204 has been activated in step 510 , air compressor 204 then supplies the designated location(s) with air as shown in step 512 . In another aspect of an embodiment of the present invention, air compressor 204 may also supply, based on an umpire's/operator's selection, smoke as generated by smoke generator 214 .
The system, in step 514 then determines whether operation of main valve 308 is pre-programmed into the system or not. In another aspect of an embodiment of the present invention, it may be determined in step 514 whether operation of main valve 308 is to be either pre-programmed (automatic) or manual. If operation of main valve 308 is determined to have been pre-programmed into the system (for example, at controller 202 ), the regulation schedule of main valve 308 , in step 516 , is then implemented. In one aspect, the regulation of main valve 308 may allow a certain amount of air flow into air chamber 310 . In another aspect, main valve 308 may be opened or closed depending on the regulation schedule. If the operation is determined to not have been pre-programmed, then in step 518 , main valve 308 regulates the air flow to air chamber 310 as air compressor 204 is activated under normal conditions.
The air flow into air chamber 310 is then used, in step 520 to clean the surface after which an umpire and/or operator in step 522 determines whether the surface is clean or whether additional cleaning is required. If it is determined that the surface is clean, the process ends. If not, the process proceeds to step 512 where air compressor 204 is further activated to supply air to the location for additional cleaning.
Although this present invention has been disclosed with reference to specific forms and embodiments, it will be evident that a great number of variations may be made without departing from the spirit and scope of the present invention. For example, steps may be reversed, equivalent elements may be substituted for those specifically disclosed and certain features of the present invention may be used independently of other features—all without departing from the present invention as defined in the appended claims. | An apparatus for cleaning the surface of a base, comprising: a base; a plurality of apertures flush with the surface of said base, said apertures being connected to a plurality of sub-channels and wherein said apertures are adapted to expel air; at least one air chamber operatively connected with said plurality of sub-channels; a main channel connected with said at least one air chamber; wherein said main channel is supplied from an air compressor; and a main valve located between said at least one air chamber and said main channel, wherein said main valve regulates the air flow from said main channel to said at least one air chamber, said valve being further adapted to close said main channel. | 1 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] U.S. Provisional Application for Patent No. 61/585,316, filed Jan. 11, 2012 which is hereby incorporated by reference. Applicant claim priority pursuant to 35 U.S.C. Par. 119(e)(i).
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a hydraulic drive circuit which solves the problem of drive slippage during steep slope operation of machinery driven by two or more hydraulic motors in a parallel circuit, such as, but not restricted to, road rollers and soil compactors.
[0005] 2. Brief Description of Prior Art
[0006] Prior art construction machines, such as but not restricted to road rollers and soil compactors, referring to FIGS. 1 , 2 and 3 , include a hydraulic drive circuit, designated as numeral 1 , with a variable displacement bi-directional hydraulic pump, 4 that is in hydraulic communication with, and drives a front fixed displacement motor 3 which is mechanically connected to, and drives, a front drive 6 , shown as a drum and a rear dual displacement hydraulic drive motor 2 , which is mechanically connected to, and drives, an axle, 5 and finally two wheels, 7 . The motors are in parallel hydraulic communication with each other and the propelling pump.
[0007] The prior art works quite well on level ground, and also when the front drive 6 is reading a machine such as, but not restricted to, a road roller or soil compactor when climbing a slope, as shown in FIG. 2 . However, when the front drive 6 is following the rear drive 5 , climbing a slope, as indicated in FIG. 3 , a road roller or soil compactor's weight distribution will shift from the rear drive 5 to the front drive 6 , lessening the weight carried by the rear drive 5 . Said another way, when operating on any slope there is a shift of the machines center of gravity towards the bottom of said slope. This effect is proportional and the degree to which it affects the travel function is directly related to the angle of the slope. As the motors 2 and 3 are in parallel communication, and there is less weight on the rear drive 5 , with a sufficiently steep slope 13 , the rear drive 5 overcomes the available traction, and slips. As the rear drive 5 slips, all hydraulic oil flows through the rear drive motor 2 . Hydraulic pressure in the drive circuit 1 is the regulated by friction between the wheels and the ground, which is insufficient pressure to actuate the front drive motor 2 , the road roller or soil compactor stalls on slopes 13 greater than 12 degrees.
[0008] The rear drive motor 2 is a two speed hydraulic motor, with dual displacements 9 and 11 preset at 25 or 75 cubic centimeters per revolution, respectively, depending on whether slow speed operation with more rear drive 5 torque for power is appropriate or whether a higher speed at less torque is desired.
[0009] The prior art front motor 3 is a fixed displacement hydraulic motor with a typical displacement of 25 cubic centimeters per revolution.
[0010] As is known in the prior art, a machine as described above will stall on slopes when travelling in reverse in the high speed setting (Rabbit) or slip at the tires if set in the high torque position (Turtle). To travel up a steep slope an operator must turn the machine around and drive in a forward direction. Under certain job conditions such as trench compaction this does not work as the drum must lead the roller down into the trench. A better way is required, in order to guarantee operations on relatively steep slopes in both forward and reverse travel.
[0011] As will be seen from the subsequent description, the preferred embodiment of the present invention improves the performance range of a bi-directional hydraulic drive system.
SUMMARY OF THE INVENTION
[0012] Briefly stated, the present invention is an improvement to a hydraulic drive circuit which broadens the effective performance range of the hydraulic drive circuit by using multiple two speed hydraulic motors in conjunction with a variable displacement bi-directional pump so as to compensate for drive member slippage occurring from weight distribution changes from sloped terrain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS. 1 , 2 , and 3 illustrate prior art hydraulic drive circuits as applied to a road roller.
[0014] FIGS. 4 and 5 illustrate a first embodiment of the present invention, a hydraulic drive circuit.
[0015] FIG. 6 illustrates a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] In accordance with the present invention, a hydraulic drive circuit for solving the problem of overcoming drive slippage in reverse operation of machinery is disclosed. More particularly, the described circuit improves the performance range of a hydraulic drive circuit by using multiple two speed hydraulic motors in conjunction with a variable displacement bi-directional pump. In the broadest context, the disclosed hydraulic drive circuit consists of components configured with respect to each other so as to obtain the desired objective.
[0017] The present invention is now exemplified by a particular embodiment which is illustrated in the accompanying drawings.
[0018] Referring to FIGS. 4 and 5 , in the preferred embodiment of the present invention, a hydraulic drive circuit 10 is disclosed. The hydraulic drive circuit 10 comprises a bi-directional hydraulic pump 40 that is in hydraulic communication with a front hydraulic motor 30 and a rear hydraulic motor 20 . The front hydraulic motor 30 is in parallel hydraulic communication with the rear hydraulic motor 20 .
[0019] In the specific illustration, the front motor 30 drives a front drive 60 , illustrated as a drum, which can be arranged, for instance, on the front of a road roller. The rear motor 20 drives a rear drive 50 illustrated as an axle 50 A with wheels 70 . However, as a generic case, the motors 20 , 30 could be driving either wheels or drums or both, depending on the function of a given driven vehicle (not shown). In this regard, the motors 20 , 30 are preferably constructed identically in order to drive either wheels or drums or both.
[0020] In one embodiment, the hydraulic motors, 20 , 30 , are two (2) speed hydraulic motors that are preset with two (2) displacements, allowing the choice of 25 cubic centimeters per revolution (“cc per rev”) or 75 cc per rev, depending on the operation direction of the vehicle.
[0021] As will be understood, the purpose of preferably having both the front and rear motors 30 , 20 , as two speed motors, is to compensate for weight shifts between the front and rear drive 60 and 50 , as the machine is driven up slopes 13 in forward or reverse.
Forward Travel
[0022] For operations where power performance at lower speed is desired, or forward travel up steep slopes, the front motor 30 is manually set at the lower displacement of 25 cc per rev and the displacement of the rear motor 20 is manually set at 75 cc per rev. This setting is named Turtle. This overcomes the significant shifting of the vehicle's weight distribution while operating on a slope in forward travel.
[0023] For higher speeds with less power, the motors 20 , 30 displacements are both manually set at 25 cc per rev. This setting is named Rabbit.
Reverse Travel
[0024] When there is a need for the vehicle to climb a slope in reverse, the invention allows the operator to select maximum displacement for the drum drive motor 30 at 75 cc per rev and the axle motor 20 to its minimum displacement of 25 cc per rev. This places maximum torque at the point of maximum friction and minimum torque at the point of minimum friction. This overcomes the significant shifting of the vehicle's weight distribution while operating on a slope in reverse travel.
[0025] The displacement shifts described are accomplished, with the two speed hydraulic motors 20 , 30 , with solenoid valve controls (not shown) that are manually operated for simple effective operation, and works very well for 8 ton and also 10 ton soil rollers. The solenoid valve sends controlled pressure to either the maximum or minimum displacement control piston (not shown) in each motor. In this embodiment, it takes 12 volts to engage minimum displacement, and the lack of 12 volts selects maximum displacement.
[0026] The solenoid valve controls can be manually operated by a dash mounted switch (not shown). The switch can be in the form of a switch/valve, which depending on preferred action as described, controls the sending of the 12 volts to the motors 20 , 30 in order to switch between Turtle, Rabbit and reverse slope operation.
[0027] If the vehicle, for instance a road roller, moves forward, the operator can manually set the displacement of the front and rear motors 30 , 20 , respectively, to the suitable control settings, namely, the Turtle setting or Rabbit setting. In the embodiment shown in FIG. 5 , the front motor 30 is assigned to the front drum of the road roller. Depending on the desired driving speed, the motors 20 , 30 are manually set at 25 cc per rev, for higher speeds with less power, or, the front motor 30 is set at the lower displacement of 25 cc per rev and the rear motor 20 is set at the higher displacement, 75 cc per rev, when a lower speed is desired or forward travel of steep slopes.
[0028] Because of this unequal distribution of the torques to the front drive 60 and rear drive 50 of the driven vehicle, during uphill motion, the drive which is relieved of load by the inclination of the plane is driven with less moment. For example, if a vehicle is moving up a hill, the leading drive tends to slip first. This tendency for slip to occur is counteracted by the reduction of the displacement on the front drive. The described distribution of the torques to the front and rear drive is carried out preventively irrespective of an actually occurring uphill motion, so that even in the case of a forward motion on level ground, the torque on the front drive can be reduced compared with the torque on the rear drive. The danger of errors in recognizing the driving situation is reduced by simply using the direction of motion as the basis.
[0029] In a change of direction of motion, the operator places the vehicle into the direction for backward motion (reverse). Corresponding to the change in direction of motion, the operator can set the displacements of the front and rear motors 30 , 20 into the reverse slope operation setting. In the reverse slope operation setting, the rear motor 30 is consequently set to the lower displacement, and the front motor 20 is set to the higher displacement.
[0030] In practice, three (3) alternatives are useful: (1) the front drive motor 30 is set at 25 cubic centimeters per revolution, and the rear drive motor 20 is set at 75 cubic centimeters per revolution which works well for level ground and slope work in forward travel; (2) the front drive motor 30 and also the rear drive motor 20 are each set at 25 cubic centimeters per revolution for a higher travel speed on level ground in forward and reverse; (3) the front drive motor 30 is set at 75 cubic centimeters per revolution and the rear drive motor 20 is set at 25 cubic centimeters per revolution which works well for both level ground operation and, most importantly, for reverse slope operation.
[0031] Referring to FIG. 6 , a second embodiment of a hydraulic circuit 10 ′ is disclosed. The hydraulic circuit 10 ′ comprises a bi-directional hydraulic pump 40 ′ that is in hydraulic communication with a front hydraulic motor 30 ′ and a rear hydraulic motor 20 ′. The front hydraulic motor 30 ′ is in parallel hydraulic communication with the rear hydraulic motor 20 ′. The front motor 30 ′ drives a front drive (not shown), and, the rear motor 20 ′ drives a rear drive (not shown). The motors 20 ′, 30 ′ are preferable constructed identically in order to drive either wheels or drums or both.
[0032] The hydraulic motors, 20 ′, 30 ′ are variable displacement motors for, as will be described, suitable control settings. For example, for operations where a power performance at lower speed is desired, or forward travel up steep slopes, the front motor 30 ′ is set at a lower displacement, such as 25 cc per rev, and the displacement of the rear motor 20 ′ is set at a higher displacement, such as 75 cc per rev. This overcomes the significant shifting of the vehicle's weight distribution while operating on a slope in forward travel.
[0033] On the other hand, when there is a need for the vehicle to climb a slope in reverse, the front motor 30 ′ is set at a higher displacement, such as 75 cc per rev, and the rear motor 20 ′ is set at a lower displacement, for example, 25 cc per rev. This places torque at the point of maximum friction and minimum torque at the point of minimum friction. This overcomes the significant shifting of the vehicle's weight distribution while operating on a slope in reverse travel.
[0034] The displacement shifts described are accomplished, with the variable displacement motors 20 ′, 30 ′, and includes a microprocessor 100 based controller 80 that is electrically disposed between a switch 85 and the motors 20 ′, 30 ′. The controller 80 receives various sensing signals and controls the displacement of the motors 20 ′, 30 ′. In particular the sensing signals include signals representing the rotational speed of the front and rear drives. For example, a first speed sensor or drum speed sensor produces a first signal in response to the rotational speed of the front drive. Similarly, a second speed sensor or wheel speed sensor produces a wheel speed signal in response to the rotational speed of the rear drive. The controller 80 receives the speed signals, can compare the speed signal magnitudes to each other to determine which set of the ground engaging traction devices are slipping, and decrease the displacement of the motor associated with the slipping ground engaging traction device to increase the torque associated with the motor associated with the non-slipping ground engaging traction device. Preferably, the microprocessor based controller 80 receives 12 volt signals from the switch 85 and converts to a digital signal. The controller 80 then sends a signal in milivolts to the motor, which sets and holds selective displacements. The controller 80 interface allows easy and infinite adjustment to both motors.
[0035] The microprocessor 100 can utilize arithmetic units to control various processes according to software programs. Typically, the programs are stored in read-only memory, random-access memory or the like.
[0036] If the vehicle, for instance a road roller, moves forward the controller 80 can set the displacement of the front and rear motors 30 ′, 20 ′, respectively, to the suitable control settings, namely, the Turtle setting or Rabbit setting. In the embodiment shown in FIG. 6 , the front motor 30 ′ is assigned to the front drum of the road roller. Depending on the desired driving speed, the motors 20 ′, 30 ′ are set for higher speeds with less power or, the front motor 30 ′ is set at the lower displacement of, for example 25 cc per rev, and the rear motor 20 ′ is set at the higher displacement of, for example, 75 cc per rev, when a lower speed is desired or forward travel of steep slopes.
[0037] In construction, efficiency is increased with the present invention by being able to drive up a relatively steep slope 13 in forward or reverse, as opposed to turning the machine around to drive up in forward.
[0038] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the preferred embodiments of the present invention.
[0039] For example, the specific machines enumerated were 8 ton and 10 ton soil rollers. However, the circuit has much broader applications than those two (2) specific models of soil rollers. The present circuit will work on many types of machines that have two (2) drives connected in a parallel circuit, especially machines that have problems during slope operations caused by the shifting of the vehicle's weight.
[0040] It will be obvious to those skilled in the art that modifications may be made to the embodiments of the invention described above without departing from the scope of the present invention. Thus the scope of the invention should be determined by the appended claims in the formal application and their legal equivalence, rather than by the examples given. | A hydraulic drive circuit using a variable displacement bi-directional pump with two (2) two speed motors enabling drive torque variation as required compensating for a changing load distribution on a machine encountering varying weight distributions at the two drives resulting from operating on slopes. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process control system for the simultaneous feeding of two separate gaseous and/or liquid fuels into a partial oxidation synthesis gas generator.
2. Description of the Prior Art
The partial oxidation process for the production of synthesis gas e.g., gaseous mixtures comprising H 2 and CO is well known. Single fuel streams are most commonly used in the partial oxidation process, such as one stream of oil or one stream of fuel gas. The simultaneous introduction of a stream of fuel gas and a separate oil stream or two separate gaseous or liquid streams into a partial oxidation gasifier can be difficult due to two phase flow problems from mixing gas and liquid streams or due to two fuel streams, either gaseous or liquid, that are substantially different so as to require separate feed processing and handling. Feeding fuel gas and liquid hydrocarbonaceous fuel to a gas generator is discussed further in coassigned U.S. Pat. Nos. 4,394,137 and 4,443,230.
It is difficult to maintain high on-stream time for the simultaneous gasification of dual fuel feeds, e.g., oil and/or gas. This is especially true when the supply reliability of one fuel source is less than desirable. With the conventional oxygen control methods should one fuel flow be lost, excess oxygen can enter the gasifier and will produce undesirable high gasifier temperatures and poor product gas quality e.g., synthesis gas, reducing gas, or fuel gas.
SUMMARY OF THE INVENTION
This process pertains to a means of maintaining high on-stream time for the simultaneous feeding of multiple gaseous and/or liquid streams and combinations thereof. For example, two parallel oxygen streams equipped with flow transmitters and control valves are used to supply oxygen for the two separate and different fuel streams. Each stream of oxygen is separately controlled by an O 2 /fuel ratio control so that if the flow rate of either stream of fuel changes the O 2 /fuel ratio of the remaining O 2 and fuel streams in the gasifier is maintained at a desired value. Further, if either fuel flow is stopped, its associated O 2 flow will stop, but the remaining fuel stream and its associated O 2 flow will continue to flow at the same rate. Complete shutdown of the unit is thereby avoided. The O/C atomic ratio of each fuel is separately controlled. Any excess oxygen that could flow to the gasifier in the event one of the fuel streams is lost, thereby quickly raising the reactor temperature to unsafe levels, is prevented by the subject invention.
BRIEF DESCRIPTION OF THE DRAWING
In order to illustrate the invention in greater detail, reference is made to a preferred embodiment as shown in the figure of the drawing wherein FIG. I is a schematic representation of the invention showing control means for the simultaneous feeding of a stream of gaseous fuel and a separate stream of liquid hydrocarbonaceous fuel to a free-flow partial oxidation gas generator.
DESCRIPTION OF THE INVENTION
The present invention pertains to a continuous process for the manufacture of gas mixtures comprising H 2 , CO, CO 2 , particulate carbon and at least one material selected from the group consisting of H 2 O, N 2 , A r , CH 4 , H 2 S, COS, and ash such as synthesis gas, fuel gas, and reducing gas, by the partial oxidation of a stream of gaseous fuel and a separate stream of liquid fuel in a conventional free-flow non-catalytic refractory lined partial oxidation gas generator.
The streams of gaseous fuel and liquid hydrocarbonaceous fuel are either mixed or separately introduced into the reaction zone of a conventional partial oxidation gas generator by way of a down-flowing burner which is inserted in the top of the gas generator. A separate stream of free-oxygen containing gas is also passed through the burner. The streams of fuel and free-oxygen-containing gas are mixed together at the burner tip. The partial oxidation reaction takes place downstream from the tip of the burner in the reaction zone of the partial oxidation gas generator at a temperature in the range of about 1800° F. to 3000° F., such as 2000° F.-2700° F., say 2400° F. -2600° F., and a pressure in the range of about 1 to 300 atmospheres. A temperature moderator may be mixed with the fuel streams and/or optionally with the free-oxygen containing gas upstream from the burner in order to maintain the reaction zone at the specified temperature.
The subject method for controlling the feed to a free-flow partial oxidation gas generator so as to maintain a high on-stream time, the desired operating temperature, and the composition of the raw effluent gas stream comprises the following steps as shown in the drawing:
(1) separately sensing each of the following feedstreams and providing separate signals corresponding to the flow rate for each of said feedstreams as follows: sensing the flow rate of the free-oxygen containing gas in line and providing signal a to O 2 /first fuel ratio control 5 and to flow control 6, sensing the flow-rate of the free-oxygen containing gas in line 2 and providing signal b to O 2 /second fuel ratio control 7 and to flow control 8, sensing the flow-rate of the second fuel in line 3 and providing signal c to O 2 /second fuel ratio control 7 and to flow control 11, sensing the flow rate of the first fuel in line 4 and providing signal d to O 2 / first fuel ratio control 5 and to flow control means 15; sensing the flow-rate of the temperature moderator in line 21 and providing signal m to flow control 23, comparing signal m in flow control 23 with a preset signal representing the desired flow rate for the stream of temperature moderator in line 26 and providing an adjustment signal n to control valve 24 in line 25; and sensing the flow rate of the temperature moderator in line 31 and providing signal o to flow control 33, comparing signal o in flow control 33 with a preset signal representing the desired flow rate for the stream of temperature moderator in line 36 and providing an adjustment signal p to control valve 34 in line 35;
(2) dividing oxygen signal a by first fuel signal d in ratio control 5 to produce internal signal r representing the actual O 2 /first fuel wt. ratio, comparing signal r in ratio control 5 with a preset signal s representing the desired O 2 /first fuel wt. ratio, and producing an adjustment signal e for oxygen controller 6 which in turn produces an adjustment signal f for oxygen control valve 9 in line 1;
(3) dividing oxygen signal b by second fuel signal c in ratio control 7 to produce internal signal t representing the actual O 2 /second fuel wt. ratio, comparing signal t in ratio control 7 with a preset signal u representing the desired O 2 /second fuel wt. ratio, and producing an adjustment signal g for oxygen controller 8 which in turn produces an adjustment signal h for oxygen control valve 10 in line 2;
(4) combining together the free-oxygen gas streams passing through lines and 2, and passing the combined streams of free-oxygen containing gas through lines 51-56 and into the reaction zone of said gas generator;
(5) comparing second fuel signal c in flow control 11 with preset signal v representing the desired flow rate of the second fuel in line 3, and producing an adjustment signal i for second fuel control valve 12 in line 3, and passing the stream of second fuel into the reaction zone of said gas generator;
(6) comparing first fuel signal d in flow controller 15 with preset signal j representing the desired flow rate of first fuel in line 4, and producing an adjustment signal k for first fuel flow rate control means in line 4, and passing the stream of first fuel into the reaction zone of said gas generator; and
(7) mixing the stream of temperature moderator from line 36 with the stream of free-oxygen containing gas from line 55, and introducing the mixture into the reaction zone of said generator, and/or mixing the stream of temperature moderator from line 26 with the stream of second fuel from line 19 and introducing the mixture into the reaction zone of said gas generator.
The term gaseous fuel or gaseous hydrocarbonaceous material as used herein to describe suitable gaseous fuels is intended to include a gaseous feedstock from the group consisting of natural gas, methane, ethane, propane, butane, pentane, hexane and dehydrogenated compounds thereof, off-gas from delayed coking, refinery off-gas, off-gas from catalytic cracking, fuel gas produced by the partial oxidation of carbon-containing fuels such as by the subject process, and mixtures thereof.
The term liquid fuel as used herein to describe suitable liquid carriers and fuels is intended to include various pumpable liquid hydrocarbon and/or liquid hydrocarbonaceous materials, such as those selected from the group consisting of liquefied petroleum gas, petroleum distillates and residues, gasoline, naphtha, kerosine, crude petroleum, gas oil, residual oil, tar sand oil, shale oil, coal derived oil, aromatic hydrocarbons (such as benzene, toluene, xylene fractions), coal tar, cycle gas oil from fluid-catalytic-cracking operation, furfural extract of coker gas oil, and mixtures thereof.
The term liquid hydrocarbonaceous material as used herein to describe suitable pumpable liquid fuels is also intended to include various oxygen-containing liquid hydrocarbonaceous organic materials, such as those selected from the group consisting of carbohydrates, cellulosic materials, aldehydes, organic acids, alcohols, ketones, oxygenated fuel, oil, waste liquids and by-products from chemical processes for producing oxygenated hydrocarbonaceous organic materials, and mixtures thereof.
The term liquid hydrocarbonaceous fuel as used herein to describe suitable liquid fuels is also intended to include pumpable slurries of solid carbonaceous fuels in a liquid carrier. In another embodiment, the liquid hydrocarbonaceous fuel comprises a pumpable mixture of coal-water slurry and sanitary sewage and said mixture has a solids content in the range of about 40 to 70 wt percent. In still another embodiment, the liquid hydrocarbonaceous fuel comprises a mixture of waste oil and dewatered sanitary sewage having a heating value of at least 6000 BTU per pound.
The term liquid carrier as used herein as the suspending medium to produce pumpable slurries of solid carbonaceous fuels is intended to include various materials from the group consisting of water, liquid hydrocarbonaceous material, and mixtures thereof. However, water is the preferred carrier for the particles of solid carbonaceous fuel. In one embodiment, the liquid carrier is liquid carbon dioxide. In such case, the liquid slurry may comprise 40-70 wt % of solid carbonaceous fuel and the remainder is liquid CO 2 . The CO 2 -solid fuel slurry may be introduced into the burner at a temperature in the range of about -67° F. to 100° F. depending on the pressure.
For example, one embodiment, the feedstream comprises a slurry of liquid hydrocarbonaceous material and solid carbonaceous fuel. H 2 O in liquid phase may be mixed with the liquid hydrocarbonaceous carrier, for example as an emulsion. A portion of the H 2 O i.e., about 0 to 25 weight % of the total amount of H 2 O present may be introduced as steam in admixture with the free-oxygen containing gas. The weight ratio of H 2 O/fuel in the reaction zone may be in the range of about 0 to 5, say about 0.1 to 3.
The term solid carbonaceous fuels, as used herein to describe suitable solid carbonaceous feedstocks, is intended to include various materials and mixtures thereof from the group consisting of coal, coke from coal, char from coal, coal liquefaction residues, petroleum coke, particulate carbon soot, and solids derived from oil shale, tar sands, and pitch. All types of coal may be used including anthracite, bituminous, sub-bituminous, and lignite. The particulate carbon may be that which is obtained as a by-product of the subject partial oxidation process, or that which is obtained by burning fossil fuels. The term solid carbonaceous fuel also includes by definition bits of garbage, dewatered sanitary sewage sludge, semi-solid organic materials such as asphalt, rubber, and rubber-like materials including rubber automobile tires which may be ground or pulverized to the proper particle size. Any suitable grinding system may be used to convert the solid carbonaceous fuels or mixtures thereof to the proper size. The solid carbonaceous fuels are preferably ground to a particle size so that 100% of the material passes through an ASTM E 11-70 Sieve Designation Standard 1.4 mm (Alternative No. 14) and at least 80% passes through an ASTM E 11-70 Sieve Designation Standard 425 um (Alternative No. 40). The moisture content of the solid carbonaceous fuel particles is in the range of about 0 to 40 wt. % such as 2 to 20 wt. %.
H 2 O in liquid or gaseous phase, is preferably introduced into the reaction zone to help control the reaction temperature, to act as a dispersant of the hydrocarbonaceous fuel fed to the reaction zone, to entrain or slurry the solid carbonaceous fuel, and to serve as a reactant to increase the relative amount of hydrogen produced. Other suitable temperature moderators include CO 2 -rich gas, a cooled portion of effluent gas from the gas generator, cooled off-gas from an integrated ore-reduction zone, nitrogen, and mixtures thereof. The temperature moderator is introduced into the gas generator to maintain the temperature of the reaction zone in the range of about 1800° F. to 3000° F. The temperature moderator may be introduced into the gasifier in admixture with the free-oxygen containing gas stream and/or the stream of gaseous fuel and/or the stream of liquid fuel.
The free-oxygen containing gas may be selected from the group consisting of air, oxygen-enriched air (22 mole percent O 2 and preferably substantially pure oxygen (95 mole percent O 2 and higher). The amount of nitrogen in the product gas may be substantially reduced or eliminated by using substantially pure oxygen. In the reaction zone, the ratio of the atoms of free-oxygen to atoms of carbon in the gaseous and/or liquid hydrocarbonaceous feed is in the range of about 0.85 to 1.5. Alternatively, this ratio may be expressed as about 0.85 to 1.5 atoms of oxygen per atom of carbon.
Conventional burners for use with the partial oxidation gasifier are suitable for the subject process. For example, reference is made to the two, three and four stream annular-type burners in coassigned U.S. Pat. Nos. 3,874,592, 3,847,564 and 4,525,175 respectively, which are incorporated herein by reference.
In one embodiment, the gaseous and/or liquid fuels optionally in admixture with the temperature moderator, are introduced into the synthesis gas generator by way of the same or separate conduits of a conventional annular-type synthesis gas burner. The free-oxygen containing gas, optionally in admixture with the temperature moderator is introduced into the gas generator by way of a separate passage in said burner.
For example, the gaseous fuel, optionally in admixture with the temperature moderator, is introduced into the gas generator by way of the central conduit of a three stream annular-type synthesis gas burner comprising a central conduit and inner and outer coaxial concentric annular free-flow passages, such as shown and described in coassigned U.S. Pat. No. 3,847,564. The liquid hydrocarbonaceous fuel is introduced into said gas generator by way of the inner annular passage in said burner. The free-oxygen containing gas, optionally in admixture with the temperature moderator, is introduced into the gas generator by way of the outer annular passage of said burner.
In another embodiment, the gaseous and liquid fuels are mixed together and introduced into said gas generator by way of one passage of an annular-type synthesis gas burner comprising a central conduit and a coaxial concentric annular passage, such as shown and described in coassigned U.S. Pat. No. 3,874,592. Simultaneously, a combined stream of temperature moderator and free-oxygen containing gas is passed into said gas generator by way of the other passage of said burner. In still another embodiment, the liquid hydrocarbonaceous fuel comprises an aqueous slurry of sanitary sewage sludge and a separate stream of oil and/or coal. Said aqueous slurry of sanitary sewage sludge is introduced into the reaction zone by way of one passage in a multi-passage annular-type synthesis gas burner while said stream of oil and/or coal is introduced into said gas generator by way of another passage of said burner. In a further embodiment, the liquid hydrocarbonaceous fuel comprises a pumpable mixture of coal-water slurry and sanitary sewage, and said mixture has a solids content in the range of about 40 to 70 weight percent. The liquid hydrocarbonaceous fuel may also comprise a mixture of waste oil and coal.
In one further embodiment, the gaseous fuel is introduced into the partial oxidation gas generator by way of the central passage of an annular-type synthesis gas burner comprising a central passage and a coaxial concentric annular passage. Simultaneously, a combined stream of free-oxygen containing gas and temperature moderator is introduced into said gas generator by way of said annular passage. By means of a 4-stream annular-type burner, such as described in coassigned U.S. Pat. No. 4,525,175, two separate streams of free-oxygen containing gas, optionally in admixture with a temperature moderator e.g. H 2 O, may be passed respectively through the central and outer passages of said burner. Further, two separate fuel streams selected from the groups consisting of gaseous fuel, liquid hydrocarbonaceous fuel, and mixtures thereof may be simultaneously passed through the two separate annular passages in said burner located between the central and outer oxygen streams.
DESCRIPTION OF THE DRAWING
A more complete understanding of the invention may be had by reference to the accompanying schematic drawing which shows the subject invention in detail. Although the drawing illustrates a preferred embodiment of the invention, it is not intended to limit the subject invention to the particular apparatus or materials described.
Referring to the drawing, FIG. I is a schematic representation of one embodiment of the invention showing control means for the continuous operation of a synthesis gas generator while maintaining the desired composition of the product gas by adjustments to the flow rates of one or more of the reactant streams. Thus, by the subject flow control system, the flow rates for all of the reactant streams are separately and independently controlled so that the free-oxygen to fuel weight ratios in the reaction zone are maintained at design conditions and within desired operating ranges for the fuels being reacted.
While the control system shown in FIG. I is specifically designed for the combination of feedstocks comprising a gaseous fuel and a liquid hydrocarbonaceous fuel, by simple modifications to the means for changing the flow rates of the fuel streams as described below, the system may be used to control other combinations of solid carbonaceous fuel slurries, liquid hydrocarbonaceous fuels, and gaseous fuels.
In FIG. I, burner 100 is mounted in central flanged inlet 102, which is located in the upper head of conventional refractory lined free-flow synthesis gas generator 105 along the central longitudinal axis. The reactant streams enter through the upstream end of burner 100, pass downward therethrough, and are discharged through downstream end 106. Burner 100 is designed so that the required system output for steady-state operation may be achieved or even exceeded by a specified amount when the flow rate through all passages is a maximum. The control system can independently change the flow rate of any one or more of the feedstreams in lines 1 to 4, 26 and 56. By this means (1) the weight ratio of free-oxygen to fuel in the reaction zone is maintained at desired conditions, (2) the composition of the product gas remains substantially unchanged, and (3) the temperature in the reaction zone 107 is maintained at the desired operating temperature.
Operation of the process and control system shown in FIG. I follows. For purposes of illustration, the principal fuels may be for example a pumpable liquid hydrocarbonaceous fuel e.g., petroleum oil from line 4, and a gaseous fuel e.g. natural gas in line 3. Of course, the principal fuels may be any gaseous fuels, liquid hydrocarbon or liquid hydrocarbonaceous fuels, and combinations thereof, as previously described.
The free-oxygen containing gas in line 50 is split into a first stream which passes through line 1 and a second stream which passes through line 2. The two streams of free-oxygen containing gas are then combined in line 51. The combined free-oxygen containing gas stream is introduced into gas generator 105 by way of lines 51 to 56 and burner 100.
The flow rate of free-oxygen containing gas in line 1 is measured and signal a is provided to free O 2 /liquid hydrocarbonaceous fuel ratio control 5 by flow transmitter 60. Signal a corresponds to the actual flow rate of the free-oxygen containing gas in line 1. A liquid hydrocarbonaceous fuel feed e.g. oil is pumped through line 4 by means of a conventional positive displacement metering pump 13 equipped with speed control 14. The actual flow rate of the liquid hydrocarbonaceous fuel in line 4 is measured and signal d is provided by flow transmitter 68. Signals a and d are simultaneously introduced into free-oxygen/liquid fuel ratio control 5. Signal a is divided by signal d in ratio control 5, thereby providing internal signal r. Signal d is simultaneously introduced into flow recorder-controller 15 where it is compared with a preset signal j representing the desired or theoretical flow rate for the liquid hydrocarbonaceous fuel. Adjustment signal k is provided to increase or decrease speed control means 14 by a specific amount so that the liquid hydrocarbonaceous fuel in line 4 assumes the desired flow rate. For example, liquid hydrocarbonaceous fuel may be pumped through line 4 by variable - speed pump 13. In an embodiment wherein a gaseous fuel is passed through line 4, pump 13 may be replaced by a gas compressor.
Ratio controller 5 includes a microcomputer means which receives and divides signals a and d to produce internal signal r representing the actual free O 2 /fuel weight ratio (basis liquid hydrocarbonaceous fuel). Signal r is then compared with a signal s representing the theoretical or set point O 2 /fuel weight ratio. A corresponding adjustment signal e is then provided to flow comptroller 6 which in turn provides signal f to open or close valve 9 a specific amount so that the free-oxygen containing gas in line 1 assumes the desired flow rate for the setpoint O 2 /oil wt. ratio (basis liquid hydrocarbonaceous fuel). The new free-oxygen containing gas rate is measured and the cycle is repeated. By this means, repeated adjustments to the rate of oxygen flow are made and the free-oxygen containing gas flowing in line 1 is phased into line 51 in an amount that will maintain the required O 2 / oil weight ratio (basis liquid hydrocarbonaceous fuel) in the reaction zone.
When the rate of oil flow in line 4 changes, then the actual O 2 /oil wt. ratio (basis liquid hydrocarbonaceous fuel) changes in an inverse manner and a corresponding signal r is produced. As previously described, adjustment signal e is produced and sent to flow controller 6 which in turn provides signal f to close or open valve 9 in oxygen-containing gas line 1 a sufficient amount so that the O/C atomic ratio (basis liquid hydrocarbonaceous fuel) in gasifier 100 remains substantially constant. For example, when the rate of oil e.g. gallons per hour through line 4 decreases, the free O 2 /oil wt. ratio increases. An adjustment signal is sent to close valve 9 a specified amount so that the desired Oz/oil wt. ratio (basis liquid hydrocarbonaceous fuel is maintained. If the flow of oil in line 4 stops, then oxygen control valve 9 is completely closed to shut off the supply of oxygen from line which is associated with the supply of liquid hydrocarbonaceous fuel from line 4.
Similarly, with respect to the gaseous fuel feed from a compressor (not shown) in line 3, the flow rate of free-oxygen containing gas in line 2 is simultaneously measured and a signal b is provided to O 2 /gas ratio control 7 by flow transmitter 65. Signal b corresponds to the actual flow rate of the free-oxygen containing gas in line 2. In addition to signal b, signal c provided by flow transmitter 67 upon measuring the flow rate of the gaseous fuel feed e.g., natural gas in line 3 is introduced into O 2 /gas ratio control 7. Signal b is divided by signal c in ratio control 7 to provide internal signal t. Ratio controller 7 includes a microcomputer means which receives and divides signals b and c to produce internal signal t representing the actual free O 2 /gas wt. ratio (basis gaseous fuel). Signal t is then compared in ratio control 7 with signal u representing the theoretical or setpoint O 2 /gas weight ratio. A corresponding adjustment signal g is then provided to flow recorder-controller 8 which in turn provides signal h to open or close valve 10 a specific amount, so that the free-oxygen containing gas in line 2 assumes the desired flow rate for the desired free O 2 /gas wt. ratio. The new free-oxygen containing gas rate is measured and the cycle is repeated. By this means repeated adjustments to the rate of oxygen flow are made and the free-oxygen containing gas flowing in line 2 is phased into line 51 in an amount that will maintain the actual O/C atomic ratio (basis gaseous fuel) in the reaction zone at design conditions.
In the embodiment wherein the gaseous fuel in line 3 is replaced by a liquid hydrocarbonaceous fuel, than a variable-speed pumping means, such as described previously e.g., 13 and 14 may be used to introduce the fuel in line 3 into the gas generator.
In one embodiment, a portion of a temperature moderator, for example steam in line 36 is mixed with the free-oxygen gas in line 55 and passed through inlet 115 and outer annular passage 116 of burner 100. Optionally, steam in line 26 may be mixed with the gaseous fuel in line 19 and simultaneously passed through central conduit 101 of burner 100. Simultaneously, the stream of liquid hydrocarbonaceous fuel is passed through intermediate annular passage 117 of burner 100.
Control of the temperature moderator is effected by sensing the flow rate of the temperature moderator in line 21 and providing signal m to flow controller 23 by means of flow transmitter 22, comparing signal m in flow control 23 with a preset signal representing the desired flow rate for the stream of temperature moderator in line 26, and providing an adjustment signal n to control valve 24 in line 25 to open or close valve 24 a specific amount so that the temperature moderator in line 26 assumes the desired flow rate for the desired temperature in the reaction zone and H 2 O/fuel wt. ratio. Similarly, the flow rate of the temperature moderator in line 31 is sensed by flow transmitter 32, and signal o is provided to flow controller 33. Signal o is compared in flow controller 33 with a preset signal representing the desired flow rate for the stream of temperature moderator in line 36, and adjustment signal p is provided to control valve 34 in line 35 to open or close valve 34 a specific amount so that the temperature moderator in line 36 assumes the desired flow rate for the desired temperature in the reaction zone and H 2 O/fuel wt ratio. For example, if the temperature moderator is H 2 O, from about 0 to 20 wt. % of the H 2 O, e.g. 20 wt. % may be mixed with the gaseous fuel in line 19 and the remainder of the H 2 O, such as about 20 to 100 wt. % e.g. 80 wt. % may be mixed with the free-oxygen containing gas in line 56.
The preset setpoint signals in O 2 /oil ratio control 5, O 2 /gas ratio control 7, and in the flow controls are determined by conventional calculations based on heat and weight balances for the entire system.
In one embodiment, the oxygen line is provided with an isolation system which uses a high pressure nitrogen barrier to prevent undesirable oxygen flows and undesirable reactor gas flows during the sequential gasifier startup procedure, during a planned manual gasifier shutdown, and during an emergency automatic gasifier shutdown. In FIG. 1, the oxygen line is provided with an isolation safety system which will become active and shutoff all of the oxygen flow in the process when the oxygen flow rate in the main line to the system is lost or falls below a preset shutdown flow value. Thus, the rate of flow of the oxygen feed in main line 50 is determined by flow transmitter 40. A signal representing the rate of oxygen flow in line 50 is sent to a safety signal means Safety System (SS) 41. When the rate of oxygen flow is to low, signals are provided by the safety system 41 to close oxygen flow valves 9 and 10, close oxygen block valves 45 and 46, and activate high pressure nitrogen barrier 47. By this means undesirable oxygen forward flow into the gasifier or vent, and undesirable reactor gas reverse flow into the oxygen lines or vent are prevented. Optionally in FIG. 1, during a manual and/or automatic gasifier shutdown, safety circuit 41 keeps oxygen vent valve 44 closed, closes oxygen flow valves 9 and 10, closes oxygen block valve 46, and activates a high pressure nitrogen purge which passes nitrogen through lines 48, 54, 55 and 56 for 30 to 60 seconds to prevent combustion in burner oxygen passage 116. After which, oxygen block valve 45 is closed to prevent undesirable oxygen and reactor gas flows.
In still another embodiment, the gaseous fuel line is provided with the isolation system which uses a high pressure nitrogen barrier to prevent undesirable reactor gas back flows during intended operation without gaseous fuel, during a planned manual gasifier shutdown, and during an emergency automatic gasifier shutdown.
Accordingly, to assure safe operation in the event the gaseous fuel flow is lost or falls below a preset value, a nitrogen pocket is used to prevent back flow to the fuel line that was lost. For example, if the gaseous fuel stream in line 3 is intentionally stopped or unintentionally lost or falls below a preset value, a signal from gas flow transmitter 67 representing the actual flowrate for the gaseous fuel is compared in said signal means 41 with a preset signal representing the desired gaseous fuel flowrate, and responsive thereto signals are provided for the closing of valves 70 and 71 and the filling of lines 72-73 connecting said valves with nitrogen 74. The associated O 2 flow will stop but the unit will not shutdown since the gasifier is provided with fuel from the other fuel feedstream e.g., liquid hydrocarbonaceous fuel from line 4.
If the flow of liquid hydrocarbonaceous fuel in line 4 is stopped, a signal from safety system 41 will result in stopping pump 13, closing valve 14 and keeping valve 76 closed to avoid depressuring any oil in the line to storage. Nitrogen 77 may be passed through line 78, inlet 103 of burner 100, and intermediate annular passage 117 to purge the burner and the lines from residual oil and thereby prevent coking.
Although modifications and variations of the invention may be made without departing from the spirit and scope thereof, only such limitations should be imposed as are indicated in the appended claims. | This process pertains to a achieving high on-stream time and maintaining the temperature and composition of the raw effluent gas stream from a partial oxidation gas generator being fed simultaneously with a stream of gaseous fuel and separate stream of liquid hydrocarbonaceous fuel. Two parallel oxygen streams equipped with flow transmitters and control valves are used to supply the oxygen associated with two separate and different fuel streams. Each stream of oxygen is controlled by an O 2 /fuel ratio control so that if the flow rate of either stream of fuel or its related oxygen stream changes, the oxygen/carbon atomic ratio of the remaining O 2 and fuel stream in the gasifier is maintained at a desired value. Further, if either fuel flow is stopped, its associated O 2 flow will stop, but the remaining fuel stream and its associated O 2 stream will continue to flow at the same rate with no change in the oxygen/fuel weight ratio. Complete shut down of the unit is thereby avoided. The quick raising of reactor temperatures to unsafe levels due to excess oxygen that occurs when one of the fuel streams is lost is thereby prevented. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2010-021531, filed on Feb. 2, 2010, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a steering column device incorporating a steering shaft capable of a tilt operation and a telescopic operation of a steering wheel.
2. Description of the Related Art
Some of steering wheels of automobiles are each capable of a tilt operation and a telescopic operation to respectively adjust the vertical position and the anteroposterior position of the steering wheel according to a driver's physical constitution. The vertical position and the anteroposterior position of the steering wheel thus adjusted are fixed by a supporting device with which a steering column for housing a steering shaft is supported onto a vehicle body side.
This supporting device includes a vehicle-body-side bracket having a fixed longitudinal wall portion disposed at a right or left side of the steering column, and a movable longitudinal wall portion provided on an outer tube to be movable relative to the fixed longitudinal wall portion in directions of a tilt operation and a telescopic operation. When an operation lever is operated, a clamping force generated by a clamp shaft brings the fixed longitudinal wall portion and the movable longitudinal wall into pressure contact with each other, and thereby the steering column is fixed. The fixation of the steering column is discontinued by releasing the pressure contact.
In other words, when the steering column is fixed by using the supporting device, relative movement of the fixed longitudinal wall portion and the movable longitudinal wall portion is prevented by friction resistance caused by the pressure contact of both of the wall portions. Here, it is difficult to ensure flat surfaces of both of the fixed longitudinal wall portion and the movable longitudinal wall portion because members of these two wall portions may be distorted. For this reason, the two wall portions may contact each other at unintended regions. If the two wall portions contact each other in the unintended regions, contact between the fixed longitudinal wall portion and the movable longitudinal wall portion is unstable. Such unstable contact has a risk of obtaining insufficient support stiffness. Moreover, resonance frequencies may vary among the vehicle body, the steering wheel and other components located therebetween. In this case, without obtaining a desired resonance frequency, the steering wheel may vibrate by resonating with the vehicle body during idling.
In this regard, Japanese Unexamined Patent Application Publication No. 2007-223383 proposes a supporting device in which upper and lower protrusions each extending in an axial direction of a steering column are formed on an outer side surface of a movable longitudinal wall portion to contact with a fixed longitudinal wall portion, and in which the movable longitudinal wall portion and the fixed longitudinal wall portion are brought into stable pressure contact with each other by use of the upper and lower protrusions.
SUMMARY OF THE INVENTION
In the steering column device disclosed in Japanese Unexamined Patent Application Publication No. 2007-223383, the upper and lower protrusions of the movable longitudinal wall portion are proactively brought into contact with the fixed longitudinal wall portion. However, the pressure contact in the axial direction of the steering column highly depends on flatness of the upper and lower protrusions in the axial direction and on planarity of the fixed longitudinal wall portion. For this reason, the pressure contact in the axial direction of the steering column is largely influenced by dimensional dispersion at the formation or material distortions of the upper and lower protrusions and the fixed longitudinal wall portion. Accordingly, insufficient support stiffness may be obtained when the contact between the fixed longitudinal wall portion and the movable longitudinal wall portion is unstable. Or, the resonance frequency may vary depending on a position of a telescopic operation, and thereby the steering wheel may vibrate by resonating with vibration of the vehicle body.
An object of the present invention is to provide a steering column device which is capable of achieving stable fixation when performing a clamping operation of an operation lever.
An aspect of the present invention is a steering column device comprising: a bracket including a fixed portion to be fixed to a vehicle body and a first wall extending downward from the fixed portion; a steering shaft having an upper end in an axial directional of the steering shaft for fixing a steering wheel; a steering column including one end supported by the vehicle body and an outer peripheral surface with a second wall, and configured to rotatably support the steering shaft inside the steering column; a clamp shaft penetrating the first wall, the clamp shaft being configured to switch between a pressure contact state where the first wall and the second wall are in pressure contact with each other and a non-pressure contact state where the first wall and the second wall are not in pressure contact with each other; a pair of first protrusions disposed on any one of the first wall and the second wall separately on both sides of the clamp shaft in a first direction parallel to an axial direction of the steering column, the pair of first protrusions extending in a second direction perpendicular to the axial direction of the steering column; and a pair of second protrusions disposed on the other one of the first wall and the second wall separately in the second direction and extending in the first direction, wherein each of the first protrusions contacts both of the second protrusions in the pressure contact state.
According to this aspect, the paired first protrusions being separately disposed in the first direction parallel to the axial direction of the steering column and extending in the second direction (the vertical direction relative to the vehicle body) perpendicular to the axial direction of the steering column are provided on any one of the first wall portion on the vehicle-body-side bracket and the second wall portion provided on the lower jacket. Meanwhile, the paired second protrusions being separately disposed in the second direction (the vertical direction relative to the vehicle body) and extending in the first direction are provided on the other one of the first wall portion and the second wall portion. Then, each of the paired first protrusions is proactively brought into contact with both of the second protrusions. This configuration always brings the first wall portion into stable contact with the second wall portion at the four contact portions on four corners, and thereby more reliably fixes the first wall portion to the second wall portion. In this way, it is possible to obtain sufficient support stiffness of the steering column and to achieve stable fixation.
Moreover, improvement in resonance frequency and elimination of variation in resonance frequency by enhancing the support stiffness makes it possible to prevent the steering wheel from resonating with vibration of the vehicle body.
The first wall may have a first elongated hole formed between the pair of first protrusions along a direction of tilt movement of the steering shaft, part of the clamp shaft may be located in the first elongated hole, and the clamp shaft may be adapted to move inside the first elongated hole in the non-pressure contact state.
According to this configuration, the first wall portion to the second wall portion can be more reliably fixed even when the tilt position adjustment mechanism is provided. Hence it is possible to obtain sufficient support stiffness of the steering column and to achieve stable fixation.
The steering column may comprise: an upper jacket configured to rotatably support the steering shaft inside a cylindrical inner portion of the upper jacket and including a second elongated hole formed along a direction of telescopic movement of the steering shaft; and a lower jacket configured to slidably support the upper jacket in the direction of telescopic movement of the steering shaft and to rotatably support the steering shaft together with the upper jacket, part of the clamp shaft may be located in the second elongated hole, the clamp shaft may be configured to penetrate the first wall and the second wall, adapted to move inside the second elongated hole in the non-pressure contact state, and configured to bring the first wall, the second wall, and the upper jacket into pressure contact with one another in the pressure contact state.
According to this configuration, the first wall portion and the second wall portion can be fixed to the upper jacket more reliably even when the telescopic position adjustment mechanism is provided. Hence it is possible to obtain sufficient support stiffness of the steering column and to achieve stable fixation.
The steering column device may comprise two contact portions out of four contact portions where the pair of first protrusions and the pair of second protrusions are in contact with each other in the pressure contact state, the two contact portions being located on a line parallel to an axial center line of the steering column while passing through an axial center of the clamp shaft.
According to this configuration, it is possible to achieve the effect similar to the above-described aspect.
The clamp shaft may be located at a center of four contact portions where the pair of first protrusions and the pair of second protrusions are in contact with each other in the pressure contact state.
According to this configuration, the clamp shaft is located in the center of the four contact portions. Hence it is possible to apply a clamping force from the clamp shaft substantially evenly to the respective contact portions and thereby to fix the steering column more stably.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a steering column device according to a first embodiment of the present invention.
FIG. 2 is a side view of the steering column device according to the first embodiment of the present invention.
FIG. 3 is a cross-sectional view taken along the line in FIG. 2 .
FIG. 4 is a plan view of a steering column device according to a second embodiment of the present invention.
FIG. 5 is a side view of the steering column device according to the second embodiment of the present invention.
FIG. 6 is a cross-sectional view taken along the IV-IV line in FIG. 5 .
FIG. 7 is a plan view of a steering column device according to a third embodiment of the present invention.
FIG. 8 is a side view of the steering column device according to the third embodiment of the present invention.
FIG. 9 is a cross-sectional view taken along the IX-IX line in FIG. 8 .
FIG. 10 is a plan view of a steering column device according to a fourth embodiment of the present invention.
FIG. 11 is a side view of the steering column device according to the fourth embodiment of the present invention.
FIG. 12 is a cross-sectional view taken along the XII-XII line in FIG. 11 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
Now, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
First Embodiment
As shown in FIG. 1 to FIG. 3 , a steering column device 1 of a first embodiment is configured to support a steering column 3 on a vehicle body side. Here, the steering column 3 houses a steering shaft 2 capable of performing a tilt operation and a telescopic operation of an unillustrated steering wheel. The steering column 3 includes a lower jacket 31 and an upper jacket 32 which are engaged with each other so as to be mutually movable in an axial direction. Overlapping portions of both of these jackets 31 and 32 are supported on the vehicle body side by a vehicle-body-side bracket 4 .
The steering column device 1 generally includes the vehicle-body-side bracket 4 , the steering column 3 (the lower jacket 31 and the upper jacket 32 ), and a clamp bolt 7 , and is a cantilever type in which a fixed longitudinal wall portion (a first wall portion) 41 and a movable longitudinal wall portion (a second wall portion) 33 are provided on one side of the steering column 3 .
The vehicle-body-side bracket 4 includes the fixed longitudinal wall portion 41 located on a left side, in a vehicle width direction, of the above-described overlapping portion of the steering column 3 , and a vertically elongated hole (a first elongated hole) 41 h formed on the fixed longitudinal wall portion in a direction of a tilt operation (movement) which is substantially equivalent to a vertical direction relative to a vehicle body. An upper side plate 42 serving as a fixing portion and having a T-shaped cross section is fixed to an upper end of the fixed longitudinal wall portion 41 , whereby the vehicle-body-side bracket 4 is fixed to an unillustrated steering member located on the vehicle body side through fixation holes 43 provided on both ends, in the vehicle width direction, of the upper side plate 42 by use of bolts and the like.
In the lower jacket 31 , a vehicle body support portion 31 a illustrated on a right end in the drawing is supported by the vehicle body so as to be swingable in the direction of the tilt operation. The lower jacket 31 includes the movable longitudinal wall portion 33 which is movable in the direction of the tilt operation relative to the above-described fixed longitudinal wall portion 41 and which is configured to rotatably bear the steering shaft 2 inside a cylindrical inner portion. In the lower jacket 31 , a support plate 34 having a U-shaped cross section and being configured to cover almost half of a circumference of the upper jacket 32 of the steering column 3 is integrally provided on both of upper and lower ends of the movable longitudinal wall portion 33 .
The upper jacket 32 is slidably inserted from a left end in the drawing of the lower jacket 31 into the cylindrical inner portion in a direction of a telescopic operation and is configured to rotatably bear the steering shaft 2 in cooperation with the lower jacket 31 . The upper jacket 32 is also provided with an anteroposteriorly elongated hole (a second elongated hole) 32 h located in a region opposed to the vertically elongated hole 41 h and in the direction of the telescopic operation (an axial direction of the steering column 3 and the steering shaft 2 ).
The clamp bolt 7 functions as a clamp shaft, which is inserted to the fixed longitudinal wall portion 41 , the movable longitudinal wall portion 33 , and the anteroposteriorly elongated hole 32 h and is provided with an operation lever 6 on one end. The clamp bolt 7 is inserted to the vertically elongated hole 41 h and the anteroposteriorly elongated hole 32 h while penetrating a bolt hole 31 h provided on the movable longitudinal wall portion 33 . A flange 71 to be locked on an inner side of the movable longitudinal wall portion 33 is formed on an end of the clamp bolt 7 close to the steering column 3 (on the right side in FIG. 3 ). On the other hand, an opposite end (on the left side in FIG. 3 ) of the clamp bolt 7 protruding from the fixed longitudinal wall portion 41 is inserted to a cam portion 8 and the operation lever 6 in this order. These constituents are clamped and fixed by use of a nut 72 .
The operation lever 6 is engaged in a noncircular fashion with a movable cam member 82 included in the cam portion 8 penetrated by the clamp bolt 7 and is integrally rotated in a direction of rotation thereof. The cam portion 8 includes a fixed cam member 81 prevented from relative rotation with respect to the vertically elongated hole 41 h and the bolt hole 31 h , and the movable cam member 82 to be rotated by operating the operation lever 6 . A cam main body which is configured to increase or decrease a dimension between both of the cam members 81 and 82 by rotating operation of the operating lever 6 either in a clamping direction or an unclamping direction, i.e., positive or negative rotation of the movable cam member 82 , is formed on opposed surfaces of the fixed cam member 81 and the movable cam member 82 . Specifically, the dimension between both of the cam members 81 and 82 of the cam portion 8 is increased in a clamped state shown in FIG. 1 to FIG. 3 . Meanwhile, the dimension between both of the cam members 81 and 82 is decreased in the unclamped state by performing the rotating operation of the operation lever 6 from the clamped state in an unclamping direction which is equivalent to a clockwise direction in FIG. 2 .
Therefore, by operating the operation lever 6 in the clamping direction, a clamping force is applied to the clamp bolt 7 so as to press the upper jacket 32 and the movable longitudinal wall portion 33 of the lower jacket 31 between the flange 71 and the fixed longitudinal wall portion 41 , thereby fixing the lower jacket 31 to the vehicle-body-side bracket 4 . When performing the unclamping operation of the operation lever 6 , the clamp bolt 7 moves inside the vertically elongated hole 41 h together with the steering column 3 . Hence it is possible to perform vertical tilting (the tilt operation) of the steering column 3 . Moreover, as the anteroposteriorly elongated hole 32 h of the upper jacket 32 moves relative to the clamp bolt 7 , the lower jacket 31 and the upper jacket 32 relatively move in the axial direction while changing an axial length of the steering shaft 2 . Hence it is possible to perform adjustment of a length in the axial direction (the telescopic operation) of the steering column 3 .
Here, in this embodiment, one of the fixed longitudinal wall portion 41 and the movable longitudinal wall portion 33 , i.e., the fixed longitudinal wall portion 41 is provided with paired vertical protrusion (first protrusions) 10 and 11 being disposed separately in the axial direction (the direction of the telescopic operation) of the steering column 3 and extending in the direction of the tilt operation (the vertical direction in FIG. 1 ). The other wall portion, i.e., the movable longitudinal wall portion 33 is provided with paired anteroposterior protrusion (second protrusions) 12 and 13 being disposed separately in the direction of the tilt operation and extending in the axial direction (the direction of the telescopic operation) of the steering column 3 .
In this embodiment, the anteroposterior protrusion 12 is disposed on a center line C 1 passing through the center of the clamp bolt 7 and extending in the axial direction of the steering column 3 . The anteroposterior protrusion 13 is located in a position at a lower end of the movable vertical wall portion 33 , i.e., a position to which the anteroposterior protrusion 12 is shifted downward in a direction perpendicular to the center line C 1 .
The vertical protrusions 10 and 11 and the anteroposterior protrusions 12 and 13 are formed such that each of the vertical protrusions 10 and 11 contacts the anteroposterior protrusions 12 and 13 within a range of the tilt operation and within a range of the telescopic operation.
Specifically, the vertical protrusions 10 and 11 are extended to contact the anteroposterior protrusion 12 and the anteroposterior protrusion 13 , no matter where the clamp bolt 7 is located in a range from an upper end to a lower end of the vertically elongated hole 41 h . Moreover, the anteroposterior protrusions 12 and 13 are extended to contact the vertical protrusion 10 and the vertical protrusion 11 , no matter where the clamp bolt 7 is located in a range from a front end to a rear end of the anteroposteriorly elongated hole 32 h . Accordingly, the fixed longitudinal wall portion 41 can contact the movable longitudinal wall portion 33 at four contact portions 14 located on four corners no matter where the steering wheel is fixed within a range covered by the tilt operation and the telescopic operation.
According to the above-described embodiment, the paired vertical protrusions 10 and 11 being separately disposed in the direction of the telescopic operation and extending in the direction of the tilt operation are provided on the fixed longitudinal wall portion 41 out of the fixed longitudinal wall portion 41 of the vehicle-body-side bracket 4 and the movable longitudinal wall portion 33 provided on the steering column 3 . Meanwhile, the paired anteroposterior protrusions 12 and 13 being separately disposed in the direction of the tilt operation and extending in the direction of the telescopic operation are provided on the movable longitudinal wall portion 33 . Moreover, the paired vertical protrusions 10 and 11 are brought into contact with the paired anteroposterior protrusions 12 and 13 within the range of the tilt operation and within the range of the telescopic operation. As a consequence, the fixed longitudinal wall portion 41 stably contacts the movable longitudinal wall portion 33 at the contact portions 14 located in four positions. Hence it is possible to more reliably fix the fixed longitudinal wall portion 41 to the movable longitudinal wall portion 33 .
In this way, it is possible to obtain sufficient support stiffness and to fix the steering column 3 stably when the steering wheel is operated in the direction of the tilt operation or in the direction of the telescopic operation. Moreover, it is also possible to improve and stabilize the resonance frequency to prevent the steering wheel from resonating with vibration of the vehicle body.
Second Embodiment
FIG. 4 to FIG. 6 show a steering column device 1 A according to a second embodiment of the present invention. In the drawings, the same constituents as those in the first embodiment are designated with the same reference numerals and duplicate description will be omitted herein.
As shown in FIG. 4 to FIG. 6 , a key difference of the steering column device 1 A of this embodiment from the steering column device 1 of the first embodiment is that the position of formation of the anteroposterior protrusion 12 is shifted to an upper end of the movable longitudinal wall portion 33 located above the center line C 1 passing through the center of the clamp bolt 7 .
Specifically, in this embodiment, the paired vertical protrusions 10 and 11 being separately disposed in the axial direction (the direction of the telescopic operation) of the steering column 3 while interposing the clamp bolt 7 therebetween and extending in the direction of the tilt operation (the vertical direction in FIG. 5 ) are provided on the fixed longitudinal wall portion 41 out of the fixed longitudinal wall portion 41 and the movable longitudinal wall portion. Meanwhile, the paired anteroposterior protrusions 12 and 13 being separately disposed in the direction of the tilt operation while interposing the clamp bolt 7 therebetween and extending in the axial direction (the direction of the telescopic operation) of the steering column 3 are provided on the movable longitudinal wall portion 33 . Hence the clamp bolt 7 is located in the center of the contact portions 14 in four positions on the fixed longitudinal wall portion 41 and the movable longitudinal wall portion 33 .
This embodiment can also exert similar effects to the first embodiment.
According to this embodiment, since the clamp bolt 7 is located in the center of the contact portions 14 in the four positions, it is possible to apply the clamping force from the clamp bolt 7 substantially evenly to the respective contact portions 14 . Hence it is possible to obtain sufficient support stiffness of the steering column 3 , to achieve more stable fixation, to improve and to further stabilize the resonance frequency upon resonance of the steering wheel with the vehicle body, and to suppress the resonance of the steering wheel.
Third Embodiment
FIG. 7 to FIG. 9 show a steering column device 1 B according to a third embodiment of the present invention. In the drawings, the same constituents as those in the first embodiment are designated with the same reference numerals and duplicate description will be omitted herein.
As shown in FIG. 7 to FIG. 9 , a key difference of the steering column device 1 B of this embodiment from the steering column device 1 of the first embodiment is that fixed longitudinal wall portions 41 A and 41 B and movable longitudinal wall portions 33 A and 33 B are respectively provided on both of right and left sides of the steering column 3 so as to establish a both-end support type.
Specifically, in this embodiment, the vehicle-body-side bracket 4 is substantially formed by disposing the fixed longitudinal wall portions 41 A and 41 B respectively on both of the right and left sides of the steering column 3 , and fixing the upper side plate 42 having an inverted U-shaped cross section to upper ends of both of the fixed longitudinal wall portions 41 A and 41 B. Further, as similar to the first embodiment, the vehicle-body-side bracket 4 is fixed to the steering member through the fixation holes 43 provided on both ends in the vehicle width direction of the upper side plate 42 by use of bolts and the like.
The movable longitudinal wall portions 33 A and 33 B formed on the lower jacket 31 are disposed on inner surfaces of the fixed longitudinal wall portions 41 A and 41 B, respectively. The upper jacket 32 is slidably supported by the upper jacket 32 .
The vertically elongated holes 41 h are formed respectively on the right and left fixed longitudinal wall portions 41 A and 41 B. Moreover, the anteroposteriorly elongated holes 32 h are formed respectively on the right and left movable longitudinal wall portions 33 A and 33 B. Here, paired right and left clamp bolts 7 A and 7 B are provided. The clamp bolt 7 A is inserted to the vertically elongated hole 41 h and the anteroposteriorly elongated hole 32 h provided on the fixed longitudinal wall portion 41 A and the movable longitudinal wall portion 33 A on the left side. Meanwhile, the clamp bolt 7 B is inserted to the vertically elongated hole 41 h and the anteroposteriorly elongated hole 32 h provided on the fixed longitudinal wall portion 41 B and the movable longitudinal wall portion 33 B on the right side.
Each of the right and left clamp bolts 7 A and 7 B is provided with the cam portion 8 which includes the fixed cam member 81 and the movable cam member 82 . Moreover, the operation lever 6 is provided with fitting portions 6 A and 6 B in a fork shape which are disposed outside the fixed longitudinal wall portions 41 A and 41 B. The fitting portion 6 A is engaged with one of the movable cam members 82 in the noncircular fashion, while the fitting portion 6 B is engaged with the other movable cam member 82 in the noncircular fashion. Hence both of the clamp bolts 7 A and 7 B are configured to generate clamping forces at the same time through the cam portions 8 by operating the operation lever 6 .
Paired vertical protrusions 10 and 11 being separately disposed in the axial direction (the direction of the telescopic operation) of the steering column 3 and extending in the direction of the tilt operation (the vertical direction in FIG. 7 ) are provided on each of the right and left fixed longitudinal wall portions 41 A and 41 B. Meanwhile, paired anteroposterior protrusions 12 and 13 being separately disposed in the direction of the tilt operation and extending in the axial direction (the direction of the telescopic operation) of the steering column 3 are provided on each of the right and left movable longitudinal wall portions 33 A and 33 B.
At this time, as similar to the first embodiment, the anteroposterior protrusion 12 is disposed on the center line C 1 passing through the centers of the clamp bolts 7 A and 7 B and extending in the axial direction of the steering column 3 , and the anteroposterior protrusion 13 is located in a position equivalent to a position where the anteroposterior protrusion 12 moves downward in a perpendicular direction relative to the center line C 1 .
The clamp bolts 7 A and 7 B cannot move in the axial direction in the clamped state due to the upper jacket 32 . Accordingly, the fixed longitudinal wall portions 41 A and 41 B are bent so as to come close to each other and establish pressure contact with the movable longitudinal wall portions 33 A and 33 B. Furthermore, the movable longitudinal wall portions 33 A and 33 B are bent inward so as to establish pressure contact with the upper jacket 32 , thereby preventing relative movement.
This embodiment can also exert similar effects to the first embodiment.
Since this embodiment applies the both-end support type by providing the fixed longitudinal wall portions 41 A and 41 B and the movable longitudinal wall portions 33 A and 33 B respectively on both of right and left sides of the steering column 3 . Accordingly, it is possible to further enhance support stiffness of the steering column 3 and thereby to improve and further stabilize the resonance frequency.
Fourth Embodiment
FIG. 10 to FIG. 12 show a steering column device 1 C according to a fourth embodiment of the present invention. In the drawings, the same constituents as those in the third embodiment are designated with the same reference numerals and duplicate description will be omitted herein.
As shown in FIG. 10 to FIG. 12 , a key difference of the steering column device 1 C of this embodiment from the steering column device 1 B of the third embodiment is that, similarly to the second embodiment, the position of formation of the anteroposterior protrusion 12 is shifted to an upper end of the movable longitudinal wall portion 33 A and 33 B located above the center line C 1 passing through the center of the clamp bolt 7 A and 7 B and the clamp bolts 7 A and 7 B are located in the center of the contact portions 14 located in four positions.
This embodiment can also exert similar effects to the third embodiment.
According to this embodiment, since the clamp bolts 7 A and 7 B are located in the center of the contact portions 14 located in four positions, it is possible to apply clamping forces from the clamp bolts 7 A and 7 B substantially evenly to the contact portions 14 . Hence it is possible to obtain sufficient support stiffness of the steering column 3 , to achieve more stable fixation, and to improve and to further stabilize the resonance frequency upon resonance of the steering wheel with the vehicle body.
Although the steering column device of the present invention has been described based on the first to fourth embodiments as examples, it is to be noted that the present invention is not limited only to these embodiments and various other embodiments may also be applicable without departing from the scope of the present invention.
For example, the first to fourth embodiments are applied to the steering column device provided with both of a function to adjust a tilt position and a function to adjust a telescopic position. However, the present invention is also applicable to a steering column device which adopts any of the function to adjust the tilt position, the function to adjust the telescopic position, and none of these functions by forming any one of or both of the vertically elongated hole and the anteroposteriorly elongated hole into a round hole. In this case as well, it is possible to achieve similar operations and effects to any of the embodiments. | A steering column device includes: a bracket to be fixed to a vehicle body and including a first wall; a steering shaft; a steering column including one end supported by the vehicle body and an outer peripheral surface with a second wall, and configured to rotatably support the steering shaft; and a clamp shaft penetrating the first wall and configured to switch between a pressure and non-pressure contact states respectively where the first and second walls are and are not in pressure contact with each other. The first and second walls include: a pair of first protrusions disposed separately on both sides of the clamp shaft in a first direction parallel to an axial direction of the steering column, and extending in a second direction perpendicular to the axial direction of the steering column; and a pair of second protrusions disposed separately in the second direction and extending in the first direction. Each of the first protrusions contacts both of the second protrusions in the pressure contact state. | 1 |
This application is a continuation of application Ser. No. 815,853, filed Jan. 3, 1986, now abandonded.
FIELD OF THE INVENTION
The present invention relates, in general, to a buffer and article injector mechanism suitable for use in an automated article handler. More particularly, the invention relates to an input buffer and injector mechanism adapted for use in a high-throughput integrated circuit handler.
BACKGROUND OF THE INVENTION
A function commonly required in an automated article handling system is that of a buffer. More precisely, it is commonly necessary to provide a buffering function between two article handling operations which proceed at different paces.
An example of such a buffering function occurs when one article handling function produces intermittent outputs consisting of a plurality of articles while the next handling function requires a relatively steady input of single articles. Obviously, a buffering function together with a capability of inputting single parts to the second operation is required.
An automated integrated circuit handling apparatus may require the buffering and input functions described above. The basic unit of input to such an apparatus is a sleeve containing many individual integrated circuits. If the sleeve handling and unloading operations are automated, the apparatus must be capable of accepting intermittent inputs of a number of integrated circuits simultaneously. Since the testing or marking function which such an apparatus serves is oriented to single units and typically requires a steady input, a buffering and input function is necessary.
In an automated integrated circuit handling apparatus, the primary concerns are throughput, direct labor costs and reliability. The effect of even minor improvements in throughput and the amount of manual labor involved in a final test operation, for instance, can be dramatic when compared with the total manufacturing cost of each integrated circuit.
In some cases, such as surface-mountable integrated circuits, a handling apparatus must also be designed to fastidiously avoid changing the position of the metal leads of the devices. When combined with the requirement of high throughput, or rapid movement of parts from one point to another, this places rather severe constraints on the buffer apparatus.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved buffer apparatus for use in an automated article handling apparatus.
A further object of the present invention is to provide an improved article buffer/injector for use in a high throughput automated article handler.
Yet a further object of the present invention is to provide an improved buffer/injector apparatus suitable for use in a high throughput integrated circuit handler.
Still a further object of the present invention is to provide a high speed integrated circuit buffer/injector apparatus which is capable of handling surface-mountable integrated circuits without damage to the leads thereof.
These and other objects and advantages of the present invention are provided by an article buffer/injector apparatus comprising a buffer track on which articles are carried and on which the articles slide. A continuous, smooth belt provides impetus to move the articles from an input end of the track toward an injector end thereof. An injector wheel at the injector end of the track engages individual articles from the track and rapidly injects articles, one at a time, into the subsequent handling apparatus. A particular embodiment comprises an integrated circuit buffer/injector apparatus capable of throughput rates greater than approximately 60,000 parts per hour and capable of handling surface-mountable integrated circuits without lead damage.
These and other objects and advantages of the present invention will be apparent to one skilled in the art from the detailed description below taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a small outline integrated circuit (SOIC) part, a sleeve for holding a plurality of such parts and an end cap for such a sleeve according to one aspect of the present invention.
FIGS. 2A, 2B and 2C are front, top and end views, respectively, of a high speed integrated circuit handler according to the principles of the present invention.
FIGS. 3A, 3B, 3C, and 3D are top, side and two detail views, respectively, of an automated integrated circuit sleeve handler according to one aspect of the present invention.
FIGS. 4A and 4B are a cross-sectional view and an end view, respectively, of a pusher mechanism according to one aspect of the present invention for use at the sleeve unloader station of the sleeve handler of FIGS. 3A-3D.
FIGS. 5A and 5B are end and cross-sectional views, respectively, of an input buffer track and pocket loader mechanism according to one aspect of the present invention.
FIGS. 6A, 6B, 6C and 6D are top, side and two detail views, respectively, of a continuous belt and pocket transport arrangement according to one aspect of the present invention.
FIGS. 7A and 7B are top and cross-sectional views, respectively, of a pocket unloader mechanism according to one aspect of the present invention.
FIGS. 8A, 8B, 8C and 8D are top, end, cross-sectional and detail views, respectively, of an output buffer track according to one aspect of the present invention.
FIG. 9 is a schematic diagram of an electrical control structure of the high speed integrated circuit handler according to the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates, in perspective, a typical integrated circuit 10 and sleeve 13 herefore and an end cap 15 for the sleeve according to one aspect of the present invention. The ensuring description of the present invention will refer to the type of IC package illustrated here, which is referred to as a small outline integrated circuit (SOIC). Of course, many different packages exist and would be equally well suited to handling with the concepts discussed with obvious modifications thereto. Part 10 generally comprises a body 12 and a plurality of leads 11 extending therefrom. In the case of an SOIC package as illustrated, leads 11 extend below the bottom of body 12 and are formed so as to end parallel to a surface to which they will be mounted, such as a circuit board. To provide reliable, automated mounting of such components, the tolerance of the lead placements must be extremely small, which requires that no malformation of the leads occur during handling of the parts at final test.
Sleeve 13 generally comprises an elongated hollow tube of plastic having a generally A-shaped cross-section, as shown. In addition, a hole 14 in the upper surface of sleeve 13 a short distance from the end thereof acts to engage a catch on end cap 15. In the case of SOIC's, sleeve 13 is approximately 19 inches long and holds either 47 or 96 parts, depending on the number of leads, or the overall length, of each part.
End cap 15 comprises a body 16 which is dimensioned to fit within sleeve 13, an end flange 17 which fits over the end of sleeve 13, a catch 18 protruding from the upper side of body 16 which engages hole 14 in sleeve 13 to retain end cap 15 therein and a passage 19 extending through end flange 17 and body 16. Passage 19 is dimensioned to allow passage of a pusher mechanism therethrough to contact the SOIC's within sleeve 13, but not to allow the SOIC's to escape. The end of passage 19 at end flange 17 is preferrably chamfered, as shown, to ease insertion of the pusher mechanism (see FIGS. 4A and 4B). In addition to the catch arrangement shown, other arrangements, such as friction fit, may be used to secure end cap 15 within sleeve 13.
FIGS. 2A-2C illustrate, in front, top and side views, respectively, a high speed integrated circuit handler according to the principles of the present invention. Because of the complexity of the handler, some details are omitted from FIGS. 2A-2C, but are shown in later FIGS.. The major portions of the handler are an automated sleeve handler apparatus 23, a sleeve unloader apparatus 24, an input buffer track 25, a pocket loading apparatus 26, a continuous belt transport system 27 with associated drive motor 28, a test area 29, a pocket unloader mechanism 30, a plurality of output buffer tracks 31 with associated sleeve loading stations 32 in sleeve handler 23 and output bins 33.
The operation of the illustrated integrated circuit handler is begun by the manual loading of a relatively large number of sleeves containing untested parts into input hopper portion 34 of sleeve handler 23. The sleeves must all be aligned with their long axes parallel, but no further manual alignment is required. Sleeve handler 23 singulates the sleeves, uniformly orients them and presents each sleeve at a sleeve unloader station 35. Sleeve unloader 24 then operates to push the parts out of the sleeve and onto input buffer track 25. The empty sleeves are moved to buffer portion 36 of sleeve handler 23 to wait until needed at sleeve loading stations 32.
Once on input buffer track 25, the parts are moved toward pocket loader mechanism 26. Continuous belt transport system 27 carries a plurality of pockets (not shown) which are each adapted to hold exactly one part. As transport 27 is indexed to bring an empty pocket in alignment with pocket loader mechanism 26, the latter is operated to inject one part from input buffer track 25 into the empty pocket. As transport 27 is further advanced, each pocket, now carrying a part, is brought into test area 29, wherein a test head (not shown) including test leads (also not shown) makes electrical contact to the leads of the part. As contact is made, transport 27 is halted for a period of time sufficient for an external test system to perform electrical tests on the part and assign the part to one of the up to six output categories.
Transport system 27 is further advanced, with a part being tested at each stop. Eventually, each pocket reaches pocket unloader mechanism 30. When the pocket bearing a particular part is aligned with the correct one of the six output buffer tracks 31, pocket unloader mechanism 30 is operated to eject that part from the pocket onto the output buffer track. The system controlling the handler keeps a count of the number of parts which have been assigned to each output category in order that an empty sleeve in buffer portion 36 of sleeve handler may be positioned in alignment with sleeve loading stations 32 in anticipation of a particular output buffer track being full. In fact, each output buffer track is long enough to hold slightly more than one sleeve-full of parts so that parts may continue to be loaded onto a track while other parts are being unloaded therefrom into an empty sleeve.
When one of output buffer tracks 31 contains a sleeve-full of parts and an empty sleeve has been aligned with that track at sleeve loading station 32, the track is operated to slide the parts into the sleeve. During subsequent movements of sleeve handler 23, this full sleeve is eventually brought into alignment with the output bin 33 which is appropriate for the parts in that sleeve. A "trapdoor" mechanism (not shown) is then operated to drop the sleeve into the bin for manual removal by an operator.
The entire system just described is designed to provide a throughput of approximately 60,000 parts per hour, or one part every 60 milliseconds. A test time of approximately 30 milliseconds per part is assumed. Thus, the handler must be capable of indexing from one part to the next at the test head in approximately 30 milliseconds. As is apparent, this figure of merit can be carried through the entire handler to calculate the throughput rate of any portion thereof. In no case is any previously known handler capable of achieving the desired throughput rates.
As will be apparent to one skilled in the art, many details have been omitted from the functional description above. Most of these will be discussed in detail below. Some, such as the detailed structure and operation of the electrical test apparatus, are beyond the scope of the present invention.
Referring now to FIGS. 3A-3D, sleeve handler 23 is described in detail. The sides of sleeve handler 23 are defined by a pair of parallel side walls 44 which are spaced so that a sleeve just fits lengthwise between them. This is because sleeves loaded into handler 23 will have only one end cap, with the other end being open to allow removal and reloading of parts. Walls 44 serve to hold the parts in the sleeves during handling.
The structure and function of sleeve handler 23 is most easily understood as comprising five major functional units or portions. An input hopper portion 34 serves to receive a plurality of sleeves, singulate them and present partially oriented single sleeves to the next portion. An orientation and sleeve unloading portion 48 receives single, partially oriented sleeves from input hopper portion 34, uniformly orients the sleeves and presents them to an unloading station 35. After the parts are ejected from the sleeve by sleeve unloader 24, the empty sleeves are passed to an empty sleeve buffer portion 36. When the handler system controller anticipates the need for an empty sleeve at one of the six sleeve loading stations 32, an empty sleeve is passed from buffer portion 36 to a sleeve loading portion 50. Sleeve loading portion 50 presents the sleeve in alignment with the appropriate output buffer track (not shown) for loading. Subsequently, the filled sleeves are passed to a sleeve binning portion 51 for output into an appropriate bin.
Input hopper portion 34 of sleeve handler 23 comprises a first hopper wall 45 and a second hopper wall 46 which extend between sleeve handler walls 44 and define the input hopper. That is, sleeves are loaded into the handler between hopper walls 45 and 46. The bottom of the input hopper is defined by a main input belt 53 having a plurality of paddles 55 thereon and a first alignment belt 54 having a plurality of paddles 56 thereon. Both belts 53 and 54 are continuous, preferably molded belts which are carried on pulleys which, in turn, are fixed to axles extending between sleeve handler walls 44. For reasons discussed below, paddles 55 and 56 have a relatively complex cross-section and may, therefore, be somewhat expensive to acquire. It may be preferrable to mold or machine the paddles separate from the belts and affix them by means of clips or the like. Main input belt 53 is carried on pulleys fixed to a first axle 58, a second axle 60, a third axle 61 and a fourth axle 62. First alignment belt 54 is carried on pulleys fixed to first axle 58 and second axle 60. As is apparent, the relative placement of paddles 55 and 56 may be adjusted by adjustment of the appropriate pulleys on axles 58 and 60. Both main input belt 53 and first alignment belt 54 are driven by a first motor 59 which drives first axle 58.
As is most clearly apparent from FIG. 3A, main input belt 53 is actually a pair of belts with wide paddles extending therebetween. As is also apparent, alignment belt 54 is, in fact, two belts which lie between the outside edges of main input belt 53 and walls 44. Between first axle 58 and second axle 60, main input belt 53 and alignment belts 54 are substantially parallel along the bottom of the input hopper.
Referring to the detailed view of FIG. 3C, the structure and function of belt 53 and 54 are described. In the cross-section of this figure, belts 53 and 54 appear coincident. In addition, paddles 55 on belt 53 and paddles 56 on belt 54 are seen to be aligned in order to define a space 57. Space 57 is defined at its back edge by the front of a main belt paddle 55, at its bottom side by belts 53 and 54 and at its front edge by the back of an alignment belt paddle 56. The shape of space 57 thus defined is chosen so that a sleeve must be in one of two orientations about its longitudinal axis in order to fall into space 57. In both orientations, the sleeve may be described as lying on its side against belts 53 and 54. The two orientations are related by a 180 degree rotation about the longitudinal axis. In addition, space 57 is defined so that only one sleeve may reside therein. Thus, the function of belts 53 and 54 is to singulate the sleeves and to partially orient them.
As sleeves are carried toward the upper end of input hopper portion 34, belts 53 and 54 pass immediately under a pair of rollers 63 and 64. Roller 64, which is driven by a second motor 68 and extends between sleeve handler walls 44 immediately under input hopper wall 46, serves to ensure that no sleeves are carried out of the input hopper atop paddles 55 and 56 by knocking any such sleeves back into the input hopper. Roller 64, which is also driven by second motor 68 through gears attached to roller 63, extends just far enough inside sleeve handler wall 44 to engage the ends of passing sleeves and contacts sleeves in the region subsequent to second axle 60. In this region, the sleeves are no longer confined in the restrictive space 57 and may be manipulated. Roller 64 does just this by knocking the sleeves down so that they rest flat on main input belt 53 between paddles 55. Once again, there are two possible orientations which the sleeves may take which are related by a 180 degree rotation about the long axis.
By the time the sleeves have been carried past rollers 63 and 64, they have passed under input hopper wall 46 and are within orientation and unloading portion 48 of sleeve handler 23. An orientation apparatus 64 is mounted in one side wall 44 in order to engage the end of each sleeve. Orientation apparatus 65 is positioned to engage the sleeves while they are being carried only by main input belt 53, the paddles 55 of which are so spaced as to allow rotation of sleeves carried therebetween.
FIG. 3D is a detailed cross-sectional view of orientation apparatus 65 taken along the line 3D of FIG. 3A. Apparatus 65 is basically a slotted rod which is adapted to receive the end of each sleeve therein as it passes the location of apparatus 65. Immediately preceding apparatus 65 is a sensor 67 attached to handler wall 44, which determines which of the two possible orientations each sleeve is in. In the embodiment illustrated, sensor 67 comprises a switch having an acutator button 69. When a sleeve is upside-down, as illustrated, button 69 falls into the space between the legs of the "A" and switch 67 is not actuated. In the other orientation, button 69 will be depressed by the top of the sleeve and actuate switch 67. If the sleeve is in the orientation illustrated in FIG. 3D, th slotted rod is rotated 180 degrees by means of third motor 66 (FIG. 3B). Since the end of the sleeve is within the slot, this also rotates the entire sleeve. Obviously, if the sleeve is already in the proper orientation, orientation apparatus 65 is not operated. Thus, sleeves leaving the location of orientation apparatus 65 are uniformly oriented.
As the sleeves are advanced further by movement of main input belt 543, their ends are engaged by a second pair of alignment belts 70 with paddles 71. Second alignment belts 70 are carried on pulleys fixed to third axle 61 and fourth axle 62 and run between the edges of main input belt 53 and walls 44. Because the space between paddles 55 of main input belt 53 must be great enough to allow orientation of the sleeves therein, the position of those sleeves is not sufficiently precise to allow reliable positioning at unloading station 35. Therefore, paddles 71 perform the function of engaging the rear edge of each sleeve and forcing the front edge thereof against the trailing edge of a paddle 55 on main input belt 53. This action determines the position of the sleeve with sufficient accuracy to allow reliable unloading.
When each sleeve has advanced to the position indicated by reference numeral 35, which is referred to as the sleeve unloading station, unloader mechanisms 24 (not shown in FIG. 3B) is operated to push the parts out of the sleeve. A wall 86 (not shown in FIG. 3A) extends over the sleeves once they are past orientation apparatus 65 and extends to output portion 51 to improve alignment and stability of the sleeves. This is described in detail below with reference to FIGS. 4A and 4B.
As main input belt 53 and second alignment belt 70 are advanced further, each sleeve is moved past unloading station 35 until its ends are supported by a pair of buffer belts 72. Buffer belts 72 are carried by pulleys which are carried by fourth axle 62, a fifth axle 73 and a sixth axle 74. The buffer belt pulleys which are carried by fourth axle 62 and fifth axle 73 are not fixed thereto, but turn freely thereon. The buffer belt pulley which is carried by sixth axle 74 is fixed thereto. Buffer belts 72 run immediately adjacent to walls 44. Sixth pulley 74 is driven by a fourth motor 75.
Buffer belts 72, which comprise empty sleeve buffer portion 36 of sleeve handler 23, are smooth in order that empty sleeves may slide thereon. A stop mechanism 76 located near the end of buffer belts 72 which is furthest removed from unloading station 35 serves to prevent empty sleeves from exiting buffer portion 36 until they are needed at a sleeve loading station 32. In the illustrated embodiment, stop mechanism 76 comprises a simple rocker arm arrangement which operates similarly to the anchor lever of a watch escapement mechanism. Stop mechanism 76 is preferably solenoid-driven. Of course, many modifications to this arrangement are possible. As will be apparent to one skilled in the art, buffer portion 36 need not be particularly large, since the rate of use of empty sleeves will be steady after an initial period during which the handler fills with parts. In the preferred embodiment, buffer portion 36 will hold approximately 10 sleeves.
The system controller, which maintains a count of the number of parts being assigned to each of the six output categories, is able to anticipate which output buffer track 31 (FIG. 2B) will be the next to need unloading. When such a need is anticipated, stop mechanism 76 is operated to release one empty sleeve from buffer belts 72.
When an empty sleeve is so released, the motion of buffer belts 72 moves it into position to be engaged by a pair of main output belts 77 having paddles 78 and a pair of output alignment belts 79 having paddles 80. Each sleeve is held between a paddle 78 of belt 77 and a paddle 80 of belt 79. As before, the purpose of the double belt arrangement is to provide adequate alignment of the sleeves, in this case so that they are properly aligned with the output buffer tracks for loading. Main output belts 77 are carried on pulleys fixed to fifth axle 73, a seventh axle 81, a ninth axle 84 and a tenth axle 85. Seventh axle 81 is driven by a fifth motor 82. Output alignment belts 79 are carried by pulleys fixed to fifth axle 73, seventh axle 81 and an eighth axle 83.
An alternate method of operation is to maintain an empty sleeve in alignment with the first sleeve loading station (the one closest to buffer belts 72. Typically, this station would be used for binning whatever category of parts is expected to receive the most parts. This scheme would reduce the amount of time necessary to index an empty sleeve into position to be filled.
As main output belts 77 and output alignment belts 79 pass over seventh axis 81, output alignment belts 79 separate and the sleevs are held only loosely between paddles 78 of main output belt 77. At this point, wall 86, which extends between sleeve handler walls 44, retains the sleeves against main output belts 77. As main output belts 77 pass over ninth axle 84, they pass into sleeve binning portion 51 of sleeve handler 23.
Sleeve binning portion 51 comprises up to six output bins 33, a retaining ridge 87, up to six doors 88 in retaining ridge 87 and up to six door actuators 89 associated therewith. Retaining ridge 87 runs along the inside of sleeve handler wall 44 and serves to maintain the full sleeves against main output belt 77 until the sleeve is over the appropriate bin 33. At this point, the appropriate door actuator 89 is triggered to open its associated door 88 and thus drop the sleeve bin 33 for removal by the operator.
A plurality of belt tensioners 90 are appropriately distributed throughout sleeve handler 23 for maintenance of tension on the various belts therein.
Referring now to FIGS. 4A and 4B, the structure and operation of sleeve unloader mechanism 24 is described in detail. A first tape guide 94 extends between sleeve handler walls 44 several inches below sleeve unloading station 35. First guide 94 is a hollow housing adapted to retain therein a metal tape 98. Tape 98 is preferably very similar in design and construction to the steel tape used in a household retractable tape measure. In fact, just such a tape has been used successfully. In this example, the leading end of tape 98 (the end which contacts the parts) was approximately doubled in thickness to improve the contact between the tape and the parts and to prevent the tape from "overriding" the parts.
Mounted on first guide 94 are a first tape sensor 95 and a second tape sensor 96. Each sensor is preferably a simple light source and sensor disposed on opposite sides of guide 94 so that tape 98 interrupts the light between the source and the sensor. In this manner, the position of tape 98 can be sensed.
Immediately adjacent the end of first guide 94 and outside sleeve handler wall 44 is a tape drive mechanism comprising a tape drive wheel 97, a drive motor 99 coupled thereto to rotate wheel 97, a first idler wheel 101 and a second idler wheel 102. Tape 98 passes out of first guide 94 and approximately 180 degrees around drive wheel 97. Idler wheels 101 and 102 serve to maintain tape 98 in close contact with drive wheel 97. By appropriate operation of drive motor 99, tape 98 can be very rapidly moved into and out of a sleeve positioned at sleeve unloading station 35.
In its normal, or unextended, position, tape 98 continues past drive wheel 97 and into a second guide 100, but stops just short of passing back into the space between sleeve handler walls 44. When a sleeve is properly positioned at sleeve unloading station 35, the passage in the end cap thereof (see FIG. 1) is precisely aligned with the opening of second tape guide 100. Thus, when tape 98 is advanced, it will pass through the end cap (see FIG. 1) of the sleeve at unloading station 35, make contact with the first part therein and force the parts out the other, uncapped end of the sleeve.
The normal position of tape 98 is unextended. In this position, tape 98 interrupts both sensor 95 and sensor 96. When a sleeve is in position to be unloaded, motor 99 is activated and tape 98 is moved until its trailing end first passes sensor 95 and eventually passes sensor 96. The signal from sensor 96 indicates that tape 98 is in its fully extended position and that all of the parts have been ejected from the sleeve. At this point, before the end of tape 98 leaves first guide 94, the direction of motor 99 is reversed. When the signal from sensor 95 once again indicates that tape 98 is int its unextended position, motor 99 is stopped.
As will be apparent to one skilled in the art, the basic mechanism of sleeve unloader 24 could readily be modified to serve a sleeve loading function. In other words, pusher tape 98 would push a sleeve-full of parts from a buffer track or the like into a properly aligned, empty sleeve.
The sleeve handler and unloader discussed above must be capable of presenting full sleeves and unloading them quickly in order to meet the high throughput targets required for economical operation. It is believed that, utilizing the concepts described, it is possible to unload approximately one sleeve per second. Approximately one-half second is required to push all of the parts out of the sleeve. Approximately 100 milliseconds are required to bring tape 98 back to its starting position. Approximately 400 milliseconds are required for the sleeve handler to position a new sleeve for unloading. With at least 47 parts per sleeve, this throughput rate exceeds that necessary to maintain an overall throughput rate of 60,000 parts per hour.
FIGS. 5A and 5B illustrate input buffer track 25. FIG. 5A is an end view of track 25 as seen from the input end; that is, the end which is aligned with sleeve unloading station 35 (FIG. 2B). A body portion 103 of track 25 comprises a central slot 104 running the length thereof, a pair of rails 105a and 105b immediately adjacent slot 104 and parallel thereto and a pair of lead spaces 106a and 106b immediately adjacent rails 105a and 105b respectively. A part (shown in phantom) may be supported on rails 105a and 105b while the leads thereof lie within lead spaces 106a and 106b. Thus, no potentially damaging contact is made with the leads.
A pair of cap members 107a and 107b are mounted to base member 103 as shown. The inner and lower edges of cap members 107a and 107b are adapted to engage the upper edges of the part and so to maintain the part in alignment down track 25. A space 111 between cap members 107a and 107b is provided to allow visual monitoring of parts within track 25 and manual adjustment of jammed parts and the like.
A pulley 108 lies within slot 104 and is carried on an axle 109 extending through body portion 103. A smooth belt 112 is carried on pulley 108 and is adjusted so as to make contact with the bottom of each part in the space between rails 105a and 105b. Belt 112 provides the motive force to propel parts down track 25. A motor 110 mounted to body portion 103 is attached to axle 109 and drives pulley 108 thereby.
Referring back, for a moment, to FIG. 2B, a sensor mounted in base portion 103 of track 25 at the location of line 113 senses when there is room in track 25 for a sleeve-full of parts. This triggers the unloading of the next sleeve at sleeve unloading station 35. The sensor may simply comprise a light source and detector disposed on opposite sides of body portion 103 so that the lack of a part therebetween provides a signal. The sensor is positioned slightly more than one sleeve length, approximately 19 inches, from the input end of track 25.
Referring now to FIG. 5B, pocket loading mechanism 26 is shown in cross-section. This is, of course, located at the output end of input buffer track 25. At this end, an idler pulley 114 carries belt 112 in slot 104 of body portion 103. Cap member 107a ends somewhat short of the end of track 25 and is replaced in function by an end cap 115. A pocket 116, which has a space 117 therein adapted to receive and hold a single part, is aligned with the end of track 25 between end cap 115 and body portion 103. As belt 112 passes over idler pulley 114, parts are removed from belt 112 and forced between a tongue portion 121 of body portion 103 and an injector wheel 119. Injector wheel 119 and tongue 121 are spaced so that a part just fits between them. Injector wheel 119 is advanced in the direction of rotation indicated by a motor 125 (see FIG. 2B) until a part occludes a light source-detector arrangement at the position indicated as 120.
Once a part is in position lodged between injector wheel 119 and tongue 121, the rotation of wheel 119 is halted until the system controller indicates that an empty pocket 116 is in position to receive the part. While injector wheel 119 is halted, parts simply back up down track 25. Normally, belt 112 is driven so as to present parts to injector wheel 119 just about as fast as they are needed. However, immediately after the loading of a new sleeve of parts onto track 25, there may be a gap between the parts. In this case, belt 112 is momentarily speeded up to close this gap.
When an empty pocket 116 is in position to receive a part, injector wheel 119 is spun rapidly in the direction indicated. This simultaneously shoots a part into pocket 116 and brings a new part into position between injector wheel 119 and tongue 121. A light source-detector arrangement 123 "looks" through a hole 122 in the back of pocket 116 to determine that the part has been successfully loaded. If the part has jammed at the mouth of pocket 116, both sensors 120 and 123 will so indicate, since the part will not clear sensor 120 and will not reach hole 122. In this case, injector wheel 119 is backed up for another try. A vacuum tube 124 extends through a wall 118 against which pocket 116 is being forced. The suction thus provided through space 117 of pocket 116 assists in locating the part completely inside pocket 116.
Referring now to FIGS. 6A and 6B, continuous belt transport system 27 is illustrated. FIG. 6A is a top view of system 27 with the pocket loader and unloader mechanisms removed for clarity. A first transport system wall 128 and a second transport system wall 129 provide a frame for system 27. At one end thereof, a drive motor 28 is mounted to first wall 128. Drive motor 28 is coupled to a pulley which is not visible in this view and which turns the transport belt. The belt is also not seen in this view because it is covered by a plurality of pockets 130, each of which is carrying an individual part and each of which has a plurality of slits 131 in the upper surface thereof through which electrical contact is made to the leads of the parts. Nearly all of the top surface of system 27 is available as test area 29. However, as is apparent, only a relatively small portion of test area 29 is actually utilized for this purpose. Typically, a load board containing interface circuits and the like is located in test area 29 so as to be physically and electrically very close to the actual test sight and may require significant portions of test area 29.
FIG. 6B is a side view of second transport system wall 129 as seen from a perspective between walls 128 and 129. The dotted lines indicate the path of the transport system belt and the arrows indicate its direction of motion. The outer and inner edges of the pockets are defined by the two dotted lines. A first hole 132 in wall 129 allows input buffer track 25 (see FIG. 2B) to contact the belt and pockets. A second hole 136 similarly provides access to output buffer tracks 31 (FIG. 2B). Both first hole 132 and second hole 136 are located along the lower horizontal portion of the path of the belt. Located along the upper horizontal portion of that path are a first guide member 133 and a second guide member 134. Guide members 133 and 134 engage the inner and outer edges, respectively, of each pocket as it passes a test sight 137. Guide members 133 and 134 serve to precisely determine the veritical position of each pocket so that reliable contact may be achieved to the leads of the part. Since the part also has some horizontal freedom of movement within its pocket, an alignment spring 135 positioned between guide members 133 and 134 engages the end of each part and forces it to the back of its pocket, thus precisely determining its horizontal position.
FIGS. 6C and 6D illustrate in detail the pocket/belt arrangement used in the transport system. Belt 140 is a common, molded, toothed belt of the type typically used as a timing belt or the like. A pocket 130 is attached to belt 140 by means of a pair of tabs 141 which extend around the edges of belt 140 in the space between two adjacent teeth thereof. This arrangement provides flexiblity to make changes in the design of pocket 130 and also allows the replacement of individual pockets as they wear. In some cases, in which the alignment of each pocket 130 with pocket loading mechanism 26 (FIG. 5B) is particularly critical, it may be desired to more accurately fix the position of each pocket 130 on belt 140. A "bump" molded onto belt 140 and a corresponding depression on the mating surface of pocket 130 may serve this function. In the extreme case, pocket 13 may be molded as a part of belt 140.
Pocket 130 is a custom-molded part of some complexity. Pocket 130 may be described as having an input face 142, an opposite, generally closed face 143, a back side 144 adjacent belt 140 and a contact face 145 opposite thereto. Input face 142 has an opening 146 therein which is adapted to receive a part therethrough. The edges of opening 146 are preferably chamfered, as shown. A pocket space 117 lies within pocket 130. Pocket space 117 is adapted to receive and hold a single part and and opening 146 provides ingress and egress to and from pocket space 117. A second opening 147 disposed in opposite face 143 is too small to allow ingress and egress of the part, but is useful in the pocket loading and unloading operation (see FIGS. 5B and 7B). A horizontal slot 148 extends through pocket 130 from input face 142 toward opposite face 143. Horizontal slot 148 allows alignment spring 135 (FIG. 6B) to make contact with a part in pocket space 117 and force it back against a stop 149, which prevents further movement toward opposite face 143.
A plurality of contact slots 131 are disposed on contact face 146 of pocket 130 and communicate with pocket space 117. Contact slots 131 are located so as to match the locations of the leads of a part which is at the back of pocket space 117 against stop 149. It should be noted that pocket 130 is carried on the outside surface of belt 140 (see FIG. 6B) so that, at the test station, pocket slots 131 are facing upward rather than downward as illustrated here. At least two methods of making contact with the leads of the part at the test station are possible with this arrangement. Preferably, a set of spring biased test leads ride in slots 131 and make contact with the part leads as each pocket is indexed to a position under the test station. As the belt is indexed, the test leads simply slide over part leads and pocket surfaces beneath them. An alternate method, which is more complex mechanically, is to place the test leads somewhat above the normal position of pocket 130 so that no contact is made while belt 140 is indexed. A solenoid or other means could be employed to raise each pocket 130 so as to make contact once belt 140 has stopped. Such a scheme may be most appropriate for parts with leads on all four sides.
As is apparent to one of skill in the art, the design of pocket 130 is highly dependent on the particular part for which it is designed. Therefore, the pocket design illustrated here is subject to wide variation.
Referring now to FIGS. 7A and 7B, the structure and function of pocket unloader mechanism 30 is described. Pocket unloader mechanism 30 serves both to remove the tested parts from the pockets and to sort the parts into the six possible output categories. A guide block 161 lies immediately adjacent to the pocket-carrying transport belt (not shown) and has six guide slots 162a-162f therein. Guide slots 162a-162f are spaced one pocket-width apart. As is apparent from FIG. 7B, guide slot 162a is aligned with one of the six output buffer tracks 175a, as is the case with each of the guide slots 162b-162f and output buffer tracks 175b-175f (not shown).
A pair of frame members 163 and 164 serve as mounting means for motors 165a-165c and 165d-165f, respectively. Six disks 166a-166f are mounted on the spindles of motors 165a-165f, respectively. Six flexible push rods 167a-167f each have one end mounted eccentrically to disks 166a-166f, respectively. When motors 165a-165f are in the positions indicated in FIG. 7A, each flexible push rod 167a-167f extends through its appropriate guide slot 162a-162f, respectively, just to the outer edge of guide block 161.
When the handler is running at a rate of 60,000 parts per hour, pocket unloader mechanism 30 must be capable of ejecting a part and returning to its home position in approximately 30 milliseconds; that is, the time during which transport apparatus 27 is stopped. This speed may only be achieved with the extremely low mass mechanism described. The use of a flexible push rod made of nylon or a similar material eccentrically mounted to a disk rotated by a DC servomotor eliminates much mechanical complexity and, therefore, mass.
FIG. 7B illustrates the unloading action. When a pocket 130 carrying a part 169 has been properly positioned in alignment with the appropriate output buffer track, in this case track 175a, motor 165a is rotated 180 degrees, thus rotating disk 166a and forcing flexible push rod 167a through guide block 161. Push rod 167a enters pocket 130, contacts part 169 and forces it out of pocket 130 and onto track 175a, as shown. The unloading action is then completed by rotating motor 165a by 180 degrees again, thus placing the entire apparatus back into its rest position and allowing the advancement of the pocket-carrying transport belt into its next position.
Referring now to FIGS. 8A-8D, the output buffer track system is explained in detail. In the preferred embodiment, six output buffer tracks 175a-175f are provided, thus providing six possible output categories into which the tester may place the parts. A body portion 176 forms the base for each of the six tracks 175a-175f. Six slots 177a-177f in body portion 176 run the length thereof, are parallel to one another and are located on the same center lines as are tracks 175a-175f. Six belts 178a-178f run in slots 177a-177f, respectively.
Six motors 179a-179f are mounted to body portion 176 along the edges thereof and drive six drive pulleys 180a-180f, respectively. Belts 178a-178f are driven by drive pulleys 180a-180f, respectively.
The detailed construction of tracks 175a-175f is described with reference to FIG. 8D, which is an enlarged end view of the indicated portion of FIG. 8B. As will be apparent, each output buffer track 175a-175f is identical in construction to input buffer track 25. Immediately adjacent slot 177a and running parallel thereto are a pair of rails 181a. Rails 181a are spaced so as to engage a part 182 (shown in phantom) along the bottom surface thereof without engaging the contacts, or leads, thereof. Immediately adjacent rails 181a and running parallel thereto are a pair of lead spaces 183a. The leads of part 182 are within lead spaces 183a, thus reducing the possibility of damage thereto. This aspect is particularly important in the case of surface mount packages such as the SOIC package illustrated here, because the tolerance which must be maintained on lead placements is quite severe.
Seven cap members 184a-184g are mounted to body portion 176 intermediate between slots 177a-177f and adjacent the outside edges of slots 177a and 177f. As shown in FIG. 8D, cap members 184a and 184b engage the upper edges of the body of part 182 and act to maintain the alignment of part 182 on rails 181a. Spaces are left between cap members 184a-184g so that parts can be visually inspected in the various output tracks, jammed parts can be freed and the overall operation of the output buffer track system can be monitored.
As is apparent from FIGS. 8B and 8D, belts 178a-178f do not actually make contact with parts which are supported on rails, such as rails 181a. This is the only major difference between the input and output buffer tracks and is readily achieved by adjusting the height of the pulleys relative to the slots. The normal motive force which propels parts down tracks 175a-175f is supplied by flexible push rods 167 (FIGS. 7A and 7B) of the pocket unloader mechanism. Rails, such as rails 181a, and cap members 184a-184g are dimensioned so as to allow parts to freely slide down the tracks formed thereby. FIG. 8C illustrates the means used to control the movement of parts along track 175f. The same structure and function are present in each of the other tracks. In order to minimize confusion, only those details associated with track 175f are shown in FIG. 8C, with foreground and background matter eliminated.
Belt 178f is carried by drive pulley 180f, by an idler pully 185 at the input end of track 175f and by a second idler pulley 186 at the output end of track 175f. Belt 178f also has first, second, third and fourth paddles thereon 187f, 188f, 189f and 190f, respectively. Each paddle is long enough to extend up from belt 178f into the space between cap members 184f and 184g, thus making contact with any part which is in track 175f. While parts are being loaded, but before track 175f contains a sleeve-full of parts, belt 178f is in the position indicated in FIG. 8C. That is, first paddle 187f is within the track near the output end thereof and acts as a barrier to limit movement of parts being loaded further down the track. Second paddle 188f, third paddle 189f and fourth paddle 190f are all outside of the track area when belt 178f is in this position and do not engage any parts.
When one sleeve-full of parts is in track 175f, belt 178f is advanced until both fourth paddle 190f and third paddle 189f have passed over first idler wheel 185 and are within the track area. This also advances first paddle 187f until it is just out of the track area. In this position, the sleeve full of parts, now being pushed from behind by fourth paddle 190f, can be held until an empty sleeve is aligned with the output end of track 175f for loading. In addition, newly unloaded parts can be loaded onto track 175f and will be prevented from further movement down the track by third paddle 189f, thus keeping the two groups of parts separate.
In order to prevent accidental ejection of parts from the output end of track 175f without an empty sleeve being present, it is intended that the above-described belt movement not be carried out until a sleeve is in position. Alternatively, some low-friction means could be inserted at or near the output end of the tracks to prevent ejection of parts therefrom until they are forced out by a paddle. To load an empty sleeve with parts, belt 178f is advanced rapidly. Fourth paddle 190f forces the parts off of the output end of track 175f and into the empty sleeve. This motion is continued until fourth paddle 190f has just passed out of the track area and is in the position of second paddle 188f in FIG. 8C. Third paddle 189f is in the position of first paddle 187f, second paddle 188f is in the position of fourth paddle 190f and first paddle 187f is in the position of third paddle 189f. As is apparent, this position is equivalent to that of FIG. 8C and loading of tested parts behind third paddle 189f can proceed.
A pair of passages 191f and 192f are disposed at the input end and output end, respectively of track 175f. Similar passages are provided for each of the other output buffer tracks, but are not shown. Passages 191f and 192f are provided to allow the monitoring of track operation by means of light source-detectors pairs placed at opposite ends thereof. At the input end, a part which has jammed partially inside track 175f can be detected by occlusion of the photocell. At the output end, a part jammed partially inside the sleeve being loaded can be detected. In addition, passage 192f at the output end is used to "home" belt 178f at the start of operations. Belt 178f is rotated and paddles 187f, 188f, 189f and 190f occlude the photocell as they pass around pulley 186. When either paddle 188f or paddle 190f has just cleared passage 192f, belt 178f is stopped and considered to be in a "home" position.
Referring now to FIG. 9, the electronic control structure of the handler described above is shown. As is apparent, the control structure is microprocessor-based. A primary microprocessor 200 (which includes associated random access and read-only memory) performs the basic control tasks. Primary MPU 200 receives indications of current system status, demands for new parts at the test station, indications of the output category for each tested part and other inputs and produces commands for the various servomotor and solenoid drivers, status outputs to the tester and other outputs.
A primary I/O bus 201 is coupled to primary microprocessor 200 and performs the familiar functions of communicating addresses, commands and data among the various devices coupled thereto. In the preferred embodiment, primary microprocessor 200 is one of the 68000 family of microprocessors available from Motorola, Inc. in Austin, Tex. The choice of microprocessor 200 will largely determine the architecture of bus 201.
An operator interface 202 is coupled to primary I/O bus 201. Operator interface 202 serves to receive commands from the operator via a control panel and to provide system status and function indicators to the operator, also via the control panel. Examples of typical commands are commands to start or stop handler operation and to unload a partially full output buffer track after all parts in a batch have been tested. Examples of typical status indicators are a warning of a jammed buffer track or of a malfunctioning sensor or motor.
A system control interface 203 is also coupled to primary I/O bus 201. The primary function of system control interface 203 is to provide an interface between primary microprocessor 200 and the test equipment which actually performs the electrical measurements on each part. This interface allows the tester to indicate its readiness to test the next part and to indicate the output category for each part, among other functions. In addition, any solenoids which are a part of the handler system are controlled through system control interface 203.
A system status receiver 204 is also coupled to primary I/O bus 201. System status receiver 204 receives inputs from each of the sense points throughout the handler. Examples are the sensor associated with the input buffer track which indicates that the buffer has room for a sleeve-full of parts and the sensor associated with the transport system which indicates that a part has been successfully injected into its pocket. System status receiver 204 provides these status indicators in appropriate form to I/O bus 201 for action by primary microprocessor 200.
Also coupled to primary I/O bus 201 is a servomotor control subsystem 205. Servomotor control subsystem 205 comprises a plurality of servomotor control boards 206. Each servomotor control board 206 is a microprocessor-based high-speed servomotor controller capable of controlling the position of a predetermined number of servomotor according to an on-line adaptive closed-loop control algorithm. An example of such an algorithm is disclosed in co-pending patent application Ser. No. 670,253, filed Nov. 9, 1984, now U.S. Pat. No. 4,609,855 and assigned to the assignee of the present invention. In the preferred embodiment, each servomotor control board 206 is capable of controlling up to four servomotors. Since there are a total of 14 servomotors in the handler exclusive of the sleeve handler and the main transport belt motor (one to drive the input buffer track, one to drive the pocket loading mechanism, six to drive the pocket unloading mechanism and six to drive the output buffer tracks), four servomotor control boards 206 are utilized. In addition to receiving position commands from primary microprocessor 200, servomotor control boards 206 provide position indications for each of the 14 servomotors to primary microprocessor 200 via I/O bus 201.
A precision servomotor control board 207 is coupled to I/O bus 201 and is dedicated to controlling the position of the main transport system motor. This motor requires dedicated control because it is a heavier-duty motor, it is running a larger percentage of the time and it requires particularly precise positioning to align the pocket with the test station leads. Again, in addition to positioning the main drive motor, controller board 207 provides position indicators to primary microprocessor 200.
A sleeve handler subsystem 208 is coupled to I/O bus 201. Sleeve handler subsystem 208 provides all necessary control and command processing for the sleeve handler portion of the handler. This subsystem is modular to allow flexibility in the sleeve handler design independent of the primary system control structure. Sleeve handler subsystem 208 comprises a subsystem microprocessor 210 with associated random access and read-only memory, a subsystem I/O bus 211, a subsystem status receiver 212, and two servomotor control boards 213 and 214.
The structure and function of each of the elements of sleeve handler subsystem 208 is substantially identical to those of the corresponding elements of the greater control system. Subsystem status receiver 212 receives status inputs from the various sensors within the sleeve handler and provides status indicators to subsystem I/O bus 211. Servomotor control boards 213 and 214 are identical to boards 206 and drive the six motors which comprise the sleeve handler (three belt drive motors, the orientation motor, the input hopper roller drive motor and the sleeve unloader motor).
An improved, high-speed integrated circuit handler has been shown and described. The disclosed handler is not gravity-driven in any of its many parts and thus avoids the several limitations of such handlers. The disclosed handler requires very minimal manual sleeve handling and thus reduces the direct labor component of handling costs. The handler is capable of at least 60,000 parts per hour throughput with a test time of 30 milliseconds per part. This throughput rate is much higher than any known prior art integrated circuit handler. | A buffer and injector apparatus for use in an automated article handling system is adapted to operate between one process which periodically outputs a plurality of articles and another which requires a steady input of individual articles. A particular embodiment is adapted for use in an automated integrated circuit handler between a sleeve unloader and a transport apparatus. Integrated circuits are slideably contained by a buffer track and moved thereon by a belt. Neither the track nor the belt contact the leads of the integrated circuits. A sensor mid-way down the track triggers the sleeve unloader to input more integrated circuits. An injector apparatus at the output end of the track comprises a wheel which engages each integrated circuit until the transport apparatus is ready, then rotates rapidly to inject the integrated circuit into the transport and simultaneously engage another integrated circuit. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/210,347 entitled TELEPHONY SECURITY SYSTEM filed Dec. 11, 1998, assigned to the assignee of the present application and incorporated by reference in its entirety.
TECHNICAL FIELD
The invention relates generally to telecommunications access control systems and, more particularly, to a system and method which permits a telecommunications firewall to enforce a security policy based on discrimination between a plurality of call content types and to autonomously terminate the call in enforcement of the security policy.
BACKGROUND OF THE INVENTION
Data network users in today's corporations and government agencies can easily add unauthorized modems to their computers to facilitate remote login. This is often done with innocuous intentions, but is a serious network security issue nonetheless. Rogue modems—modems that are not authorized by the organization, but have been connected to a computer system by an employee, circumvent the traditional Internet firewall, routers and intrusion detection systems.
With a rogue modem having opened the “back door” of the security perimeter, the organization's network is vulnerable to “hackers” or “phreakers” attempting to access the private data network via the Public Switched Telephone Network (PSTN). Unscrupulous individuals with larcenous or malicious intent can use a war dialer to seek out and identify insecure modems, penetrate their computer systems and gain access to the data network beyond.
An additional vulnerability involves authorized users performing unauthorized activities from within the private network. This is of special concern in high-security environments where outside transmissions are normally carefully monitored to ensure corporate or government secrets are not inadvertently or deliberately transmitted.
Telecommunication firewalls, such as the device described in U.S. Pat. No. 6,249,575 entitled TELEPHONY SECURITY SYSTEM to the same assignee are recently-developed devices that protect an organization's data network from access via telephony resources. A telecommunications firewall is configured with a user-defined security policy that is downloaded to one or more line sensors installed in-line on the user's side of the demarcation line. A line sensor determines the plurality of call attributes comprising call source, estimation and call content type from the call passing through the line sensor. Prescribed actions (including that of the line sensor allowing or denying the call) are performed based upon the call attributes determined and the security policy.
Although the line sensor is capable of determining a plurality of call attributes, the call content type (e.g., whether the call content is voice, fax or data), is a pivotal attribute in the security rules that address many of the calls that a telecommunications firewall is designed to detect and/or terminate. For instance, a modem transmission from a line that is designated for only voice use is indicative of a rogue modem. A data transmission to a voice-designated line is indicative of a possible hacking attempt, or again, a rogue modem on the line. An after-hours voice call or modem transmission from a line designated for fax use is indicative of an unauthorized call or possible espionage.
Very clever hackers may attempt to penetrate data networks by emulating one type of call to get past the firewall, then change to another type once the call is allowed. Therefore, changes in call content type are highly suspect and a security policy may require termination of such a call.
However, some government agencies such as the FBI and the CIA, the military and some NATO agencies, use a telephone encryption device known as Secure Telephone Unit-III (STU-III), to conduct classified conversations or transmit classified data. A STU-III may be used as a typical telephone to initiate a call, but when users “go secure” by turning an encryption-activation key, the voice conversation is digitized at the unit, encrypted and then transmitted using a standard modem to the receiving STU-III device where the process is reversed. The term “STU-III-voice” is used herein to refer to the call content type of a STU-III encrypted voice transmission.
A STU-III device is also used as a modem to transmit data to another STU-III location. In the “data modem” mode, the data is encrypted before it is sent to the receiving STU-III device. The term “STU-III data” is used herein to refer to the call content type of a STU-III encrypted data transmission.
Obviously the change in call content type when a STU-III transmission goes from insecure voice to secure data would be permitted in a security policy. Therefore a further discrimination between the voice band data of STU-III encrypted call content types and that of typical data (modem) and fax content types is needed.
A plurality of telecommunications fraud prevention devices exist which use and determine call-type attributes such as if the call is made from a pay phone, if it is cellular originated or terminated, if it is made to/from a number or country code with a high occurrence of billing fraud, if the call is long distance, toll free, a credit card call, etc. However, call-type attributes such as these are not relevant to protecting a private data network from unauthorized access via the telecommunications network. Additionally, devices such as these do not continue to discriminate content type after the call is connected.
Other devices are capable of detecting calls that violate a security policy, but cause time delays and a drain on manpower resources because they require notices to be sent to supervisory personnel for either approval to terminate or for manual follow-through by personnel to ultimately terminate the call.
Still other devices include components for classifying telephone signals, but none of these devices comprise the comparable arrangement of single, combined transmit and receive signal processing, continuous content discrimination and autonomous call termination capabilities needed for the specialized task of protecting a private data network from unauthorized access via the telecommunications network.
Therefore, what is needed is a system and method by which an in-line sensor continuously discriminates between call content types comprising voice, fax, data (modem), STU-III voice and STU-III data (modem) using inputs derived from analysis of the call passing through the sensor, and then autonomously enforces a security policy.
SUMMARY OF THE INVENTION
The present invention, accordingly, provides a system and method for an in-line sensor to enforce a security policy by discriminating between call content types including voice, fax, data (modem), STU-III voice and STU-III data (modem), and to continue to enforce the security policy against an allowed call, discriminating content type changes after the call is connected. Inbound and outbound calls are allowed or denied (i.e., blocked or “hung-up”) according to a security policy that is managed by a security administrator. If the call violates security policy at any time, the call is autonomously terminated.
To this end, in one embodiment, the line sensor processes the combined signal from both the transmit and the receive side of the communication channel as one single signal. Filtered tonal events as well as raw signal frequency and energy indices are used to discriminate between voice and voice band data (VBD) content type. Voice band data is considered herein to be any modulated data output by devices such as a fax, modem, or a secured STU-III. Further discrimination between voice and a plurality of VBD content types (fax, data modem and STU-III), is provided by a content type discrimination state machine which uses tonal event notices, the output of the previously mentioned frequency and energy statistical analysis between voice and VBD, and demodulated signal analysis. The line sensor operates in a continuous processing loop, continuing to discriminate call content type after the call is connected.
A system and method for discriminating call content types for individual telephone lines at a plurality of user sites outside of a Public Switched Telephone Network (PSTN) is described. The system may include: a database containing security rules for each of a plurality of extensions, the rules specifying actions to be taken based upon a call content type of the call on the extension, wherein the call content type is determined at the user sites outside the PSTN; and a line sensor within the user sites outside the PSTN for determining the call content type of the call. The line sensor continuously checks the call content type to determine if the call content type changes.
Alternate embodiments are contemplated whereby other VBD content types such as transmissions from a teletypewriter (TTY) device (used by deaf or speech-impaired individuals), are discriminated from fax, data (modem), STU-III voice and STU-III data to allow additional content type-specific security policy rules to be implemented.
In another alternate embodiment it is contemplated that discrimination of fax and data (modem) content type is further refined to discriminate transmission protocols and/or host-based applications, thereby allowing implementation of protocol-dependent or application-dependent security policy rules. Such rules require use of an “organizationapproved” or more highly secure protocols and applications in order for calls to be allowed.
An additional alternate embodiment is contemplated whereby the information from the transmit side and the receive side of the communication channel is processed separately instead of being combined into one single signal.
A technical advantage achieved with the invention is the ability to discriminate between call content types comprising voice, fax, data modem, STU-III voice and STU-III data, thereby providing call attributes that are critical to protecting a data network from access via telecommunications resources.
Another technical advantage achieved with the invention is the ability to discriminate if the call type changes after the call is connected, thereby providing protection from hackers emulating one call type and later changing once the call is connected, while still allowing STU-III calls.
Another technical advantage is the ability to autonomously terminate a call if it is in violation of the security policy, thereby eliminating unacceptable time delays or manpower requirements.
Yet another technical advantage achieved with the invention is the ability to process a single, combined transmit and receive signal, thereby achieving efficient and minimal use of processing resources.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as other features and advantages thereof, will be best understood by reference to the description which follows, read in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic block diagram of an exemplary telecommunications firewall;
FIGS. 2A and 2B illustrate a schematic block diagram of the preferred embodiment of the present invention;
FIG. 3 is a flow diagram illustrating discrimination between voice and voice band data by the system of FIGS. 2A and 2B;
FIG. 4 is a is a state transition diagram illustrating further discrimination of voice or voice band data content types by the system of FIG. 2B;
FIG. 5 is a schematic block diagram of the call termination circuitry for analog lines in the present invention;
FIG. 6A is a schematic block diagram of one embodiment of the call termination circuitry for T 1 lines in the present invention;
FIG. 6B is a schematic block diagram of an alternate embodiment of call termination circuitry for T 1 lines in the present invention; and
FIG. 7 is a schematic block diagram of the call termination circuitry for ISDN lines in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention can be described with several examples given below. It is understood, however, that the examples below are not necessarily limitations to the present invention, but are used to describe typical embodiments of operation.
FIG. 1 is a schematic block diagram of an exemplary telecommunications firewall similar to the one implemented as shown and described in U.S. Pat. No. 6,249,575 comprising a plurality of line sensors 100 of the present invention (designated by a line sensor 102 , 104 and 106 ), a firewall client 108 , and a firewall management server 100 , all electrically connected for interaction as described below.
The firewall client 108 is a point of user interface for configuring a security policy, displaying and viewing real-time alerts, printing event logs, reports, and other operational features of the telecommunications firewall.
The firewall management server 110 receives the security policy from the firewall client 108 and pushes a copy of the security policy to each line sensor 100 . Each line sensor 100 receives the security policy from the firewall management server 110 , monitors incoming and outgoing calls, and allows, denies, or otherwise manipulates calls in accordance with the security policy and based on a plurality of call attributes including call content type.
The line sensor 100 is connected in-line, on the user's side of a demarcation line 112 between a central office 114 and public branch exchange (PBX) 116 , whereby connectivity may be a combination of direct connects at line sensor 102 , PBX trunk-side connections at line sensor 104 , or PBX station-side connections at line sensor 106 . Line sensors 104 - 106 are not required at all of these points, but can be installed in accordance with the configuration of lines and the user's desired level of security control.
Also in FIG. 1, numerals 118 , 120 , and 122 designate end-user stations 124 , representing as examples, one or more modems 118 , fax machines 120 , and telephones 122 . The modems 118 may be connected to a desktop or portable personal computer. Individual extensions 126 connect each of the stations 124 at line sensor 106 (or to the PBX 116 if this configuration of line sensor is not present).
FIGS. 2A and 2B illustrate the line sensor 100 by which inputs are made into a content type discriminator (CTD) 200 , which operates to discriminate the content type of an inbound or outbound call passing through the line sensor.
A line interface unit (LIU) 201 , and a LIU 202 continuously monitors traffic on both a transmit side 203 and a receive side 204 of a plurality of communication channels. The LIUs 201 and 202 send a copy of a digitized audio signal 206 and 208 to a conferencing processor 210 . Although it is not shown, it is understood that in some telephone line protocols, both the receiving and transmitting signal are present on the same wire pair, thereby requiring only one LIU. If this is not the case, the conferencing processor 210 combines the separate signals into a combined transmit and receive (CTR) signal 212 . The CTR signal 212 is sent to a demodulator 214 , a Fourier transformer 216 , and a voice/voice band data (V/VBD) detector 218 .
The demodulator 214 is representative of a plurality of modems operating at protocols comprising V.21 and Bell 103 . V.21 demodulation is used to detect T-30 flags, which are indicative of fax handshaking. V.21 demodulated data 220 is sent to a T-30 flag counter 222 . If a sequence of m T-30 flags is detected; where m is a predetermined number of a consecutive series of T-30 flags sufficient to indicate standard fax handshaking and not just random data equivalent to a T-30 flag; a T-30 flag notice 224 is sent to the CTD 200 . Similarly, Bell 103 protocol is used to detect STU-III handshaking. Bell 103 demodulated data 226 is sent to a STU-III validator 228 . The data is evaluated against STU-III specifications, and either an invalid STU-III data notice 230 or a valid STU-III data notice 232 specifying the type of STU-III content (STU-III voice, STU-III data, or STU-III unspecified), is sent to the CTD 200 .
In the Fourier transformer 216 , an algorithm based on the Fourier transform is used to transform the CTR signal 212 into spectral components (frequency/amplitude pairs), that define the frequency content. A copy of the transform result 234 is sent to a DTMF tone detector 238 , an MF tone detector 240 and a general tone detector 242 , each of which filter and analyze the transform result 234 for the presence of specific tonal frequencies.
The DTMF tone detector 238 and the MF tone detector 240 look for the presence of DTMF and MF tones. The general tone detector 242 analyzes the transform result 234 for CNG (fax), ANS (modem), and 1800 Hz (STU-III) tones, as well as common call progress tones (ring back, busy, and/or dial tone).
The presence of DTMF tones is reported to the CTD 200 and the V/VBD detector 218 via a DTMF notice 246 . The presence of MF tones is reported to the CTD and the V/VBD detector via an MF notice 248 . The presence of general tones (CNG, ANS, 1800 Hz, ring back, busy, and/or dial tones) is reported to the CTD and the V/VBD detector via a CNG notice 250 , an ANS notice 252 , an 1800 Hz notice 254 and/or a call progress notice 255 . Additionally, the ANS notice 252 is sent to a timer 256 . The timer 256 sends a timeout notice 258 to the CTD 200 n milliseconds after receiving the ANS notice 252 , where n is sufficient elapsed time for an 1800 Hz tone to be issued during standard STU-III modem negotiation.
The V/VBD detector 218 analyzes all inputs, to provide a voice detected notice 260 or a VBD detected notice 262 , (indicative of the presence of either voice or voice band data on the line), to the CTD 200 .
The LIUs 201 and 202 also send a copy of call event signaling 235 and 236 to a call state detector 237 . The call state detector 237 reports “off-hook” and “on-hook” events to the CTD 200 via a call state notice 244 .
The CTD 200 analyzes all inputs to provide a content type discrimination notice, specifically either a content type “voice” notice 264 , a content type “fax” notice 266 , a content type “data” (modem) notice 268 , or a content type “STU-III ” notice 270 (indicating either STU-III voice, STU-III data, or STU-III unspecified).
The content type notice 264 - 270 is sent to a security processor 272 that is pre-programmed with the security policy to meet the user's security needs, which may include terminating the call. If the security policy dictates that the call should be terminated, the security processor 272 sends signals 274 and 276 to the LIUs 201 and 202 , thereby terminating the call. Configurations of the line sensor 100 call termination circuitry varies depending upon the line medium (e.g., analog, T 1 and ISDN), and are discussed below with reference to FIGS. 5, 6 A, 6 B and 7 .
FIG. 3 illustrates the process 300 whereby the V/VBD detector 218 discriminates the content type of a call as either voice or VBD based on the plurality of inputs shown in FIGS. 2A and 2B. It is understood that the line sensor 100 is operates in a continuous loop, continuously and simultaneously discriminating call content type on a plurality of telecommunication lines/channels.
The V/VBD detector 218 continuously receives the CTR signal 212 , takes p samples of the data stream and creates a frame, as shown in step 302 , where p represents any predetermined number of samples. The V/VBD detector 218 also receives notice of the presence of any DTMF, MF, CNG, ANS, 1800 Hz , and/or call progress tones from the DTMF tone detector 238 , MF tone detector 240 and general tone detector 242 , as shown in step 304 .
Copies of each frame of p samples are simultaneously statistically analyzed in steps 306 , 308 and 310 . In step 306 , an algorithm is processed on each frame to determine the number of zero crossings within the frame. Voice content generally has lower zero crossing counts than data content.
In step 308 , an algorithm is processed on each frame to determine the Root-Mean-Square (the energy) of the frame. If the frame contains mostly silence, this value is low, but if it contains a loud noise the value is high. Voice content generally has lower energy than data content.
In step 310 , an algorithm is processed on each frame to determine the center frequency of all the frequencies contained in the frame. If the frame contains higher frequency components, the center frequency is higher. Voice content generally has a lower center frequency than data content.
The frames are grouped into a window containing q frames in step 312 , where q represents the number of frames totaling approximately one second in duration. The statistical results of step 306 , 308 and 310 are tabulated for each frame and used in step 314 to determine the following eight indices associated with each window:
1. Number of frames with zero crossing counts above a threshold;
2. Variance of the zero crossing counts in total (q) frames in window;
3. Number of frames with RMS energy above a threshold;
4. Variance of the RMS energy in total (q) frames in window;
5. Number of frames with RMS energy below the mean RMS Energy in a window;
6. Number of frames with center frequency below a threshold;
7. Variance of frame center frequency; and
8. Number of other tones detected.
The indices for each window are processed by a classification algorithm in step 316 . Hard thresholds are used to analyze the indices and provide a call content type output of “voice”, “VBD” or “unknown” for each window.
The “per window” voice outputs from step 316 are tracked and counted. If r consecutive windows indicate voice in step 318 ; where r represents any predetermined number of windows; the call content type is classified as voice, and a voice detected notice 260 is sent to the CTD 200 in step 320 .
If the “per window” output from step 316 is “VBD”, it is also tracked and counted. If s consecutive windows indicate VBD in step 324 , the call content type is classified as VBD and a VBD detected notice 262 is sent to the CTS 200 in step 326 .
If the “per window” output from step 316 is “unknown”, the counters for both the voice and VBD used in step 318 and 324 are reset to zero in step 328 . In each scenario resulting from the classification output of step 316 , a process loop is applied whereby the next consecutive window of frames is processed and classified, and outputs are provided to the security processor 272 accordingly.
In an alternate embodiment, use of a neural network is contemplated to “learn” content type patterns and thresholds for use in discriminating between voice and VDB, as well as discriminating between fax, data (modem), STU-III voice and STU-III data. The neural network builds a feature map during an initial learning period of the patterns and thresholds associated with the call content types found in day-to-day telecom usage.
It is also contemplated that the neural network may be operated in an adaptive fashion. If a call content type falls outside known patterns and thresholds, a verification of the call content type is provided by administrators and the neural network updates the feature map to add new patterns and thresholds as they emerge over time.
FIG. 4 is a state transition diagram illustrating the process 400 whereby the CTD 200 further refines the discrimination of voice or VBD received from the V/VBD detector 218 , thereby determining if the VBD content type is fax, data (modem), STU-III voice or STU-III data, based on the plurality of inputs shown in FIG. 2 B. It will become evident that the state of the CTD 200 is fluid, transitioning from a start state 402 to a plurality of other states as appropriate, in response to inputs derived from the call passing through the line sensor 100 . It is not shown nor stated below, but it is understood that prior to transitioning from the start state 402 , a call state notice 244 reporting an “off hook” event is received by the CTD 200 from the call state detector 237 .
Prior to call connection, the CTD 200 transitions to the start state 402 . If the voice detected notice 260 is received, the CTD transitions to a voice detected state 404 , thereby providing the content type “voice” output 264 . The CTD then automatically resets itself and transitions back to the start state 402 to detect any change in the call content type.
If the CTD 200 is in the start state 402 and receives either the CNG notice 250 or the T-30 flags notice 224 . The CTD transitions to a possible fax state 408 . If a second T-30 flags notice 224 is received, the CTD transitions to a fax detected state 410 , thereby providing the content type “fax” output 266 . When the call state notice 244 reporting an “on-hook state” is received, the CTD returns to the start state 402 .
However, if the CDT 200 is in the fax detected state 410 and the fax handset is used to place a voice call during the fax transmission, either the voice detected notice 260 , the DTMF notice 246 , or the MF notice 248 is received and the CTD transitions to the voice detected state 404 , thereby providing the content type “voice” output 264 .
If the CTD 200 is in the start state 402 and receives a VBD detected notice 262 , the CTD transitions to a possible modem state 414 . If a second VBD detected notice 262 is received, the CTD transitions to a modem detected state 416 , thereby providing the content type “data (modem)” output 268 . If the call state notice 244 reporting an “on-hook state” is received, the CTD returns to the start state 402 .
When the CTD 200 is in either the possible modem state 414 , the modem detected state 416 , or the STU-III detected state 420 , if either the CNG notice 250 or the T-30 flags notice 224 is received, the CTD transitions to the possible fax state 408 . As previously discussed, if a second T-30 flags notice 224 is received, the CTD transitions to the fax detected state 410 , thereby providing the content type “fax” output 266 . If the call state notice 244 reporting an “on-hook state” is received, the CTD returns to the start state 402 .
If the CTD 200 is in the start state 402 and receives the ANS notice 252 , the CTD transitions to a modem answer detected state 412 . The CTD then awaits additional input to discriminate between fax, data (modem) or STU-III content type. If a timeout notice 258 is received prior to any other input such as the 1800 Hz notice 254 , the CTD transitions to the possible modem state 414 and awaits further input. If the 1800 Hz notice 254 is received, the CTD transitions to a possible STU-III state 418 .
While in the possible STU-III state 418 , the CTD awaits the collection and validation of Bell 103 data by the STU-III validator 228 . If the invalid STU-III data notice 230 is received, the CTD transitions to the possible modem state 414 and awaits further input. If the valid STU-III data notice 232 is received, the CTD transitions to a STU-III detected state 420 , thereby providing the content type “STU-III voice”, “STU-III data” or “STU-III unspecified” output 270 , as indicated in the valid STU-III data notice 232 . If the call state notice 244 reporting an “on-hook state” is received, the CTD returns to the start state 402 . However, if either the voice detected notice 260 , the DTMF notice 246 , or the MF notice 248 is received, the CTD transitions to the voice detected state 404 , thereby providing the content type “voice” output 264 .
Additionally, although not shown, if the call ends or an “on hook” call state notice 244 is sent from the call state detector 237 to the CTD 200 , the state machine to will transition back to start. This can happen at any state, but for clarity is shown only at states 410 , 416 and 420 .
FIG. 5 illustrates a schematic block diagram of a call termination circuitry 500 for analog lines in the present invention. When the line sensor 100 is installed in an analog line, a tip conductor 502 is connected to a relay 504 and a ring conductor 506 is connected to a relay 508 . The relays are normally closed such that in case of a power failure or reset, the relays remain closed, thereby allowing calls to occur without interruption. If the security processor 272 determines a call is in violation of the security policy, it sends a signal 510 to the relays 506 and 508 , thereby opening the relays and terminating the call. While not shown, it is understood that alternative devices other than relays, including but not limited to a transistor or switch, may be used to break the electrical connection and terminate the call.
In an alternate embodiment of the call termination circuitry for analog lines, the relays are normally open such that in case of a power failure or reset, the relays remain open, thereby interrupting all calls until transmissions is monitored by the line sensor 100 .
In another alternate embodiment of the call termination circuitry for analog lines, receiving and transmitting circuits are placed in-line with the telephone line, allowing the line sensor to manipulate the signal before re-transmitting it. This configuration allows “blanking” the call by transmitting silence or sending an audio message.
FIG. 6A illustrates a schematic block diagram of one embodiment of a call termination circuitry 600 for T 1 lines in the present invention. When the line sensor 100 is installed in a T 1 line, signal receiving and transmitting circuitry is in-line with the existing T 1 line. In this configuration, the line sensor 100 electrically receives and re-transmits the T 1 signal traveling in both the transmit side 203 and the receive side 204 of the communication channel. The security processor 272 is capable of manipulating the T 1 data that travels between the receiving and transmitting circuits. If the call is allowed, the security processor 272 does not alter the A/B bits and the data is re-transmitted the same as it is received. If the security processor 272 determines a call is in violation of the security policy, the signals 274 and 276 are sent to the receiving and transmitting circuits and then transmitted, and contain altered A/B signaling bits plus voice/VBD, thereby signaling the end of the call to the central office 114 and the PBX 116 .
FIG. 6B illustrates a schematic block diagram of an alternate embodiment of a call termination circuitry 650 for T 1 lines in the present invention. Connections and configurations are similar to those described for FIG. 6 A. The security processor 272 is capable of manipulating the T 1 data that travels between the receiving and transmitting circuits. If the security processor 272 determines a call is in violation of the security policy, the signals 274 and 276 are sent to the receiving and transmitting circuits and then transmitted, and contain the A/B bits plus altered voice/VBD of digital silence, an audio message, or some other voice data sequence to convey termination to the call parties. If the call is allowed, the security processor 272 does not alter the data and it is re-transmitted the same as it is received.
FIG. 7 illustrates a schematic block diagram of a call termination circuitry 700 for ISDN lines in the present invention. When the line sensor 100 is installed in an ISDN line, signal receiving and transmitting circuitry is in-line with the existing ISDN line. In this configuration, the line sensor 100 electrically receives and re-transmits the ISDN signal traveling in both the transmit side 203 and the receive side 204 of the communication channel. The security processor 272 is capable of manipulating the ISDN data that travels between the receiving and transmitting circuits. If the call is allowed, the security processor 272 does not alter the voice/VBD nor the D channel messages. If the security processor 272 determines a call is in violation of the security policy, the signals 274 and 276 are sent to the receiving and transmitting circuits and then transmitted, and include voice/VBD plus D channel messages altered to include an ISDN tear-down message, thereby signaling the end of the call to the central office 114 and the PBX 116 . The line sensor 100 handles the response messages from the central office and PBX in order to prevent corruption of the link.
It is contemplated that the call drop circuitry described above with reference to FIGS. 5, 6 A, 6 B, and 7 can be integrated into a large, integrated communications device such as a PBX or into another in-line device such as but not limited to a surge suppressor, repeater, CSU (Channel Service Unit), or channel bank.
Alternatively, it is contemplated that the call drop circuitry described above can be controlled via wired or wireless connections.
It is understood that several modifications, changes and substitutions are intended in the foregoing disclosure and in some instances some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A system and method for discriminating call content types for individual telephone lines at a plurality of user sites outside of a Public Switched Telephone Network (PSTN) is described. The system includes: a database containing security rules for each of a plurality of extensions, the rules specifying actions to be taken based upon a call content type of the call on the extension, wherein the call content type is determined at the user sites outside the PSTN; and a line sensor within the user sites outside the PSTN for determining the call content type of the call. The line sensor continuously checks the call content type to determine if the call content type changes. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of pending U.S. patent application Ser. No. 11/240,099 filed Sep. 30, 2005, which is a continuation of U.S. patent application Ser. No. 10/192,957, filed Jul. 11, 2002 and issued as U.S. Pat. No. 6,954,836 B2 on Oct. 11, 2005. These applications and patent are each incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to computer processors. More specifically, the present invention relates to a system and method for processing compiled object code to help reduce memory latency-related delays and, therefore, improve the speed with which the object code can be processed.
BACKGROUND OF THE INVENTION
[0003] As processors become ever faster, increasingly the bottleneck restricting processing throughput is the speed—or lack thereof—of computer memory in responding to processor directives. This “memory latency” is a very serious problem, because processors process instructions and data much faster than these instructions and data can be retrieved from memory. Today, the speed with which microprocessors can process instructions commonly is rated in gigahertz. Unfortunately, overall system performance is hamstrung by motherboards operating between one hundred and three hundred megahertz, i.e., almost an order of magnitude slower.
[0004] To make matters worse, the disparity between the speed of processor clocks and memory clocks is growing. Currently, the ratio of processor clock speed to memory clock speed typically is 8:1, but that ratio is predicted to increase to 100:1 in the next few years. Compounding the problem is the fact that a memory system may require ten or more of its own memory clock cycles to respond to a memory retrieval request, thus, the ratio for a complete memory cycle is far worse. Today, completion of one full memory cycle may result in the waste of hundreds of processing cycles. In the near future, based on current performance trends in microprocessors, completion of a memory cycle may result in the waste of thousands of processing cycles.
[0005] To help reduce delays caused by memory latency, processors incorporate an execution pipeline. In the execution pipeline, a sequence of instructions to be executed are queued to avoid the interminable memory retrieval delays that would result if each instruction were retrieved from memory one at a time. However, if the wrong instructions and/or data have been loaded into the pipeline, the processor will fall idle while the wrong instructions are cleared and replaced with the correct instructions.
[0006] FIG. 1 is a flowchart illustrating these problems and some of the solutions. To expedite processing, once a program or routine is initiated, at 110 instructions are queued in the execution pipeline, and the processor begins to execute the queued instructions at 130 . The processor continues executing instructions from the pipeline until one of two things happens. If the processor reaches the end of the queued instructions at 140 , the processor will wait idle at 150 until the next instructions are queued, then resume executing queued instructions at 130 . In this instance, memory pages storing the next instructions may be in the process of being opened to transfer their contents to the execution pipeline, so the memory latency delay may not be too lengthy.
[0007] If the processor has not reached the end of the instructions queued in the execution pipeline, delays still may result when conditional branch instructions are encountered. A typical CPU may sequentially load a range of instructions from memory in the order they appear, ignoring the possibility that a conditional branch instruction in that range could redirect processing to a different set of instructions. FIGS. 2A and 2B represent two situations in which instructions were loaded into the execution pipelines 210 and 220 , respectively, making the assumption that the conditional branch would not be taken, and queuing the instructions following the conditional branch instruction in the execution pipelines 210 and 220 . In both FIGS. 2A and 2B , the conditional branch will be taken if “VARIABLE” is equal to CONDITION.”
[0008] In the situation depicted in FIG. 2A , it is assumed that VARIABLE is not equal to CONDITION. Therefore, the conditional branch is not taken. As a result, the next instructions that should be processed are those immediately following the conditional branch instruction. Thus, as it turns out, queuing the instructions following the conditional branch was the correct course of action, and the processor can continue processing the next instructions in the execution pipeline without delay, as though the conditional branch instruction did not exist.
[0009] On the other hand, FIG. 2B depicts the situation if VARIABLE is equal to CONDITION, indicating the branch should be taken. Because the execution pipeline had been loaded with instructions on the assumption that the conditional branch would not be followed, this is considered to be an unexpected branch 160 ( FIG. 1 ). Because the condition is met and the branch must be taken, then the instructions following the conditional branch, which were queued as they were in the execution pipeline 210 in FIG. 2A , will not be processed. Accordingly, the execution pipeline 220 must be cleared as shown in FIG. 2B , and the processor will fall idle while the execution pipeline is reloaded. Having to reload the execution pipeline 220 as shown in FIG. 2B is comparable to the situation if the execution pipeline had not been loaded with any instructions beyond the conditional branch instruction. Thus, the entire queuing process begins anew at 110 ( FIG. 1 ) with the processor waiting for a full memory retrieval cycle to get the next instruction, “INSTRUCTION AFTER BRANCH 1 ,” which eventually is loaded into the pipeline at 230 .
[0010] The taking of an unexpected branch 160 may result in a significantly longer processor idle interval than the processor reaching the end of the queued instructions at 150 . If the processor reaches the end of the queued instructions, the next needed instructions may be in the process of being fetched to the execution pipeline. If the instructions are in the process of being retrieved, only a few processor cycles might remain before the instructions reach the execution pipeline. However, if an unexpected branch is taken as at 160 , the retrieval of the next instructions starts anew, and hundreds of processor cycles might pass before the next instructions reach the execution pipeline.
[0011] To avoid processing delays resulting from unexpected branching, techniques such as branch speculation and prediction have been devised. With reference to FIG. 1 , speculation and/or prediction 180 occurs once a conditional branch instruction like “IF VARIABLE=CONDITION” has been encountered at 170 . Using speculation or speculative branching, instructions queued in the pipeline are previewed. If an instruction comprises a conditional branch, the system speculates as to the outcome of the branch condition, and loads in the execution pipeline instructions and data from the predicted branch. Speculation renders an educated guess by attempting to precalculate the key variable to project the likelihood the branch is taken, and instructions from the more or most likely branch are queued for processing.
[0012] If the correct educated guess is made, the effect is the same as if the instructions in sequence were loaded ignoring any possible branches, as shown in FIG. 2A , and the processor can continue processing without having to wait for new instructions to be retrieved. However, if the speculation incorrectly predicts the branch, incorrect and unusable instructions will have been loaded in the pipeline, and the effect is the same as illustrated in FIG. 2B . The processor will, therefore, fall idle while instructions in the pipeline are cleared and replaced with the instructions from the branch actually followed. In sum, speculation can avoid wasted processing cycles, but only if the speculation routine guesses correctly as to what branch will be followed.
[0013] Prediction is a technique which exploits multiscalar or superscalar processors. A multiscalar processor includes multiple functional units which provides independent execution slots to simultaneously and independently process different, short word instructions. Using prediction, a multiscalar processor can simultaneously execute both eventualities of an IF-THEN-ELSE-type instruction, making the outcome of each available without having to wait the time required for the sequential execution of both eventualities. Based on the parallel processing of instructions, the execution pipeline can be kept filled for more than one branch possibility. “Very Long Instruction Word” processing methodologies, such as Expressly Parallel Instruction Computing (“EPIC”) devised by Intel and Hewlett-Packard, are designed to take advantage of multiscalar processors in this manner. The EPIC methodology relies on the compiler to detect such potential parallelism and generated object code to exploit multiscalar processing.
[0014] FIG. 2C depicts a scenario in which a microprocessor with two functional units processes instructions in two execution slots in parallel. Upon encountering the same conditional branch instruction as seen in FIGS. 2A and 2B , the width of the execution 230 pipeline allows it to be partitioned into a first execution slot 240 and a second execution slot 250 , each of which is loaded with instructions conditioned on each possibility. The first execution slot 240 is loaded with instructions responsive to the possibility that “VARIABLE” is not equal to “CONDITION” and the branch is not taken, and the second execution slot 250 with instructions responsive to the possibility that “VARIABLE=CONDITION” and the branch is taken. Both of these sets of instructions can be loaded and executed in parallel. As a result, no processing cycles are lost in having to reload the pipeline if an unexpected branch is not taken.
[0015] Prediction, too, has many limitations. Of course, if available processing parallelism is not detected, prediction simply will not be used. In addition, if the instructions are long word instructions such that a single instruction consumes all of the available functional units, there can be no parallel processing, and, thus, no prediction. Alternatively, because a string of conditional branches potentially can invoke many different possible branches, the possibility remains that instructions might be loaded into the execution pipeline for an incorrect branch. In such a case, the result would be that as illustrated in FIG. 2B , where the pipeline must be emptied and reloaded while the processor falls idle.
[0016] In sum, the object of branch speculation, and/or prediction is to avoid wasting processor by filling the execution pipeline with instructions are most likely to be needed as a result of a conditional branch or with parallel sets instructions to allow for multiple conditional branch outcomes, respectively. However, even if speculation or prediction help to fill the execution pipeline with the appropriate instructions, those instructions might invoke other branches, routine calls, or data references, which may not be resolved until the processor actually processes the instruction. This would result in memory latency delays even when branch speculation or prediction work as intended.
[0017] For example, referring to FIG. 2C , the empty lines in execution slot 250 represent the time lost as a result of the reference to “BRANCH” in the first execution slot. Although instructions can continue to be loaded into execution slot 240 , the memory page where “BRANCH” is stored must be opened before the instructions at that address can be retrieved into the pipeline. Similarly, instruction 270 calls for data to be retrieved from memory and moved into a register. Empty spaces in the execution slot 250 represent the delay which results while the memory page where “dataref” is stored is opened. Once again, the processor would fall idle during the many cycles required to retrieve the referenced information from memory.
[0018] Cache memory may avoid some of these delays by reducing the time required to retrieve information from memory by transferring portions of the contents of memory into fast memory devices disposed on the microprocessor itself (level one cache) or directly coupled to the microprocessor (level two cache). Typically, the processor can retrieve data from level two cache usually in half the time it can retrieve data from main memory, and in one-third or even one-sixth the time it would take to retrieve the same data from main memory. When a processor calls for instructions or data from memory, other information stored nearby in memory also are transferred to cache memory because it is very common for a large percentage of the work done by a particular program or routine to be performed by programming loops manifested in localized groups of instructions.
[0019] However, the use of cache memory does not completely solve the memory latency problem. Unless the desired data happens to be present in cache, the presence of cache memory saves no time at all. Cache memory has only a small fraction of the capacity of main memory, therefore, it can store only a fraction of the data stored in main memory. Should the processor call for data beyond the limited range of data transferred to cache, the data will have to be retrieved from memory, again leaving the processor idle for tens or hundreds of cycles while the relevant memory pages are fetched.
[0020] What is needed is a way to help expedite the retrieval of memory pages from memory into the execution pipeline to avoid or reduce memory latency delays. It is to improving this process that the present invention is directed.
SUMMARY OF THE INVENTION
[0021] One aspect of the invention provides a method for processing programming instructions by an instruction processor. The method includes loading a reference table having at least one reference and an associated memory address. The reference table is associated with a group of programming instructions. The method further includes identifying programming instructions of the group having invocation of a reference in the reference table. Prior to processing a programming instruction having an invocation, retrieval of information corresponding to the respective associated memory address is initiated in response to identifying the invocation. The programming instruction having the invocation is then processed.
[0022] Another aspect of the invention provides a method for retrieving data referenced by an address reference invoked by a programming instruction queued for execution in an execution pipeline from a memory system. The method includes receiving a reference table having an entry for a memory address corresponding to the address reference. The reference table is associated with a segment of programming instructions including the programming instruction invoking the address reference. The method further includes identifying the address reference in the execution pipeline and initiating retrieval of contents stored at the corresponding memory address.
[0023] Another aspect of the invention provides a method for retrieving information identified by address references invoked by programming instructions loaded in an instruction queue. The method includes receiving a reference table having entries for memory addresses corresponding to respective address references. Prior to processing, programming instructions loaded in the instruction queue are parsed for programming instructions invoking an address reference. In response to finding a programming instruction invoking an address reference, retrieval of the contents of the memory address entered in the reference table corresponding to the invoked address reference is initiated.
[0024] Another aspect of the invention provides a system for processing programming instructions. The system includes an execution pipeline cache operable to queue programming instructions and a memory controller operable to retrieve information corresponding to a memory address. The system further includes a memory management processor coupled to the execution pipeline cache and the memory controller. The memory management processor includes a reference table buffer operable to store a reference table having at least one reference and an associated memory address. The reference table is associated with a segment of programming instructions. The memory management processor is operable to identify programming instructions of the segment that are queued in the execution pipeline cache that have invocation of a reference in the reference table. The memory management processor is further operable to control the memory controller to initiate retrieval of information corresponding to the respective associated memory address in response to identifying the invocation prior to the processing of a programming instruction having an invocation. An instruction processor coupled to the execution pipeline cache and memory management processor is operable to process the programming instruction having the invocation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a flowchart showing the typical operation of a processor executing a conventionally compiled program.
[0026] FIG. 2A is a representation of instructions in an execution pipeline to be executed by a processor in a conventionally compiled program when no branch is taken or when speculation as to which branch will be followed is correct.
[0027] FIG. 2B is a representation of the instructions in an execution pipeline to be executed by a processor in a conventionally compiled program when an unexpected branch is taken or when speculation as to which branch will be followed is incorrect.
[0028] FIG. 2C is a representation of the instructions in an execution pipeline to be executed by a multiscalar or superscalar processor in a conventionally compiled program when prediction is employed to process two different possible branches in parallel.
[0029] FIG. 3 is a block diagram of a processing system incorporating an embodiment of the present invention.
[0030] FIG. 4 is a flowchart showing the process followed by an embodiment of the present invention.
[0031] FIG. 5 is an excerpt of an assembly language representation of object code compiled or assembled using an embodiment of the present invention.
[0032] FIG. 6 is a block diagram of a computer system incorporating an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0033] It should be noted that the preferred embodiment of a system and method of the present invention are equally applicable both to programs created high-level language source code and assembly language source code. Throughout this description, the term compiler will be used, but it can be taken to mean a compiler or an assembler. Similarly, while functional blocks of programming are referred to as routines, the term routines can be taken to mean routines, subroutines, procedures, or other similar programming segments.
[0034] FIG. 3 illustrates an embodiment of the present invention manifested as part of a central processing unit 300 . The conventional central processing unit 300 adapted to use an embodiment of the present includes an instruction processor 304 which processes instructions directed by an associated instruction decoder 308 . The instruction decoder 308 decodes instructions queued in an execution pipeline cache 312 . Associated with the central processing unit 300 may be a branch prediction processor 316 . The instruction processor 304 , the instruction decoder 308 , the execution pipeline cache 312 , and the branch prediction processor 316 are interconnected by an internal bus 320 . As previously described, the branch prediction processor 316 is operable to review instructions in the execution pipeline cache 312 where it attempts to predetermine the result of conditional branch instructions by precalculating the conditions determining the branch. Based on its determination, the branch prediction processor 316 might communicate using the internal bus 320 with a memory controller 324 to direct retrieval of a different set of instructions than those appearing in sequence following a conditional branch instruction. Similarly, if the central processing unit 300 was a multiscalar processor, a prediction processor (not shown) might be coupled through the internal bus 320 to the same devices to direct multiple supply short word instructions be queued in parallel in the execution pipeline 312 , and eventually processed in parallel by multiple functional units of the instruction processor 304 .
[0035] When instructions or other information are sought by the instruction processor 304 or other devices, the requests are passed across the internal bus 320 to a memory controller 324 . The memory controller 324 controls the operation of the on-board level 1 cache 328 , the level 2 cache controller 332 , and the bus interface controller 336 through an internal memory bus 340 . The memory controller 324 receives requests for instructions or other data, and determines whether the requested information is resident in cache or whether it must be retrieved from elsewhere in the system 352 . For information not resident in level 1 cache 328 , if it is resident in level 2 cache 344 , the level 2 cache controller retrieves it through a level 2 cache channel 348 . For information not resident in either level 1 cache 328 or level 2 cache 344 , the bus interface controller 336 seeks the requested information from the system 352 via the processor bus 356 . It will be appreciated that the processor architecture depicted in FIG. 3 is just one example used for the sake of illustration. Myriad processor designs exist, and embodiments of the present invention can be adapted to use any number of such processor designs.
[0036] The central processing unit 300 includes an embodiment of the memory management processor 360 of the present invention. The memory management processor 360 is coupled with the execution pipeline 312 and the internal bus 320 . So coupled, the memory management processor 360 can exploit a reference table contained within object code. The preparation of a suitable reference table is described in filed U.S. patent application Ser. No. 10/192,923 by Klein entitled “METHOD AND SYSTEM FOR GENERATING OBJECT CODE TO FACILITATE PREDICTIVE MEMORY RETRIEVAL.” In a preferred embodiment, and as further described below, the reference table will be indicated by a signature which will signify to the memory controller 324 that the reference table should be routed to the memory management processor 360 . In a preferred embodiment, the memory management processor 360 will incorporate a reference table buffer (not shown) to store reference tables as they are received via the internal bus 320 . As the object code for new programs or new routines are received by the central processing unit 300 , the memory controller 324 can route any new or additional reference tables to the memory management processor 360 .
[0037] FIG. 4 flowcharts the operation of the memory management processor 360 . After receiving or otherwise accessing the reference table at 410 , the memory management processor 360 ( FIG. 3 ) parses the execution pipeline 312 ( FIG. 3 ) for instructions at 420 ( FIG. 4 ). If the memory management processor 360 ( FIG. 3 ) does not find an instruction invoking a reference included in the reference table, the memory management processor 360 continues parsing the execution pipeline 312 ( FIG. 3 ) at 420 ( FIG. 4 ). However, if the memory management processor 360 ( FIG. 3 ) finds an instruction invoking a reference included in the reference table at 430 ( FIG. 4 ), the memory management processor 360 ( FIG. 3 ) will look up the address listed in the reference table for the reference at 440 . The memory management processor 360 ( FIG. 3 ) then will initiate opening of the memory location referenced at 450 ( FIG. 4 ) by transmitting the address to the memory controller 324 ( FIG. 3 ).
[0038] If no references have yet been retrieved, the memory management processor 360 ( FIG. 3 ) resumes parsing the execution pipeline 312 at 420 ( FIG. 4 ). On the other hand, if a reference has been retrieved from cache or memory at 460 , the memory management processor 360 ( FIG. 3 ) can direct the insertion of the retrieved references into the execution pipeline 312 at 470 ( FIG. 4 ). For example, if a reference to a variable has been retrieved, the memory management processor 360 ( FIG. 3 ) can substitute the value of the variable for the reference in the execution pipeline 312 . Alternatively, if instructions from a routine invoked by an instruction in the pipeline have been retrieved, the memory management processor 360 can direct those instructions be inserted in the execution pipeline following the invoking instruction. This process repeats continually. If a new program or routine is accessed by the central processing unit 300 which includes a new reference table, the table will be accessed by the memory management processor 360 at 410 ( FIG. 4 ) and the process described in FIG. 4 begins anew.
[0039] Returning to FIG. 3 , if instructions queued in the execution pipeline 312 invoke references listed in the reference table, the memory management processor 360 initiates retrieval of reference information by signaling to the memory controller 324 to retrieve the contents stored at the address referenced. The memory controller 324 can then determine if the contents of the address are resident in level 1 cache 328 , level 2 cache 344 as indicated by the level 2 cache controller 332 , or must be retrieved from main memory or elsewhere in the system 352 via the bus interface controller 336 . As a result, if the information sought already is in cache, the information need not be sought from main memory. It will be appreciated that the same contention checking used in prediction, caching, and similar processes can be applied in embodiments of the present invention to ensure that values changed in cache or memory after they have been transferred into the execution pipeline will be updated.
[0040] FIG. 5 shows an assembly language representation of object code for a routine 500 containing a reference table which can be exploited by embodiments of the present invention to lessen processing delays caused by memory latency. The routine 500 includes a sequence of instructions 504 , which is conventional for a programming routine to include. Preceding the instructions 504 , however, is a reference table 508 generated by a compiler or assembler directed to avoiding memory latency delays using an embodiment of the present invention. It should be noted that the table 508 begins with a jump instruction, “JMPS TABLE_END” 512 which allows a computing system that is not equipped with an embodiment of the present invention to take advantage of this reference table 508 to skip to the end of the table 514 . By directing a computing system not equipped to use the table 508 to the end of the table 514 , the computing system is directed to where the instructions 504 begin, where a conventional computing system would start a conventional routine.
[0041] After the jump instruction 512 , which is ignored by a computing system equipped with an embodiment of the present invention, a signature 516 identifies to an embodiment of the present invention that this is a suitable reference table 508 . The first substantive entry in the reference table 520 is “DDW OFFSET JUMP 1 ,” which reserves a double data word at an offset position within the table for the reference JUMP 1 . JUMP 1 is a reference invoked by a first conditional branch instruction 524 appearing in the instruction section 504 of the routine 500 . This branch reference is identified by a compiler designed to take advantage of embodiments of the present invention. Accordingly, for the reference JUMP 1 in the table 508 , an address space a double data word in length is reserved in the table at 520 . Similarly, the table entry 528 is to reserve in the table 508 a double data word address space for JUMP 2 , a reference invoked by a second conditional branch instruction 532 in the instructions 504 . Appearing next in the table 508 is an entry 536 reserving a double data word address space for dataref, which is a data reference made by instruction 540 . Next, table entry 544 reserves a double data word address space for CALL 1 , which is the address of a routine call invoked by CALL instruction 548 . The last table entry 552 is a final double data word table entry for JUMP 3 , the address of a branch address invoked in the last conditional branch instruction 556 .
[0042] There are three things to note about this table 508 . First, the double data word designation appears because, in the system for which the routine 500 has been compiled, the system has an address range defined by an address a double data word in size. Second, the designation OFFSET signifies that the address to be entered is an offset address, not an absolute address. As is known in the art, the designation offset allows the program, as it is being loaded into memory, to resolve offset addresses relative to an initial address. As a result, this program can be loaded anywhere in the system's memory.
[0043] Third, this table 508 is what is stored in a reference table buffer in a memory management processor 360 ( FIG. 3 ) and used to initiate retrieval of data referenced by instructions in the routine 500 ( FIG. 5 ). When the routine 500 is being queued in the execution pipeline 312 ( FIG. 3 ) for processing, the table 508 ( FIG. 5 ) is provided to the memory management processor 360 ( FIG. 3 ). Once the instructions 504 are loaded into the execution pipeline 312 ( FIG. 3 ), the memory management processor 360 can parse the execution pipeline 312 looking for references listed in the table. Thus, for example, when the memory management processor 360 encounters in the execution pipeline 312 the first conditional branch instruction 524 ( FIG. 5 ), the memory management processor 360 ( FIG. 3 ) initiates retrieval of the instructions at the address listed in the resolved table entry 520 ( FIG. 5 ) for the reference JUMP 1 . Then, if the instruction processor 304 ( FIG. 3 ) conditional branch is taken at 532 ( FIG. 5 ), the memory pages where the instructions at the branch JUMP 1 are stored are in the process of being opened and their contents retrieved. Because these pages are already being opened, memory latency delays as a result of taking this conditional branch are reduced.
[0044] Similarly, for example, upon parsing the execution pipeline 312 ( FIG. 3 ) and finding the instruction 540 ( FIG. 5 ) referencing dataref, the memory management processor can initiate retrieval of data from memory at the address listed in the resolved table entry 536 . Thus, when the instruction processor 304 ( FIG. 3 ) reaches the instruction 540 ( FIG. 5 ) invoking dataref, memory latency delays are reduced. The delay is reduced because, while the instruction processor 304 ( FIG. 3 ) was executing the preceding instructions, the memory management processor 360 initiated opening of the memory pages where the contents of dataref were stored. As a result, when the instruction processor 304 reaches the instruction invoking dataref 540 ( FIG. 5 ), the contents of dataref are already in the process of being retrieved, instead of that process beginning when the instruction processor 304 first reached the instruction 540 ( FIG. 5 ) invoking the reference.
[0045] In fact, if a sufficient number of processing cycles pass between the time the memory management processor 360 ( FIG. 3 ) initiates retrieval of the contents of dataref and the time the instruction processor 304 reaches the instruction invoking dataref, the memory management processor 360 might be able to substitute the value of dataref for the label dataref in the instruction 540 ( FIG. 5 ), allowing the instruction to be processed without any memory latency delay. This would be possible if dataref happens to have been resident in level 1 cache 328 ( FIG. 3 ) or level 2 cache 344 , or otherwise enough time passed to allow dataref to be retrieved from main memory.
[0046] FIG. 6 is a block diagram of a computer system incorporating an embodiment of the present invention. In the computer system 600 , a central processor 602 is adapted with a preferred embodiment of the present invention (not shown) as previously described. The computer system 600 including the DRAM 601 includes a central processor 602 for performing various functions, such as performing specific calculations or tasks. In addition, the computer system 600 includes one or more input devices 604 , such as a keyboard or a mouse, coupled to the central processor 602 through a memory controller 606 and a processor bus 607 to allow an operator to interface with the computer system 600 . Typically, the computer system 600 also includes one or more output devices 608 coupled with the central processor 602 , such output devices typically being a printer or a video terminal. One or more data storage devices 610 are also typically coupled with the central processor 602 through the memory controller 606 to store data or retrieve data from external storage media (not shown). Examples of typical data storage devices 610 include hard and floppy disks, tape cassettes, and compact disk read-only memories (CD-ROMs). The DRAM 601 is typically coupled to the memory controller 606 through the control bus 620 and the address bus 630 . The data bus 640 of the DRAM 601 is coupled to the processor 602 either directly (as shown) or through the memory controller 606 to allow data to be written to and read from the DRAM 601 . The computer system 600 may also include a cache memory 614 coupled to the central processor 602 through the processor bus 607 to provide for the rapid storage and reading of data and/or instructions, as is well known in the art.
[0047] It is to be understood that, even though various embodiments and advantages of the present invention have been set forth in the foregoing description, the above disclosure is illustrative only. Changes may be made in detail, and yet remain within the broad principles of the invention. For example, a memory management processor could be external to the central processor, where it could receive and parse instructions before they reach the processor. This and other embodiments could make use of and fall within the principles of the invention. | A system and method are described for a memory management processor which, using a table of reference addresses embedded in the object code, can open the appropriate memory pages to expedite the retrieval of information from memory referenced by instructions in the execution pipeline. A suitable compiler parses the source code and collects references to branch addresses, calls to other routines, or data references, and creates reference tables listing the addresses for these references at the beginning of each routine. These tables are received by the memory management processor as the instructions of the routine are beginning to be loaded into the execution pipeline, so that the memory management processor can begin opening memory pages where the referenced information is stored. Opening the memory pages where the referenced information is located before the instructions reach the instruction processor helps lessen memory latency delays which can greatly impede processing performance. | 6 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a printing press having an inking unit, especially a short inking unit, and to a method of operating an inking unit.
Such printing presses and methods have become known heretofore. A conventional printing press comprises an inking unit, for example an anilox inking unit, having a screen roller for metering a printing medium, for example ink or varnish, to be transferred to an ink applicator roller cooperating with the screen roller. The screen roller is formed in the circumferential surface thereof with a pattern of depressions, such as individual cells or lines, for example. The printing medium is transferred from the screen roller to a printing form, for example a plate cylinder, and from the latter to printing material. Due to the pattern of the screen roller, full-tone areas of a printed image applied to the printing material are not closed, but rather one can detect instead the fine screen roller structure, which is not desired.
In order to prevent the pattern of the screen roller from being detected on the printed image, additional rider rollers, for example, are used on the ink applicator roller, for the purpose of distributing this pattern. Disadvantages here are the costly construction of the printing unit and the fact that the additional rollers cause the inking unit to be no longer free of ghosting. Furthermore, it has become known heretofore to form the pattern of the screen roller so fine that it is no longer perceived as disruptive by the eye of an observer. However, as the pattern becomes finer, the amount of ink that is transferable, i.e., the scooping volume of the depressions formed in the screen roller and, therewith, also the density of the printed image applied to the printing material decreases. As a result, the cleaning of the screen roller is very difficult. Furthermore, the published German Patent Document DE 44 31 464 A1 discloses a device which permits a differential circumferential speed between screen roller and ink applicator roller in order to blur the printing-medium pattern on the ink applicator roller. It has been shown, however, that the printing medium film on the ink applicator roller cannot thereby be evened out in the desired manner and that for differential circumferential speeds of greater than about 5%, the printing medium density simply decreases, while the pattern in the printed image continues to remain visible.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a printing press having an inking unit with which a most possibly closed full-tone area can be printed, and which preferably has a simple and cost-effective construction. A further object of the invention is to provide a method of operating an inking unit wherein a most possibly closed full-tone area is produced preferably simply.
With the foregoing and other objects in view, there is provided, in accordance with one aspect of the invention, a printing press, comprising an inking unit provided with a screen roller having, on a circumference thereof, a pattern formed of depressions fillable with a printing medium, another roller co-operatively engageable with the screen roller, and a drive device, the screen roller and the other roller being drivingly coupled with one another so that, after each revolution of the screen roller, a pattern depicted by the printing medium on the other roller in a form of printing medium accumulations has a slight offset, in circumferential direction, with respect to a pattern depicted on the other roller during a preceding revolution of the screen roller, so that the new printing medium accumulations are positionable on the other roller in at least approximately printing-medium free gaps in, respectively, adjacent printing medium residual accumulations.
In accordance with another feature of the invention, the screen roller and the other roller are coupled with one another via at least a one-stage drive gear transmission.
In accordance with a further feature of the invention, the printing press further comprises a main drive with which the other roller is coupled, and a separate motor with which the screen roller is coupled.
In accordance with an added feature of the invention, the printing press further comprises a variable-ratio gear transmission via which the screen roller and the other roller are connected to one another.
In accordance with an additional feature of the invention, the other roller is drivable at printing-press speed, and the screen roller has a selectively increasable and decreasable circumferential speed for setting a differential circumferential speed between the screen roller and the other roller.
In accordance with yet another feature of the invention, the inking unit is a short inking unit.
In accordance with another aspect of the invention, there is provided a method of operating an inking unit having a screen roller in co-operative engagement with another roller, the screen roller having, on the circumference thereof, a pattern formed of depressions fillable with a printing medium, which comprises rotating the screen roller and the other roller in a manner coordinated with one another so that after each revolution of the screen roller, the pattern depicted by the printing medium on the other roller in a form of printing medium accumulations has a slight offset in circumferential direction with respect to a pattern depicted on the other roller during a preceding revolution of the screen roller so that new printing medium accumulations are positionable on the other roller in at least approximately printing-medium free gaps in respectively adjacent printing medium residual accumulations.
In accordance with a concomitant aspect of the invention, the method is for operating a short inking unit.
Thus, the inking unit, and more specifically, a short inking unit, has a screen roller, for example an anilox roller, which has, on the circumference thereof, a pattern formed of depressions. The depressions can be filled with a printing medium, for example liquid ink or varnish. The screen roller is in contact with another roller, for example an ink applicator roller, to which the printing medium in the depressions is applied. The printing press is distinguished by the fact that the screen roller and the other roller have a drive connection with one another so that after each revolution of the screen roller, the pattern depicted by the printing medium on the other roller in the form of printing medium accumulations has a slight offset in the circumferential direction with respect to a pattern depicted on the other roller during a preceding revolution of the screen roller so that the new printing medium accumulations can be positioned on the other roller in the printing-medium free gap or approximately printing-medium free gaps in respectively adjacent printing medium residual accumulations. The printing medium in the depressions is therefore transferred to the other roller in the nip formed between the screen roller and the other roller and, on the circumferential surface of the latter, forms small printing medium accumulations which, in the circumferential direction of the other roller, are at a constant distance from one another corresponding to the pattern of depressions. In the course of a rotation of the other roller, after part of the accumulated printing medium has been discharged by splitting to a printing form co-operating with the other roller, for example a plate cylinder, printing medium residual accumulations having a volume and a height which have been reduced remain on the other roller. Between these printing medium residual accumulations are virtually printing-medium free gaps. The rolling of the screen roller and the other roller on one another is set so that when the printing-medium free gaps on the other roller are moved past the screen roller, the next, fresh printing medium accumulations are placed by the latter onto the other roller exactly in these gaps between the printing medium residual accumulations. In order to provide the gaps between the printing medium accumulations with printing medium, as distinct from heretofore known methods, these accumulations are therefore not blurred; instead, the virtually printing-medium free gaps between the printing medium residual accumulations on the other roller are filled in a controlled manner with fresh printing medium accumulations. As a result, a printing medium surface relief is produced on the other roller, the printing medium layer thickness thereof fluctuating comparatively only slightly, as a result of which the print quality is increased and continuous inking of a printed full-tone area is realizable. The pattern formed by the depressions on the screen roller can therefore not be detected in the printed image applied to a printing material.
The size of the offset between the fresh printing medium accumulation and the printing medium residual accumulation depends upon the distance from one another of the depressions provided on the screen roller. If, for example, the screen roller has a cell or line pattern, then, for example up to 50 lines can be provided in one centimeter. Here, the distance between two adjacent lines can lie in a range from a few hundredths of a millimeter up to a very few tenths of a millimeter.
In the case of likewise suitable screen roller engraving, the screen roller pattern is formed by cells or lines, of which more than 100 can be arranged on one centimeter. It becomes clear that the offset must be extremely precise in order that the new printing medium accumulations are placed exactly in the printing-medium free gaps or approximately printing-medium free gaps of respectively adjacent printing medium residual accumulations on the other roller.
In an advantageous exemplary embodiment of the printing press, provision is made for the screen roller and the other roller to be coupled with one another via a single-stage or multi-stage drive gear transmission. In a particularly advantageous variation in construction, the overall transmission ratio “i” of the drive gear transmission is selected, and the diameter d R of the screen roller and the diameter d W of the other roller are coordinated with one another in such a way that the circumferential speed difference is zero, i.e., the screen roller and the other roller roll on one another without slip, but nevertheless, following each revolution of the screen roller, the pattern depicted on the other roller having a slight offset in the circumferential direction so that the new printing medium accumulations are placed on the other roller in the virtually printing-medium free gaps of respectively adjacent printing medium residual accumulations. This is realized, for example, by the transmission ratio being 1:1.999, the diameter d W of the other roller being 200 mm, and the diameter d R of the screen roller being 100.05 mm. The diameter d W of the other roller is preferably the same as the diameter of a plate cylinder in contact with the other roller.
Furthermore, the method of the invention provides for the screen roller and the other roller to rotate on one another in a manner coordinated so that after each revolution of the screen roller, the pattern depicted by the printing medium on the other roller in the form of printing medium accumulations has a slight offset in the circumferential direction with respect to a pattern depicted on the other roller during a preceding revolution of the screen roller, so that the new printing medium accumulations can be positioned on the other roller in the printing-medium free gaps or approximately printing-medium free gaps in respectively adjacent printing medium residual accumulations. The offset can be implemented both in the direction of rotation of the rollers and counter to the direction of rotation of the rollers.
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 printing press having an inking unit, and a method of operating an inking unit, 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.
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
FIG. 1 is a fragmentary diagrammatic side elevational view of an exemplary embodiment of a printing press, namely two rollers rolling on one another;
FIG. 2 is a fragmentary diagrammatic side elevational view of an exemplary embodiment of a multistage drive gear transmission for the rollers of the printing press;
FIG. 3 is a diagrammatic top plan view of a further exemplary embodiment of a drive device for the rollers in the printing press, as viewed in the machine running direction; and
FIG. 4 is a fragmentary diagrammatic side elevational view of a third exemplary embodiment of the drive device for the rollers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, first, particularly to FIG. 1 thereof, there is shown therein a printing press 1 which is described hereinafter. Purely by way of example, it is assumed that the printing press 1 is an offset printing press which is operated in the wet offset or dry offset process. The printing medium selected for printing a printing image onto a printing material, for example a sheet or a web of paper, board, plastic material or sheetmetal, may be liquid or pasty ink or varnish, for example. In the hereinafter following text, it is assumed that a liquid ink is being used here.
FIG. 1 shows part of an exemplary embodiment of the printing press 1 , namely an inking unit 3 , which is formed here as an anilox inking unit. The inking unit 3 comprises a screen roller 5 , also known as an anilox roller, which is in contact with another roller 7 , i.e., the screen roller 5 and the other roller 7 roll on one another. Here, the other roller 7 is formed as an ink applicator roller having a rubber-elastic cover, which co-operates with a plate cylinder that is not illustrated in FIG. 1 . The diameter of the other roller 7 is preferably the same as that of the plate cylinder, in this exemplary embodiment the diameter of the screen roller 5 being half that of the other roller 7 .
Provided in the circumferential surface 9 of the screen roller 5 are depressions 11 which are arranged at equal distances from one another, forming a pattern. The depressions 11 are formed here as cells, the cell geometry and the cell distribution determining the scooping volume of the screen roller. The depressions 11 fillable with ink, and a doctor-blade device, not illustrated in FIG. 1, which wipes or scrapes off the circumferential surface 9 of the screen roller 5 , ensure that the depressions 11 are reproducibly filled with ink and, therefore, a prescribed volume of ink is always transferred to the other roller 7 .
The screen roller 5 and the other roller 7 are drivable by a drive device that is not illustrated in FIG. 1, a small circumferential speed difference being set between the screen roller 5 and the other roller 7 , i.e., there is slip between the rollers 5 and 7 , as is discussed hereinafter. In order to set a desired circumferential speed difference, provision is preferably made for a non-illustrated control device, by which the drive device is controlled.
From the depressions 11 in the screen roller 5 , ink is transferred to the circumferential surface 13 of the other roller 7 and forms, on the latter, small ink accumulations 15 (printing medium accumulations) which, as viewed in the circumferential direction of the other roller 7 , are at a constant distance from one another. In this regard, the depressions 11 of the screen roller 5 are partly emptied. Due to the ink accumulations 15 , the pattern and the structure, respectively, of the screen roller 5 is depicted on the circumferential surface 13 of the other roller 7 . The ink accumulations 15 applied to the other roller 7 are not transferred completely to the plate cylinder, because ink splitting takes place, and instead, part of each of the ink accumulations 15 remains on the other roller 7 . These remaining ink accumulations are referred to as residual ink accumulations 17 (printing medium residual accumulations) hereinafter. Ink-free gaps 19 are located between respectively adjacent residual ink accumulations 17 . As is apparent from FIG. 1, the residual ink accumulations 17 have a lower ink volume and a lower height than the ink accumulations 15 , because, respectively, a part of the ink accumulations 15 has been transferred to the plate cylinder due to ink splitting.
The enrolling relationships of the screen roller 5 and the other roller 7 are selected so that as the gaps 19 pass the screen roller 5 in the region of the nip, the new ink accumulations 15 are, respectively, set on and transferred to the other roller 7 by the screen roller 5 precisely in the gaps 19 between the residual ink accumulations 17 . A continuously inked ink film is consequently formed on the circumferential surface 13 of the other roller 7 , the thickness of the ink film fluctuating only slightly. Due to the continuous inking, a closed full-tone area can be printed on the printing material, the pattern on the screen roller being not recognizable in this area. For this purpose, therefore, no additional rollers or other equipment are needed for spreading or wiping the ink accumulations 15 , such as are used in conventional printing presses.
A gap 19 completely free of printing medium, which is located between adjacent residual ink accumulations 17 , ultimately exists only after a first revolution of the other roller 7 . After the gaps 19 have passed the nip, the previously ink-free gaps 19 are provided with ink accumulations 15 , so that a closed ink film is formed, as illustrated in FIG. 1, on that part of the circumferential surface 13 of the other roller 7 which is arranged downstream from the nip. Because, during each revolution of the other roller 7 , parts of the ink accumulations 15 and of the residual ink accumulations 17 are transferred to the plate cylinder, it is finally only the thickness of the ink film which fluctuates.
FIG. 2 shows a fragment of a further exemplary embodiment of the printing press 1 , namely the screen roller 5 and the other roller 7 , which are coupled with one another via a multistage drive gear transmission 21 . The drive gear transmission 21 is part of the drive device for the rollers 5 and 7 . The drive gear transmission 21 comprises a first gear transmission stage 23 , a second gear transmission stage 25 and a third gear transmission stage 27 . The drive gear transmission 21 has a first gear 29 and a second gear 31 , which are firmly connected to a shaft 33 so as to rotate therewith, and also a third gear 35 and a fourth gear 37 , which are firmly connected to a shaft 39 so as to rotate therewith. The drive device 21 further comprises a fifth gear 41 , which is firmly connected so as to rotate with a bearing pin 43 of the screen roller 5 . The first gear 29 and a gear 75 coupled with the other roller 7 form the first gear transmission stage 23 , the intermeshing gears 31 and 35 form the second gear transmission stage 25 , and the gears 37 and 41 form the third gear transmission stage 27 . The overall transmission ratio of the drive gear transmission 21 is selected so that, as described with respect to FIG. 1, the ink accumulations 15 are positioned in the gaps 19 between the residual ink accumulations 17 , the circumferential speeds of the screen roller 5 and of the other roller 7 preferably being equal to one another or differing slightly from one another.
In addition, in the diagrammatic view of FIG. 2, a doctor-blade device 45 assigned to the screen roller 5 is illustrated in the form of a chamber-type doctor blade, for example.
In an exemplary embodiment not illustrated in the figures, the drive gear transmission is of single-stage construction, i.e., only two gears are provided, of which a first gear is coupled with the other roller 7 and a second gear is coupled with the screen roller 5 , with both of the gears intermeshing.
FIG. 3 is a diagrammatic top plan view of an exemplary embodiment of the printing press 1 in the region of the inking unit 3 . Here, a printing form 49 formed by a plate cylinder 47 is shown, which is in contact with the other roller 7 . Also shown is a further exemplary embodiment of the drive device. The other roller 7 is coupled with a main drive 51 of the printing press 1 . For this purpose, a gear 53 connected to the other roller 7 and a gear 55 connected to the plate cylinder 47 are provided. The gear 55 meshes with the gear 53 and with a gear 57 connected to the main drive 51 . In this exemplary embodiment, the gears 53 and 55 have the same rotational speeds, so that the other roller 7 and the plate cylinder 47 , which are of the same diameter, roll on one another without slip. The screen roller 5 is coupled with a separate motor 59 , so that a desired circumferential speed difference between the screen roller 5 and the other roller 7 can be performed by influencing the motor control system. The exemplary embodiment of the drive device illustrated in FIG. 3 offers the advantage that the circumferential speed difference can be set optimally for every desired pattern on the screen roller 5 . With the aid of the separate motor 59 , therefore, an extremely small transmission ratio can be realized, so that the screen roller 5 , for each revolution in the circumferential direction, i.e., in or counter to the direction of rotation thereof, has an offset with respect to the other roller 7 which is preferably a few tenths of a millimeter or hundredths of a millimeter.
FIG. 4 shows a fragmentary side elevational view of a further exemplary embodiment of the printing press 1 , wherein the screen roller 5 is also driven via gears by the main printing-press drive, which is otherwise not specifically illustrated here. The offset between the fresh printing medium accumulations and the residual printing medium accumulations is brought about by a variable-ratio gear transmission 61 . In this exemplary embodiment, the non-illustrated plate cylinder, the other roller 7 and the screen roller 5 are connected to one another via gears in a single plane. The variable-ratio gear transmission 61 here is formed by a planetary or epicyclic gear train, which comprises a gear 63 with internal toothing, a web or flange 65 whereon three planet gears 67 arranged in pairs are arranged so as to be rotatable, and a gear 69 firmly connected so as to rotate with the screen roller 5 . The gear layout is selected here so that during a conceivable standstill of a motor 71 and, therefore, with the web 65 at a standstill, the screen roller would rotate twice when the other roller 7 had made one revolution. During operation, the web 65 is rotated so slowly by the motor 71 that the overall transmission ratio of the variable-ratio gear transmission 61 is set so as to correspond to the cell and line structure of the screen roller 5 , respectively, which is used, and so that the inking of the other roller 7 is again such that the ink accumulations 15 are positioned in the gaps 19 between the residual ink accumulations 17 .
The motor 71 needs only very little power to rotate the web 65 and can, therefore, be constructed to be correspondingly small. In addition, high accuracy for setting the circumferential speed difference between the screen roller 5 and the other roller 7 can be adjusted easily, because the motor 71 has a high transmission ratio for the slowly running pinion 73 thereof, as a result of which the resolution is also multiplied. The embodiment shown in FIG. 4 also offers the advantage that, in the event of failure of the motor 71 , it is always possible to continue printing, even if no longer as desired, because the circumferential speed difference between the screen roller 5 and the other roller 7 is then zero.
As an alternative to the variable-ratio gear transmission 61 described with regard to FIG. 4, it is of course also possible to use other ways for producing a very small, exactly adjustable circumferential speed difference between the screen roller 5 and the other roller 7 . | A printing press includes an inking unit provided with a screen roller having, on a circumference thereof, a pattern formed of depressions fillable with a printing medium, another roller co-operatively engageable with the screen roller, and a drive device, the screen roller and the other roller being drivingly coupled with one another so that, after each revolution of the screen roller, a pattern depicted by the printing medium on the other roller in a form of printing medium accumulations has a slight offset, in circumferential direction, with respect to a pattern depicted on the other roller during a preceding revolution of the screen roller, so that the new printing medium accumulations are positionable on the other roller in at least approximately printing-medium free gaps in, respectively, adjacent printing medium residual accumulations; and a method of operating the printing unit. | 1 |
FIELD OF THE INVENTION
[0001] The present invention is related to a bottom antireflective coating layer for suppressing a reflective notching that occurs at a substrate surface under a photoresist during an exposing process of photolithography using a deep ultraviolet light source to form a submicron-level, large-scale semiconductor integrated circuit and eliminating an effect of standing wave that occurs due to a variation of thickness of photoresist and using light source. More particularly, it is related to the compositions of antireflective coating materials containing an isoflavone chromophore and to a method of producing the compositions.
BACKGROUND OF THE INVENTION
[0002] An organic antireflective coating (ARC) layer is a very thin film of light absorbing material being used in photolithography for stably forming a submicron pattern of 100 nm˜200 nm or less that is essential to produce a giga-bit level, large-scale integrated chips. This thin film is called as a bottom antireflective coating (BARC or bottom ARC) because it is coated primarily on a substrate surface under the photoresist for exposing process of deep ultraviolet light.
[0003] In a conventional photolithography, there are problems of reflective notching being occurred at a substrate surface under a photoresist during an exposing process and an effect of standing wave being occurred due to a variation of thickness of photoresist and using light source. Due to those problems, it is hard to stably form a submicron pattern of 100 nm˜200 nm or less on the substrate surface. Therefore, an organic bottom ARC layer is needed for absorbing incident light having a specific wavelength.
[0004] The ARC layer must have an excellent property of light absorption as the wavelength of light source is shortened (G-line, I-line, KrF, ArF, F 2 etc.) in accordance with the technology of submicron-level, large-scale integrated chip is advanced [M. Padmanaban et al., Proc. SPIE, 3678, 550 (1999); E. Iguchi et al., Proc. SPIE, 3999, 521 (2000); M. Padmanaban et al., Proc. SPIE, 3333, 206 (1998)]
[0005] Even a variety of techniques have remarkably been developed in the semiconductor manufacturing industry, the conventional photolithography being spin coated a photoresist on a silicone substrate for a subsequent exposure process becomes no more suitable to apply for stably producing a sub-micron pattern of 100˜200 nm. Consequently, a special technique of thin film coating is essentially needed prior to coating a photoresist. The antireflective coating layer in the photolithography becomes indispensable for preventing an effect of standing wave in the photoresist occurred from interference between an incident light to photoresist and the reflected light from the substrate surface. It will also prevent or remarkably reduce the reflections caused from the topography of already-formed circuits and the reflective notching on the edges. Therefore, a desired critical dimension (CD) of submicron circuit could be accurately controlled. It also eases the tolerance conditions for producing process.
[0006] This antireflective coating layer could be divided into an organic material being spin-coated according to its compositions and an inorganic material being coated by chemical vapor deposition. In the recent year, an organic antireflective coating is increasingly used.
[0007] Particularly, due to an advanced exposure process used in a high energy short wavelength such as the deep ultraviolet light, a chromophore having a high light absorption in the deep ultraviolet light spectrum is required, mainly leading the development of organic antireflection coating layer using the naphthalene or anthracene derivatives. [J. Fahey et al., Proc. SPIE, 2195, 422 (1994); K. Mizutani et al., Porc. SPIE. 3678, 518 (1999)]. This technique is disclosed in the U.S. Pat. Nos. 5,693,692, 5,851,738, 5,919,599 and 6,033,830.
SUMMARY OF THE INVENTION
[0008] A technological object of the present invention is to provide a novel organic photosensitive material containing an isoflavone chromophore and a method for producing the same, which enable to use as an antireflective coating layer in a photolithographic process using a Krytonfluoride (KrF) eximer laser of 248 nm-wavelength and Argonfluoride (ArF) eximer laser of 193 nm-wavelength as an exposing light source for producing a large-scale integrated semiconductor device.
[0009] Another object of the present invention is to provide the organic polymer material having an isoflavone chromophore as a side chain for preventing light reflections that are transmitted through the photoresist during a light exposing process and a method for producing the same.
[0010] Other object of the present invention is to provide the compositions of bottom antireflective coating layer using the organic polymer materials.
[0011] Still other object of the present invention is to provide a protective coating layer produced by using the compositions of bottom antireflective coating layer and a method for producing the same.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Generally, an incident light is transmitted, absorbed, reflected or refracted depending on the optical property of materials and encountered interfaces. By utilizing this well known property of light, the present invention is developed an organic antireflective coating (ARC) layer for absorbing the incident light. If an organic ARC layer has the same refractive index as the photoresist has, there would be no reflections at an interface of photoresist and ARC layer. For this reason, the ARC layer must have the same optical property with a commercial DUV photoresist to have identical performance of lithographic. Consequently, the organic antireflective coating (ARC) layer of the present invention is designed for absorbing the incident light so that the penetrated light thru the interface of photoresist and ARC layer will be absorbed before reaching the substrate surface.
[0013] Therefore, the organic bottom ARC layer should have an excellent property of high light absorption against a specific exposure wavelength of 248 nm, 193 nm and 157 nm of eximer laser for photolithographic process.
[0014] Along the propagation of photolithographic process that is using a Krytonfluoride (KrF) eximer laser, the role of antireflective coating layer becomes more important matter. Therefore, most compositions of organic antireflective layer are required to have following conditions:
[0015] It must have a proper optical constant such as a refractive index (n) and extinction coefficient (k) for a light source, which is used in a semiconductor production.
[0016] The organic bottom antireflective coating layer should have a high selection ratio with respect to plasma dry etching compared with an upper layer of photoresist and should not have defects in accordance with dry etching.
[0017] It must not have a phenomenon of intermixing the photoresist with bottom antireflective coating layer, and have a reactive site for the sake of forming an appropriate crosslink in the organic polymer.
[0018] The organic bottom antireflective coating layer should be in acid equilibrium with photoresist after exposing and developing process so as not to occur undercutting or footing at a sublayer of pattern.
[0019] It must have capability of layer formation and layer uniformity for forming a proper thickness of bottom antireflective coating layer suitable to process revolution per minute (RPM).
[0020] A polymer for a bottom antireflective coating (BARC) layer of the present invention comprises isoflavone chromophore having a high light absorption at 248 nm and 193 nm of exposure wavelengths in a main chain, monomer contained a hydroxyl group for crosslinking during a formation of antireflective coating layer, co-monomer for adjusting the property of polymer and co-polymer, ter-polymer or quarto-polymer comprised with three or four different kinds of monomers. A general formula of polymer is represented as follows:
[0021] That is, a polymer of the present invention for bottom antireflective coating layer has a structure -(Ma) k -(M b ) l -(M c ) m -(M d ) n -. Among them,
[0022] M a is an (meth) acrylate monomer containing an isoflavone chromophore, being represented by the above Formula (1).
[0023] M b is an (meth) acrylate monomer containing a hydroxyl group, which is represented by the above Formula (2).
[0024] M c is an alkylmaleimide monomer containing hydroxyl group, which is represented by the above Formula (3).
[0025] And M d is (meth) acrylate monomer, represented by the above Formula (4).
[0026] In the above Formulas (1), (2), (3) and (4), R 1 ˜R 7 independently represent each of hydrogen, methoxy, hydroxy, halogen, aldehyde. C 1 ˜C 6 represent alkoxyalkyl or C 1 ˜C 5 represent alkoxyalkane. R 8 , R 9 and R 10 represent hydrogen or methyl group, and R 11 and x represent C 1 ˜C 6 alkyl group.
[0027] In the General Formula I, the values of mol ratio are k, 0.1˜0.5, l and m, 0.0˜0.4 and n, 0.3˜0.6 based on the total molar feed ratio of k+l+m+n.
[0028] The isoflavone chromophore monomer (1) of the present invention has excellent property of plasma etching compared with the conventional anthracene group chromophore derivative. It has not only a high light absorption at 248 nm wavelength spectrum of Krytonfluoride (KrF) eximer laser, but also enhanced adhesion on a wafer due to the substitution of hydrophilic moiety.
[0029] The polymer of General Formula I of the present invention could be produced by reacting a radical initiator for 2 to 24 hours under an inert gas environment such as a Nitrogen or Argon. The radical initiators commonly used are thermal decomposition initiators such as a benzoil peroxide (BPO), 2,2′-azobisisobutyronitrile (AIBN) and Di-tert-butyl peroxide (DTBP). If one of these radical initiators is used, a reaction would be performed at the temperature of 50°˜90° C. A solvent such as a dioxane, tetrahydrofuran and benzene is popularly used for a polymerizing solvent. Therefore, it is possible to synthesize a polymer having a proper molecular weight with etching performance by adjusting each amount of monomer, polymerizing solvent or radical initiator. The molecular weight of polymer of General Formula I should be within a range of 5,000 to 100,000 g/mol measured by a gel-permeation chromatography (GPC). The range of molecular weight of polymer could be adjusted for proper coating capability by varying the synthesizing conditions.
[0030] The composition of organic bottom antireflective coating (BARC) material is produced through the following process: 0.5˜50 weight % of polymer of the General Formula I is added to an organic solvent having an excellent coating layer forming capability, such as a propyleneglycol monomethylether acetate (PGMEA), ethyl 3-ethoxypropionate, methyl 3-methoxypropionate and cyclohexanone being used for manufacturing semiconductor device. Then, the solution is dissolved by adding various functional additives. Next, the solution is filtered and coated on a silicon wafer to form a bottom ARC film layer. Then, the coated silicon wafer is hard-baked to bring crosslinking at a proper temperature.
[0031] By applying this antireflective coating layer, the problems due to the reflections in a photolithographic process using deep ultraviolet could be entirely controlled so that the production of semiconductor devices is facilely performed.
[0032] According to the present invention, the polymer of antireflective coating layer being contained isoflavone chromophore reveals an excellent lithographic performance as an organic bottom antireflective coating layer in 248 nm, 193 nm and 157 nm of light exposure wavelength. The present polymer is verified as a useful material for forming a submicron circuit of semiconductor chips due to fast plasma etching speed being compared with the conventional antireflective coating layer formed based on anthracene chromophore.
Implementing Example
[0033] Hereinafter, according to the present invention, a producing method of methacrylic monomer and methacrylic polymer contained an isoflavone chromophore, the compositions of organic bottom antireflective coating layer being applied methacrylic monomer and methacrylic polymer and the producing method are specifically described in a detail accompanying with implementing examples. However, a purpose of implementing examples is for explaining the present invention, but not limited to the implementing examples.
EXAMPLE 1
Synthesizing Isoflavonyl Methacylate as a Chromophore Monomer (IFVMA)
[0034] [0034]
[0035] Dissolve 7-hydroxyisoflavone (5)(100.00 g, 0.42 mol) into pyridine (150 ml) and stir for five hours at the temperature of 4° C. by gradually adding methacryloyl chloride (42.00 g, 0.42 mol). After precipitating reactant in the cold water and filtering, extract the filtered reactant several times with methylene chloride, and refining. Then, dry the product in a vacuum for recovering a light yellowish crystalline of isoflavonyl methacrylate (6). Yield: 116.4 g (82%). Melting point: 168° C.
EXAMPLE 2
Synthesizing Isoflavonyl Methacrylate Monomer (MIFVMA) Contained Methoxy Group
[0036] [0036]
[0037] Dissolve formononetin (7)(100.00 g, 0.37 mol) into pyridine (150 ml) and stir the solution for 3 hours at temperature of 4° C. by gradually adding methacryloyl chloride (37.00 g, 0.37 mol). After precipitating reactant in the cold water and filtering, extract the filtered reactant several times with chloroform and refining. Then, dry the product in a vacuum to recover a deep yellowish crystalline of isoflavonyl methacrylate (8) having methoxy group. Yield: 119.2 g (87%) Melting point: 194° C.
EXAMPLE 3
Synthesizing Terpolymer Using Monomer (2), (4) and (6)
[0038] In a polymerizing container, Isoflavonyl Methacylate (IFVMA) (6) (20.00 g, 65.5 mmol), hydroxyethymethacrylate (HEMA) (2) (8.52 g, 65.5 mmol), methylmethacrylate (MMA) (4) (8.74 g, 87.3 mmol) and 5-mol % of AIBN are placed and dissolved with dioxane (70 ml). Then, the solution is polymerized for 10 hours at the temperature of 60° C. under a nitrogen environment. After precipitating reactant in a sufficient methanol, the filtering and drying process are performed thru for synthesizing terpolymer of poly (IFVMA-HEMA-MMA). A yield of poly (IFVMA-HEMA-MMA) is 83%. A weight average molecular weight being measured by GPC is about 46,000 g/mol so as to easily form a film layer.
EXAMPLE 4
Synthesizing Terpolymer Using Monomer (2), (4) and (8)
[0039] In a synthesizing container, methoxy substituted Isoflavonyl Methacrylate (MIFVMA)(8)(22.00 g, 65.4 mmol), hydroxyethylmethacrylate (HEMA)(2)(98.52 g, 65.5 mmol), methymethacrylate (MMA)(4)(8.74 g, 87.3 mmol) and 5-mol % of AIBN are placed and dissolved with tetrahydrofuran (79 ml). The solution is polymerized for 10 hours at the temperature of 60° C. under a nitrogen environment. After precipitating reactant in a sufficient methanol, the filtering and drying process are performed for synthesizing terpolymer of poly (MIFVMA-HEMA-MMA). A yield of poly (MIFVMA-HEMA-MMA) is 91%. A weight average molecular weight measured by GPC is approximately 44,000 g/mol so as to easily form a film layer.
EXAMPLE 5
Synthesizing Quatropolymer Using Monomer (2), (3), (4) and (6)
[0040] In a polymerizing container, Isoflavonyl Methacylate (IFVMA)(6) (9.00 g, 38 mmol), hydroxyethylmaleimide (HOEMI) (3) (5.36 g, 38 mmol), hydroxyethylmethacrylate (HEMA) (2) (8.52 g, 65.5 mmol), methymethacrylate (MMA) (4) (8.74 g, 87.3 mmol) and 5-mol % of AIBN are placed and dissolved with a mixed solvent of tetrahydrofuran and methylethylketone (73 ml). The solution is polymerized for 10 hours at the temperature of 60° C. under a nitrogen environment. After precipitating reactant in a sufficient methanol, the filtering and drying process are performed for synthesizing quatropolymer of poly (IFVMA-HOEMI-HEMA-MMA). A yield of poly (IFVMA-HOEMI-HEMA-MMA) is 79%. A weight average molecular weight being measured by GPC is about 40,500 g/mol so as to easily form a film layer.
EXAMPLE 6
Synthesizing Quatropolymer Using Monomer (2), (4), (6) and (8)
[0041] In a polymerizing container, IFVMA Monomer (6) (9.00 g, 38 mmol), MIFVMA Monomer (8) (10.3 g, 38 mmol), hydroxyethylmethacrylate (2) (HEMA) (8.52 g. 65.5 mmol), methylmethacrylate (MMA) (4) (8.74 g, 87.3 mmol) and 5 mol % of AIBN are placed and dissolved with a mixed solvent of tetrahydrofuran and methylethylketone (73 ml). Then, the solution is polymerized for 10 hours at the temperature of 60° C. in a nitrogen environment. After precipitating reactant in a sufficient methanol, the filtering and drying process are performed for synthesizing quatropolymer of poly (IFVMA-MIFVMA-HEMA-MMA). A yield of poly (IFVMA-MIFVMA-HEMA-MMA) is 88%. A weight average molecular weight being measured by GPC is approximately 43,500 g/mol so as to easily form a film layer.
EXAMPLE 7
Producing and Applying the Compositions of Organic Bottom Antireflective Coating Layer
[0042] One of polymers being obtained in the above examples 1 thru 6 is dissolved in propylene glycol monomethylether acetate with a weight ratio of 1:20˜1:50. Stir the solution after adding various additives such as an acid-catalyzed thermo-crosslinker and stabilizer. The solution is filtered through a 0.05 μm of membrane filter to produce an organic solution of antireflective coating layer. This organic solution is spin-coated on a silicon wafer and crosslinked for 10 to 120 seconds at the temperature of 100° C.˜250° C. to prevent intermixing with a photoresist. Hereinafter, following a general producing process, a photolithographic process for submicron circuit is performed by spin coating a commercial photoresist on the antireflective coating layer. The compositions of organic bottom antireflective coating layer being applied the polymers, which is obtained from implementing examples, are in acid equilibrium with photoresist after the light exposing process during a development. Consequently, there is no undercutting or footing formed at the sublayer pattern of photoresist. A dimensional variation in a submicron pattern due to reflective notching is so negligible that the formation of submicron circuit is stably performed.
[0043] As disclosed throughout the implementing examples, because the antireflective coating layer being used polymer having basic structure of terpolymer or quartopolymer adapts a covalent bond of side chain having a high light-absorptive isoflavone chromophore, the ARC layer has excellent heat stability without generating gases during a high heat exposure process. The ARC layer of the present invention also has not only a capability of sufficient light absorption to be qualified a bottom antireflective coating layer, but also a capability of suppressing reflections of light that occurs underneath the substrate layer during an exposure process and eliminating the standing waves that occurs due to the thickness variation of photoresist and using light source. Due to a high etching capability with respect to plasma, it enables to stably photo-transmit a clear image of submicron circuit on the substrate surface
[0044] Accordingly, when a copolymer of the present invention is applied to an exposure process of bottom antireflective coating layer, which is used 248 nm, 193 nm or 157 nm of exposure wavelength of eximer laser, a formation of submicron pattern for an integrated circuit system having a 64-mega bit DRAM or higher memory device of Giga bit or 0.1˜0.2 micron level pattern is stably performed. Consequently, the production rate of semiconductor devices could be remarkably increased.
[0045] While the present invention has been described in detail with its preferred embodiments, it will be understood that it further modifications are possible. The present application is therefore intended to cover any variations, uses or adaptations of the invention following the general principles thereof, and includes such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains within the limits of the appended claims. | A bottom antireflective coating layer is made from the compositions of organic photosensitive materials containing isoflavone chromophore by photolithography utilizing deep ultraviolet light source for producing a submicro-level, large-scale integrated chip. A copolymer being contained an isoflavone chromophore is used as a bottom antireflective coating layer for fabricating a 64-megabit or gigabit DRAMs. The antireflective coating layer enables not only to suppress reflection of light that occurs under the substrate layer but also to remove standing waves. Consequently, a high-resolution sub-micron of 100˜200 nm integrated circuit is able to be stably formed. Therefore, it is possible to increase the production of semiconductors. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an automatic positioning apparatus for an automative vehicle to the used for automatically driving a vehicle mounted device into a memorized position suitable for the driver, and more particularly to a system and a method for controlling the attitude of the vehicle mounted device such as a seat, a steering wheel or the like, back and forth, up and down, for example.
2. Description of the Prior Art
Heretofore, there has been used an automatic positioning apparatus as shown in FIG. 11.
The automatic positioning apparatus 100 illustrated in the figure is so designed as to actuate a shaft 103 of a steering wheel 104 up and down between the upper position a and the lower position b through a tilt motor 102 and move the steering wheel 104 back and forth between the front side position c and the rear side position d by actuating the steering wheel shaft 103 telescopically through a telescopic movement motor 105 in accordance with a manual operation of a steering wheel positioning switch 101. The automatic positioning apparatus 100 is also designed so as to drive a seat 108 back and forth slidingly through a seat motor 109 in response to a manual operation of a seat positioning switch 110.
The tilt motor 102 and the telescopic movement motor 105 are connected with a controller 106 housed with a microcomputer through the steering wheel positioning switch 101, and the controller 106 is connected with a battery 107. The controller 106 is connected with the seat motor 109 through the seat positioning switch 110, and tilt data representing an inclination angle of the steering wheel shaft 103 detected by a tilt sensor 111, telescopic movement data representing a telescopic location of the steering wheel 104 detected by a telescopic movement sensor 112 and slide data representing a sliding location of the seat 108 detected by a seat sensor 113 are input to the controller 106 through an I/O interface circuit (not shown).
In case of memorizing driving positions suitable for a driver, the steering wheel shaft 103 is moved into the position e by actuating the tilt motor 102 and the steering wheel 104 is moved to the position f suitable for the driver by adjusting telescopic location of the steering wheel shaft 103 through the telescopic movement motor 105 according to the manual operation of the steering wheel positioning switch 101, and the seat 108 is moved slidingly into the position g suitable for the driver by actuating the seat motor 109 according to the manual operation of the seat positioning switch 110. In this state, the controller 105 memorizes the position e detected by the tilt sensor 111, the position f detected by the telescopic movement sensor 112 and the position g detected by the seat sensor 113 as the driving positions suitable for the driver in response to a presetting operation of a set switch (not shown) disposed on a switch board together with the seat positioning switch 110.
After this, the steering wheel 104 and the seat 108 move automatically to the respective positions e, f and g memorized by the controller as the driving positions suitable for the driver by actuating the tilt motor 102, the telescopic movement motor 105 and the seat motor 109 according to a positioning operation of the set switch.
Additionally, in the automatic positioning apparatus 100, electric currents are supplied to the tilt motor 102, the telescopic movement motor 105 and the seat motor 109 so as to actuate the steering wheel 104 and the seat 108 toward turnout positions by sensing an ignition key (not shown) to be pulled out from an ignition switch, sensing a door on the driver's seat side to be opened in case the ignition key is inserted into the ignition switch, or sensing the ignition key to be turned to the OFF-position from the ACC-position in the ignition switch in case the door is opened when the steering wheel positioning switch 101 is switched into the automatically operable state. Whereby, the shaft 103 of the steering wheel 104 is moved from the position e to the upper position a (turnout position) by the tilt motor 102, the sterring wheel 104 is moved from the position f to the front side position c (turnout position) by the telescopic movement motor 105, and the seat 108 is moved from the position g to position h (turnout position) shifted backwardly from the position g by predetermined distance after the positions where the steering wheel 104 and the seat 108 are at present (position e, position f and position g in this case) are memorized in the microcomputer of the controller 106. Therefore, the space between the steering wheel 104 and the seat is made wider, and it becomes easy to get in and out from the driver's seat of the automative vehicle.
At the state in which the steering wheel 104 and the seat 108 are in the turnout position, if the ignition key is inserted into the ignition switch, the door is closed when the ignition key is inserted into the ignition switch or the ignition key is turned to the (ON-position from the ACC-position in the ignition switch when the door is opened, electric currents are supplied to the tilt motor 102, the telescopic movement motor 105 and the seat motor 109 so as to actuate the steering wheel 104 and the seat 108 toward the previous positions memorized in the microcomputer of the controller 106 immediately before the steering wheel 104 and the seat 108 are actuated to the turnout positions. Whereby the steering wheel shaft 103 is moved from the turnout position a to the position e by the tilt motor 102, the steering wheel 104 is moved from the turnout position c to the position f by the telescopic motor 105 and the seat 108 is moved slidingly from the turnout position h to the position g by the saeat motor 109. In such a manner, the steering wheel 104 and the seat 108 return automatically to the positions memorized immediately before starting to the turnout positions, that is, the originally memorized positions e, f and g.
On the other side, in a case of actuating the steering wheel 104 or the seat 108 by manual operation while the vehicle is travelling for example, the automatic positioning apparatus 100 is so designed as to inch the motors so as not to obstruct the safety driving.
Namely, when the steering positioning switch 101 is switched on in the upward direction at time i as shown in FIG. 12 for example, an electric current is supplied to the tilt motor 102 in the forward rotational direction, thereby rotating the tilt motor 102 in the forward direction and actuating the steering wheel shaft 103 upwardly.
After the predetermined time, an electric current is supplied to the tilt motor 102 in the reverse rotational direction according to a downward signal output from the controller 106 at time j shown in the figure, whereby the tilt motor 102 stops by dynamic braking becasue the tilt motor 102 is supplied with the electric current in the forward rotational direction according to the manual operation of the steering wheel positioning switch 101 and the electric current in the reverse rotational direction according to the downward driving signal output from the controller 106 at the same time. Then the controller 106 discontinues to output the downward signal by sensing the steering wheel positioning switch 101 to be changed off, thereby shutting off the electric current in the reverse rotational direction to the tilt motor 102.
In such a manner, the motors are so designed as to be inched in the automatic positioning apparatus 100.
However, there is the possibility that the steering wheel 104 and the seat 108 pass over the memorized driving positions by inertia even if the power supply to the motors (tilt motor 102, telescopic motor 105, seat motor 109 and the like) is cut off at the time of the return to the memorized driving positions according to the positioning operation of the set switch.
Therefore, there is a problem since the steering wheel 104 and the seat 109 stop at the positions deviated from the proper driving positions memorized by the controller 106.
Additionally, if the presetting operation of the set switch is done in this time, there is another problem in that the positions deviating from the proper driving positions are newly memorized in the controller 106 as driving positions in spite that the driver does not have an intention to change the memorized driving positions. Where the driver repeats to get in and out from the driver's seat many times, there is also a problem in that the difference between the returning positions and the originally memorized driving positions gradually increases because the returning positions memorized in the controller 106 are renewed every time the driver gets out the vehicle and the steering wheel 104 and the seat 108 are actuated toward the turnout positions.
Furthermore, if the positioning operation of the set switch is done again after the steering wheel 104 and the seat 108 return toward the memorized driving positions according to the positioning operation of the set switch and stop once, the steering wheel 104 and the seat 108 are moved in the opposite direction because the steering wheel 104 and the seat 108 stop at the positions deviated from the memorized driving positions. Therefore, there is a problem since the driver is uncomfortable.
In addition to above, in case of manually actuating the steering wheel 104 or the seat 108 while the vehicle is travelling, the steering wheel 104 or the seat 108 is so designed as to be acutated by inching the tilt motor 102, the telescopic movement motor 105 or the seat motor 109 under the aforementioned control. However, as shown in FIG. 12, a time lag may be caused until the electric current in the reverse rotational direction is cut off after changing off the steering wheel positioning switch 101 at time k shown in the figure because the control needs some time to sensing the steering wheel positioning switch 101 to be changed off and to actuate a relay for cutting off the electric current to the tilt motor 102.
Accordingly, there is another problem in that the steering wheel 104 is actuated over again in the downward direction after moving in the upward direction and the driver feels displeasure because the electric current in the reverse rotational direction continue to be supplied to the tilt motor 102 for a short time even after the electric current in the forward rotational direction is cut off according to the manual operation of the steering wheel positioning switch 101.
SUMMARY OF THE INVENTION
The present invention is directed to solve the above-mentioned problems of the prior art, it is an object to provide an automatic positioning apparatus which is possible to minimize various inconvenience and malfunction due to the passing over of the vehicle mounted device such as the steering wheel, the seat or the like caused by inertia, and a method for controlling the attitude of the vehicle mounted device possible to minimize the influence of the inertia. It is another object to provide a method which is possible to prevent the vehicle mounted device from the reversal movement at the time of inching the vehicle mounted device by manual operation.
The construction of the automatic positioning apparatus for controlling the attitude of a vehicle mounted device according to this invention in order to accomplish the above-mentioned object is characterized by comprising motor means for actuating the vehicle mounted device, sensor means for detecting a position of the vehicle mounted device, and a control means which memorizes the position of the vehicle mounted device detected by the sensor means at the time of presetting a set switch in response to the presetting operation of the set switch and drives automatically the vehicle mounted device to the memorized position through the motor means in response to a positioning operation of the set switch. The control means which sets a motor-suspensive zone having a predetermined range in front and in rear of the memorized position and stops the motor means when the vehicle mounted device enters the motor-suspensive zone at the time of returning the vehicle mounted device to the memorized position automatically according to the positioning operation of the set switch. Accordingly, the vehicle mounted device such as a seat, a steering wheel or the like stops at the position immediate near the memorized position suitable for the driver because the motor means are suspended on an early occasion.
The control means also set a renewal-prohibitive zone having a predetermined range in front and in rear of the memorized position and prohibits to renew the memorized position when the vehicle mounted device are within the renewal-prohibitive zone. Whereby, as the renewal of the memorized position is prohibited in the renewal-prohibitive zone, the memorized position never shifts even if the presetting operation of the set switch or the turnout action of the vehicle mounted device is repeated, and the original position memorized suitably for the driver are maintained as it is.
Furthermore, the control means sets a readjustment-prohibitive zone having a predetermined range in front and in rear of the memorized position and prohibits the motor means to actuate the vehicle mounted device to the memorized position according to the positioning operation of the set switch once the vehicle mounted device stops within the readjustment-prohibitive zone. Therefore, the vehicle mounted device never moves in the opposite direction even if the positioning operation of the set switch is done again after the vehicle mounted device is actuated toward the memorized position and stops in the readjustment-prohibitive zone automatically.
Additionally, in the case of actuating the vehicle mounted device by manual operation while the vehicle is travelling for example, the motor means is stopped by supplying an electric current in the forward rotational direction and an electric current in the reverse rotational direction to the motor at the same time after the predetermined time since on-operation of a manual switch, and shutting off the electric currents in the both directions at the same time by detecting the manual switch to be changed off. Therefore, the vehicle mounted device never moves in the opposite direction after moving in one direction even if the time lag is caused by sensing the manual switch to be changed off or by actuating the relay to cut the current supply.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the configuration of the automatic drive-positioning device according to this invention;
FIG. 2 is a circuit diagram for driving the tilt motor in the automatic drive-positioning device shown in FIG. 1;
FIG. 3 is a conceptional diagram of the control using a motor-suspensive zone;
FIG. 4 is a flowchart explaining the control using the motor-suspensive zone shown in FIG. 3;
FIG. 5 is a conceptional diagram of the control using a renewal-prohibitive zone;
FIG. 6 is a flowchart explaining the control using the renewal-prohibitive zone shown in FIG. 5;
FIG. 7 is a conceptional diagram of the control using a readjustment-prohibitive zone;
FIG. 8 is a flowchart explaining the control using the readjustment-prohibitive zone shown in FIG. 7;
FIG. 9 is a flowchart explaining the control at the time of manually actuating the steering wheel in the automatic positioning apparatus shown in FIG. 1;
FIG. 10 is a time chart illustrating the timing of the control shown in FIG. 9;
FIG. 11 is a block diagram of the conventional automatic positioning apparatus; and
FIG. 12 is a time chart explaining the control at the time of manually actuating the steering wheel in the conventional positioning apparatus shown in FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An automatic positioning apparatus according to an embodiment of this invention and the control will be explained below on bases of FIG. 1 to FIG. 10.
The automatic positioning apparatus 1 shown in FIG. 1 is provided with a controller 4, which is connected with a tilt motor 3 for actuating a shaft 2a of a steering wheel 2 up and down and adjusting an inclination angle of the steering wheel shaft 2a between upper position A and lower position B, a telescopic movement motor 5 for actuating the steering wheel shaft 2a back and forth telescopically and adjusting the steering wheel 2 between front side position C and rear side position D, a slide motor 7 for actuating a seat 6 back and forth slidingly between forward position E and backward position F, a lift motor 8 for actuating the seat 6 up and down and adjusting height of the seat 6 and a recliner motor 9 for adjusting an reclination angle of a seat back of the seat 6.
The controller 4 is housed with an I/O interface circuit and a microcomputer (not shown) connected with the I/O interface circuit. And the I/O interface circuit of the controller 4 is connected with a tilt sensor 3a for detecting the inclination angle of the steering wheel shaft 2a, a telescopic movement sensor 3a for detecting a telescopic location of the steering wheel 2, a slide sensor 7a for detecting a sliding location of the seat 6, a lift sensor 8a for detecting the height of the seat 6 and an reclining sensor 9a for detecting the reclination angle of the seat back of the seat 6. The controller 4 is so designed that tilt data from the tilt sensor 3a representing the inclination angle of the steering wheel shaft 2a, telescopic movement data from the telescopic movement sensor 5a representing the telescopic location of the steering wheel 2, slide data from the slide sensor 7a representing the sliding location of the seat 6, lift data from the lift sensor 8a representing the height of the seat 6 and reclination data from the reclining sensor 9a representing the reclination angle of the seat back of the seat 6 may be input to the microcomputer through the I/O interface circuit in the microcomputer 4.
The controller 4 is connected with a seat positioning switch 10 (manual switch), the seat 6 is actuated back and forth, or up and down through the slide motor 7 or the lift motor 8, and the seat back of the seat 6 is actuated back and forth recliningly through the recliner motor 9 by manually operating the seat positioning switch 10. The controller 4 is also connected with a set switch 10a to be operated in order to memorize present positions of the seat 6 and the steering wheel 2 in the microcomputer and to return them automatically into the memorized driving positions as described later, which is disposed on a switch board together with the seat positioning switch 10.
Additionally, the controller 4 is connected with a cancel switch 11a operable to cancel the automatic action of the seat 6 and the steering wheel 2, and a steering wheel positioning switch 11 (manual switch). The steering wheel 2 is actuated up and down, or back and forth telescopically through the tilt motor 3 or the telescopic movement motor 5 by manually operating the steering wheel positioning switch 11.
FIG. 2 is a diagram showing a driving circuit of the tilt motor 3 among the motors as mentioned above, and the telescopic movement motor 5, the slide motor 7, the lift motor 8 and the recliner motor 9 also have similar driving circuits respectively.
As shown in FIG. 2, a power terminal 3b of the tilt motor 3 is connected to a travelling contact rl 1-1 of a forward rotational (upward driving) relay RL1, a normal close fixed contact rl 1-2 of the relay RL1 is connected to a power source 50 and a relay coil rl 1-3 of the relay RL1.
The relay coil rl 1-3 of the relay RL1 is connected to a fixed contact 11A-2 of a upward driving (forward rotational) switch 11A having a movable contact 11A-1 grounded of the steering wheel positioning switch 11 through a diode D1 and connected with collector of a transistor Tr1, a node between the diode D1 and the fixed contact 11A-2 is connected to a forward rotational (upward driving) signal input port 4a of the controller 4.
A normal open fixed contact rl 1-4 of the relay RL1 and emitter of the transistor Tr1 are grounded, and base of the transistor Tr1 is connected to a forward rotational (upward driving) signal output port 4b of the controller 4.
Another power terminal 3c of the tilt motor 3 is connected to a travelling contact rl 2-1 of a reverse rotational (downward driving) relay RL2, and a normal close fixed contact rl 2-2 of the relay RL2 is connected to the power source 50 and a relay coil rl 2-3 of the relay RL2.
The relay coil rl 2-3 of the relay RL2 is connected to a fixed contact 11B-2 of a downward driving (reverse rotational) switch 11B having a movable contact 11B-1 grounded of the steering wheel positioning switch 11 through a diode D2 and connected with collector of a transistor Tr2, a node between the diode D2 and the fixed contact 11B-2 is connected to a reverse rotational (downward driving) signal input port 4c of the controller 4.
A normal open fixed contact rl 2-4 of the relay RL2 and emitter of the transistor Tr2 are grounded, and base of the transistor Tr2 is connected to a reverse rotational (downward driving) signal output 4d of the controller 4.
Further, the controller 4 is provided with a data input port 4e to be input with tilt data detected by the tilt sensor 3a in addition to the respective ports 4a, 4b, 4c and 4d.
In case of setting driving positions suitable for the driver, in the first place the shaft 2a of the steering wheel 2 is shifted to position G suitable for the driver by manually operating the upward driving switch 11A or the downward driving switch 11B of the steering wheel positioning switch 11 into its ON-state. Namely, when the movable contact 11A-1 contacts with the fixed contact 11A-2 by changing the upward driving switch 11A of the steering wheel driving switch 11 on, the relay coil rl 1-3 of the relay RL1 is excited and the travelling contact rl 1-1 contacts with the normal open fixed contact rl 1-4 . An electric current is supplied to the tilt motor 3 in the forward rotational direction (rightward direction in FIG. 2), thereby actuating the steering wheel shaft 2a upwardly. Contrary to above, if the downward driving switch 11B of the steering wheel positioning switch 11 is changed on, the relay coil rl 2-3 of the relay RL2 is excited and the travelling contact rl 2-1 contacts with the normal open fixed contact rl 2-4 thereby supplying an electric current to the tilt motor 3 in the reverse rotational direction (leftward direction in FIG. 2), and the steering wheel shaft 2a is actuating downwardly.
Similarly to above, the steering wheel 2 is shifted to position H suitable for the driver by actuating the telescopic movement motor 5 through its driving circuit in response to an ON-operation of a forward driving switch or a backward driving switch (not shown) of the steering wheel positioning switch 11. Subsequently, by manually operating the seat positioning switch 10, the seat 6 is shifted sliding to position I suitable for the driver through the slide motor 7, and the seat 6 and the seat back of the seat 6 are also adjusted to the appropriate height and the reclination angle for the driver through the lift motor 8 and the recliner motor 9 respectively in the same manner.
In this state, by presetting the set switch 10a, the position G detected by the tilt sensor 3a, the position H detected by the telescopic movement sensor 5a, the position I of the seat 6 detected by the slide sensor 7a, the height of the seat 6 and the reclination angle of the seat back of the seat 6 detected the lift sensor 8a and the reclining sensor 9a are memorized respectively in the microcomputer of the controller 4 as driving positions suitable for the driver.
From this time forth, the steering wheel 2 and the seat 6 return automatically to the respective positions G, H, I and so on memorized in the microcomputer of the controller 4 as the driving positions suitable for the driver by actuating the tilt motor 3, the telescopic movement motor 5, the slide motor 7, the lift motor 8 and the recliner motor 9 in response to the positioning operation of the set switch 8a no matter where they are.
In this time, the controller 4 drives, for example, the tilt motor 3 shown in FIG. 2 in the forward or the reverse direction by outputting a forward rotational signal from the output port 4b to the transistor Tr1 or by outputting a reverse rotational signal from the output port 4d to the transistor Tr2. Namely, if the transistor Tr1 comes to its ON-state by the forward rotational signal from the output port 4b of the controller 4, the relay coil rl 1-3 is excited, the tilt motor 3 rotates in the forward direction and the steering wheel shaft 2a is driven upwardly. If the transistor Tr2 comes to its ON-state by the reverse rotational signal from the output port 4d of the controller 4, the relay coil rl 2-3 is excited, the tilt motor 3 rotates in the reverse direction and the steering wheel shaft 2a is driven downwardly.
Additionally, at the state in which the cancel switch 11a is changed off (automatically operable state) the controller 4 actuates the tilt motor 3, the telescopic movement motor 5 and the slide motor 7 in order to drive the steering wheel 2 and the seat 6 into turnout positions (turnout action) after the positions where they are just before the turnout action (position H, position H and position I) are memorized in the microcomputer as returning positions by sensing an ignition key to be pulled out from an ignition switch, sensing a door on the driver's seat side to be opened in case the ignition key is inserted into the ignition switch or sensing the ignition key to be turned to the OFF-position from the ACC-position of the ignition switch. Whereby, the steering wheel shaft 2a is driven to the upper position A (turnout position) from the memorized position G, the steering wheel 2 is driven to the front side position C (turnout position) from the memorized position H, and the seat 6 is also driven to the turnout position shifted backwardly from the memorized position I by predetermined distance so as not to obstruct the driver from getting on and off the vehicle.
In this state, when the controller 4 senses that the ignition key is inserted into the ignition switch, the door is closed in the case the ignition key is inserted into the ignition switch, or the ignition key is turned to the ON-position from the ACC-position in the case the door is opened, the controller 4 actuates the tilt motor 3, the telescopic movement motor 5 and the slide motor 7 so as to return the steering wheel 2 and the seat 6 into the returning positions memorized in the microcomputer. Whereby the steering wheel shaft 2a returns to the position G, the steering wheel 2 returns to the position H, and the seat 6 return to the position I suitable for the driver from the respective turnout positions.
Next, explanation will be given about control in the automatic drive-positioning device 1 according to this invention on basis of FIG. 3 to FIG. 10.
First, of all, a motor-suspensive zone A1 having a predetermined range R1 is set in front and in rear of a memorized position X of the steering wheel 2 or the seat 6 as shown in FIG. 3.
Starting a program shown in FIG. 4, judgement is done at step 100 as to whether or not the steering wheel 2 or the seat 6 is actuated automatically to the memorized position X. The judgement at step 100 is repeated until the steering wheel 2 or the seat 6 starts to the memorized position X according to, for example, the positioning operation of the set switch 10a. When the steering wheel 2 or the seat 6 starts according to the positioning operation of the set switch 10a, difference A between address number M representing the memorized position X and address number P detected by the appropriate sensor and representing the position of the steering wheel 2 or the seat 6 at present is calculated at step 101. And control proceeds to succeeding step 102.
In step 102, judgement is done as to whether the absolute value of the difference A is smaller than the predetermined range R1 or not, namely whether the steering wheel 2 or the seat 6 is within the motor-suspensive zone Z1 or not. If the steering wheel 2 or the seat 6 does not yet arrive within the motor-suspensive zone Z1 (NO), judgement is done as to whether the difference A is positive or not at step 103.
When the difference A is not positive at step 203 (NO), control returns to step 100 after rotating the motor in the forward direction in order to actuate the steering wheel 2 or the seat 6 toward the memorized position Z at succeeding step 104. And if the difference A is positive at step 103 (YES), control returns to step 100 after rotating the motor in the opposite direction at step 105.
When the absolute value of the difference A is smaller than the predetermined range R1 at step 102 (YES), the steering wheel 2 or the seat 6 is judged to arrive within the motor-suspensive zone Z1 the motor is stopped at step 106, and control returns to step 100 after cancelling the automatic action in the automatic positioning apparatus 1.
Namely, as shown in FIG. 3, the steering wheel 2 or the seat 6 starts from the position Y for the memorized position X, and the electric current to the motor is shut off at the position S when the steering wheel 2 or the seat 6 arrives in the motor-suspensive zone Z1. Therefore the steering wheel 2 or the seat 6 stops in the immediate neighborhood of the memorized position X suitable for the driver by the inertia.
A renewal-prohibitive zone Z2 having a predetermined range R2 is also set in front and in rear of a memorized position X of the steering wheel 2 or the seat 6 as shown in FIG. 5.
As shown in the flowchart of FIG. 6, judgement is done as to whether a turnout action signal is output or not, that is, whether or not the ignition key is pulled out from the ignition switch, the door is opened or the ignition key is turned to the OFF-position from the ACC-position at step 200. The judgement in step 200 is repeated until the turnout action signal is output.
When the turnout action signal is output, control proceeds to step 201 and judgement is done as to whether a control flag F is "1" or not. The control flag F is judged not to be "1" at step 201 in the first stage of the control because the control flag F is cleared, and difference A between address number M representing the memorized position X and address number P detected by the sensor and representing the position where the steering wheel 2 or the seat 6 is at present is calculated at step 202. And control proceeds to succeeding step 203.
In step 203, judgement is done as to whether the absolute value of the difference A is smaller than the predetermined range R2 or not, that is whether the steering wheel 2 or the seat 6 is within the renewal-prohibitive zone Z2 or not. If the absolute value of the difference A is not smaller than R2 (NO), namely the steering wheel 2 or the seat 6 is judged to be out of the renewal-prohibitive zone Z2, the memorized position X is renewed and the position where the steering wheel 2 or the seat 6 at present is newly memorized in the microcomputer in the controller 4 at step 204, control proceeds to step 205. If the steering wheel 2 or the seat 6 is judged to be within the renewal-prohibitive zone Z2 at step 203, control proceeds to step 205 directly.
In the step 205, judgement is done as to whether the steering wheel 2 or the seat 6 arrives in the turnout position or not. The judgement is "NO" at step 205 because the steering wheel 2 or the seat 6 does not yet arrive in the turnout position in the earlier stage of the control, and the motor is rotated in order to actuate the steering wheel 2 or the seat 6 into the turnout position at succeeding step 206. Control returns to step 200 after setting the control flag F into "1" at step 207.
In step 201 after judging to be "YES" at step 200, the control flag F is judged to be "1" (YES) in this time as the flag F is set into "1" at step 207 and control proceeds to step 205 directly.
In step 205, judgement is done as to whether the steering wheel 2 or the seat 6 arrives in the turnout position or not, the judgement in step 205 is repeated until the steering wheel 2 or the seat 6 arrives in the turnout position. And the steering wheel 2 or the seat 6 arrives in the turnout position, the motor is stopped at step 208 and control return to step 200 after clearing the control flag F at step 209.
Namely, in the case where the steering wheel 2 or the seat 6 starts from the position Y for the memorized position X and stops at position X' deviated from the position X by the inertia at the time of stopping the motor at the position X as show in FIG. 5, the memorized position X is never renewed into the position X' deviated from the position X even if the positioning operation of the set switch 10a or the turnout action is done. Accordingly, the originally memorized position X suitable for the driver is maintained as it is.
In addition to above, also in the case where the positioning operation of the set switch 10a is done at step 200, the control is executed similarly to above.
Furthermore, a readjustment-prohibitive zone Z3 having a predetermined range R3 is set in front and in rear of a memorized position X of the steering wheel 2 or the seat 6 as shown in FIG. 7 and control is executing according to the flowchart shown in FIG. 8.
In step 300, judgement is done as to whether the positioning operation of the set switch 10a is done or not, that is, the automatic action is started or not. The judgement at step 300 is repeated until the automatic action is started.
When the positioning operation of the set switch 10a is done at step 300 (YES), control proceeds to step 301 difference A is calculated similarly to the step 101 in FIG. 4 and the step 202 in FIG. 6 and control proceeds to step 302.
In step 302, judgement is done as to whether the absolute value of the difference A is smaller than the predetermined range R3 or not, that is, whether the steering wheel 2 or the seat 6 is within the readjustment-prohibitive zone Z3 or not. If the absolute value of the difference A is not smaller than R3, the steering wheel 2 or the seat 6 is judged to be out of the readjustment-prohibitive zone Z3 and the automatic action of the steering wheel 2 or the seat 6 is started at step 303. Judgement is done at step 303, the motor is rotated in the forward direction or the opposite direction according to the position of the steering wheel 2 or the seat 6 at step 305 and step 306, respectively, and control returns to step 300.
When the steering wheel 2 or the seat 6 is judged to be within the readjustment-prohibitive zone Z3 at step 302, the automatic action of the steering wheel 2 or the seat 6 is cancelled at step 307, and control returns to step 300.
Namely, in the case where the steering wheel 2 or the seat 2 starts from the position Y toward the memorized position X and stops at position X' deviated from the position X by the function of the inertia at the time of stopping the motor at the position X as shown in FIG. 7, the steering wheel 2 or the seat 6 is not actuated to the memorized position X in the opposite direction even if the positioning operation of the set switch 10a is done again.
Additionally, control is done as shown in FIG. 9 in case of actuating the steering wheel 2 or the seat 6 by inching the motor while, for example, the vehicle is travelling. Explanation will be given below on basis of FIG. 2, FIG. 9 and FIG. 10 taking the case of the tilt motor 3 as an example.
In step 400 in the flowchart shown in FIG. 9, judgement is done as to whether the steering wheel positioning switch 11 (manual switch) is changed on or not. When the steering wheel positioning switch 11 is changed on (YES), judgement is done as to whether the predetermined time N set in a switch timer elapses or not at step 401. Control proceeds to step 404 and increment of the switch timer is done because the predetermined time does not yet elapse in the early stage of the control.
The judgement is repeated at step 401 until the predetermined time elapses, when the predetermined time elapses, judgement is "YES" at step 401 and control proceeds to step 403.
Judgement is done as to whether the upward driving (forward rotational) switch 11A of the steering wheel positioning switch 11 is operated or not at step 403, and judgement is done as to whether the downward driving (reverse rotational) switch 11B of the steering wheel positioning switch 11 is operated or not at step 406. When the judgement is done at steps 403 and 406 that the upward driving switch 11A or the downward driving switch 11B is operated, control proceeds to step 405 and the controller 4 outputs the upward driving (forward rotational) signal and the downward driving (reverse rotational) signal to the transistors Tr1 and Tr2 from the output ports 4b and 4d at step 405, thereby actuating the relays RL1 and RL2, the electric current in the forward rotational direction and the electric current in the reverse rotational direction are supplied to the tilt motor 3 at the same time, therefore the tilt motor 3 stops by dynamic braking. Control returns to step 400.
If the judgement is done at steps 403 and 406 that both the upward driving switch 11A and the downward driving switch 11B are not operated, the controller 4 judges the steering wheel positioning switch 11 to be operated in another direction and cancels the upward driving signal and the downward signal at the same time at step 407. Control returns to step 400.
In step 400, if the judgement is done that the steering wheel positioning switch 11 is changed off (NO), the upward driving signal and the down ward signal are cancelled at the same time in step 407 after clearing the SW timer at step 402, and control returns to step 400.
Namely, as shown in FIG. 10, when the upward driving switch 11a of the steering wheel positioning switch 11 is changed on at point K, an electric current in the forward rotational direction is supplied to the tilt motor 3 and the tilt motor 3 rotates so as to actuate the steering wheel shaft 2a in the upward direction. In this time, the controller 4 detects the upward driving switch 11a to be changed on at point L after some time lag.
The controller 4 outputs the upward driving signal and the downward driving signal from the output ports 4b and 4d to the transistors Tr1 and Tr2 at point N after the predetermined time whereby, the tilt motor 3 is stopped rotational direction and an electric current in the reverse rotational direction at the same time, and stops by dynamic braking.
When the upward driving switch 11a of the steering wheel positioning switch 11 is changed off at point O, the controller 4 detects the off-operation and discontinues to output the upward driving signal and the downward driving signal at the same time at point Q after some time lag.
Therefore, the tilt motor 3 is inched for only predetermined time by manually operating the steering wheel positioning switch 11 without the reverse rotation.
Although the explanation is only given about the tilt motor 3, the other motors such as the telescopic movement motor 5, the slide motor 7, the lift motor 8 and so on can be controlled in the same manner.
As mentioned above, in the automatic positioning apparatus and the method for controlling the attitude of the vehicle mounted device according to this invention, it is possible to minimize various inconvenience and malfunction due to the passing over of the vehicle mounted device caused by the inertia, and possible to prevent the vehicle mounted device from the reversal movement at the time of inching the vehicle mounted device by manual operation. | An automatic positioning apparatus which comprises motors for actuating a vehicle mounted device, sensors for detecting position of the vehicle mounted device such as a seat, steering wheel or the like, and a control means which memorizes the position of the vehicle mounted device and drives it into the memorized position automatically and which sets a motor-suspensive zone, a renewal-prohibitive zone and a readjustment prohibitive zone in the vicinity of the memorized position, and stops the motors when the vehicle mounted device enters the motor-suspensive zone, prohibits to renewal the memorized position when the vehicle mounted device is within the renewal-prohibitive zone and prohibits an automatic action within the readjustment-prohibitive zone. | 1 |
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